AMT DEC/JAN 2021 by AMTIL

DEC JAN 2021

Deburring System

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33 Brodie Street NSW 2016 Phone: +61 2 9638 9600 Mobile: +61 4 1111 5585

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DEC JAN 2021

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AUTOMOTIVE & ROAD TRANSPORT

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BMSO-320 PRICED FROM

$11,500 EX GST

A Made in Turkey EY DE IN TURK

BMSY-440-CGH SHOWN

BMSO-320 SHOWN

ORDER CODE

B038

B136

B140

B141

B142

MODEL

BMSO-320

BMSY-320DG

BMSY-440-CGH

BMSY-540-CGH

BMSY-810-CGH

Round @ 90ยบ

(mm)

320

450

540

810

Rectangle (W x H) @ 90ยบ

(mm)

300 x 300

450 x 320

695 x 425

750 x 540

810 x 770

Rectangle (W x H) @ 60ยบ

(mm)

230 x 220

260 x 425

250 x 540

310 x 770

Table Working Height

(mm)

640

860

690

695

725

Cutting Head Down Feed Control

Adjustable Hydraulic

Vice Clamping Fixture

Manual

Automatic-Hydraulic

Adjustable Hydraulic

(m/mm)

Variable 20-100

(mm)

3660 x 27 x 0.9

4160 x 34 x 1.1

5400 x 41 x 1.3

6000 x 41 x 1.3

8400 x 41 x 1.3

Blade Speeds Blade Size (L x W x T) Motor Power Voltage Nett Weight PRICE

(kW / hp)

2.2 / 3

4 / 5.5

(V)

415

(kg)

735

1040

1630

2445

4050

$11,500

$14,950

$29,950

$34,950

$43,500

EX gst

Available at www.machineryhouse.com.au Specifications are subject to change without notice. All prices exclude GST and are valid until 31-01-20

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D N A C I T A M O SEMI AUT D ND SAWS A A B E H L E V I W S BMSY-440-CGH PRICED FROM

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EX GST

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BMSY-320DG SHOWN

BMSO-320

BMSY-320DG

Fixed Head Automatic Roller Feed

Swivel Head - Dual Mitre, Semi - Automatic

300 x 300mm Rectangle Capacity

450 x 320mm Rectangle Capacity

Automatic material feed roller system with micro switch stop

Inverter controlled infinitely variable blade speed

Blade breakage sensor

Material height sensor for beam

Digital readout display for accurate mitre cutting

Automatic arm rise after completion of cut

Full stroke hydraulic clamping vice

695 x 425mm | 750 x 540mm | 810 x 770mm Rectangle Capacity 2ยบ blade incline for improved cutting Inverter variable blade speed control Material height sensor for beam Digital readout display

Inverter controlled variable blade speed

Adjustable hydraulic feed cutting rate

Adjustable carbide blade guides

Blade breakage sensor fitted that automatically shuts machine off

Head mitre hydraulic brake locking system Linear guide ways for improved accuracy Auto optical material height adjustment

Quality Hydro-pack hydraulic system

SITI industrial duty gearbox drive

Adjustable length stop with micro

Built-in coolant system

SAP coolant pump system

Saw blade cleaning brush

NSW

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QLD

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VIC

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Integrated hydraulic unit with arm feed control trimming

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006

CONTENTS

Volume 20 Number 06 DEC/JAN 2021 ISSN 1832-6080

FEATURES AUTOMOTIVE & ROAD TRANSPORT Set to charge – Australia and the EV revolution Bentley Group invests in versatility from MaxiTRANS HSP 4x4 Accessories: Australian-made, competing globally 3D printing electric vehicles: The future of automotive? Carbon Revolution – Automating to gain an edge ViscoTec revolutionises dispensing applications in e-mobility Jayco Australia – Safe working with Smart Badge

42 48 50 52 54 56 58

CUTTING TOOLS Iscar – Stainless competence Overcoming process uncertainty to reduce scrap/rework Deep hole drilling with high pressure MQL

60 64 66

MATERIAL REMOVAL Hargo Engineering: Remaining positive, pushing ahead Bremont luxury watchmaker doubles capacity Mazak unveils next-gen compact five-axis VMC New MultiSwiss helps SPM progress medical turning

70 72 73 74

FORMING & FABRICATION New fibre laser gives JC Butko total quality control Hypertherm’s XPR300 - Raising productivity, quality

76 78

STATE SPOTLIGHT - NEW SOUTH WALES Leussink Engineering – ever-growing capabilities Sustainability woven into the fabric Raymax Applications – 25 years of laser solutions Melvelle’s rail maintenance on track with Mazak

80 82 84 86

PLASTICS SHOC: 3D printing the perfect fit for visor upgrade Cut To Size launches chemically resistant thermoplastic Foamex wins West Gate Tunnel Project contract CSIRO and partners take aim at ending plastic waste Additive manfuacturing lights the way for Burn Brite

92 93 93 94 96

MOTORS & DRIVES Variable speed drives: the dark side Motoring a revival for the food & beverage industry maxon motors heading to Mars

97 98 99

WELDING The essential nature of welding

100

NANOTECHNOLOGY A new approach to making aircraft parts Deakin’s Boron Nitride Nanotubes are industry-ready ‘Nano-pillared’ surface traps/kills COVID-19

102 104 104

SENSORS & PROCESS CONTROL RMIT electronic skin can react to pain like human skin

105

REGULARS From the Editor From the CEO From the Ministry From the Industry From The Union

8 10 12 14 16

INDUSTRY NEWS Current news from the Industry

VOICEBOX Opinions from across the manufacturing industry 28 PRODUCT NEWS Our selection of new and interesting products

COMPANY FOCUS Modernising classic vehicles with advanced manufacturing

ONE ON ONE Ian Christensen - MD of iMOVE Australia

AMTIL FORUMS

106

AMTIL INSIDE 110 MANUFACTURING HISTORY – A look back in time

AMT DEC/JAN 2021

118

42 Set to charge – Australia and the EV revolution The global automotive market is undergoing a radical transformation, with electric vehicles rapidly gaining market share – but Australia is in danger of falling behind. Nonetheless, a small group of Australian manufacturers are bucking this trend.

58 Jayco Australia – Safe working with Smart Badge Our leading producer of RVs and caravans, Jayco has become one of the first manufacturing companies in Australia to roll out Smart Badge, an innovative new COVID-safe technology that is helping it get operations back on track.

68 Renner Auto – Modernising classic vehicles Jason Ferraro has a passion for the golden age of auto design between 1950 and 1970, paying tribute via the modernisation of these dream machines using advanced manufacturing.

88 Ian Christensen Ian Christensen is the Managing Director of iMOVE Australia – the national centre for research & development in transport and mobility.

HEADING

FROM THE EDITOR WILLIAM POOLE

Obstacles to innovation So that was 2020 then. It started, if you can cast your mind that far back, with bushfires. Then, just as the smell of smoke was receding, we faced a global pandemic, and the worst economic crash in almost a century. Finally, we had the spectacle of the leader of the “world’s greatest democracy” rejecting the result of that country’s elections. It’s been a year to forget. But there have been silver linings. One undoubted positive has been a renewed appreciation for manufacturing in this country. The COVID-19 pandemic saw our industry rapidly adapt in response to the crisis. It saw businesses pivot, shifting operations almost overnight to produce everything from hand sanitiser to ventilators … even to office furniture for the legions of people suddenly working from home. In a word, it saw Australian manufacturers innovate. It kind of begs the question: why not just innovate all the time? A new report from CSIRO seeks to answer that question. The Value of science and technology report identified five key barriers to realising value from innovation. Those barriers are: • Declining innovation investment: Business investment in innovation has declined 30% in the past decade with businesses tending to invest smaller amounts on shorter-term goals. • Poor research commercialisation: While Australia is home to world-class researchers, we struggle to commercialise breakthroughs in the lab. • Skills gap: Australian education is high quality by international standards, but we don’t have a culture of ongoing training for employees outside formal education. • Resistence to overseas ideas: Businesses invest in keeping up with competitors in Australia, but rarely keep up with overseas rivals. • Wariness of new technologies: Investing in innovation can be seen as the road to automating jobs, widening the gap between profitable and unprofitable businesses, and resulting in big royalties for a few but bigger losses for others. These are interesting points, though admittedly we have heard them made a few times before. Perhaps there’s another one that could be added to that list: leadership. Take for example the subject of our lead article this issue: electric vehicles. A breakthrough technology, taking off around the world, where Australia holds various critical advantages. Yet as we go to print, state governments in SA and Victoria have announced plans to slap new taxes on them, disincentivising adoption by consumers. Talk about “wariness of new technologies”. It’s a similar case at federal level. With the rest of the developed world setting ambitious targets on energy transiton and emissions reduction, Canberra’s plan is to double down on fossil fuels, with the singularly uninspiring ‘gas-fired recovery’. It has of course been argued (and widely contested) that the plan will deliver lower energy costs for manufacturers, but it’s kind of the same old “dig-stuff-up” approach Australia has always taken. Not exactly a bold, stirring vision for the future … is it? Not exactly innovative. This year has shown that Australian manufacturers have plenty of the attributes required to innovate in the face of a crisis – but there are still big structural obstacles getting in the way. If we’re to meet the challenges waiting for us in 2021, we’re going to need to up our game. *** With this being our last edition of AMT Magazine for 2020, I’d like to finish up by thanking our readers, contributors and advertisers for their support over the last 12 months. On behalf of myself, Anne, Gabriele and Franco, and all of the AMTIL team, I’d like to wish all our readers and everyone involved in Australian manufacturing a Merry Christmas and a Happy New Year.

Editor William Poole wpoole@amtil.com.au Contributors Carole Goldsmith Head of Partnerships & Sales Anne Samuelsson asamuelsson@amtil.com.au Publications Co-ordinator Gabriele Richter grichter@amtil.com.au Publisher Shane Infanti sinfanti@amtil.com.au Designer Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed in Australia using PEFC™ Programme for the Endorsement of Forestry Certification Chain of Custody certified from sustainable forests Contact Details AMT Magazine AMTIL Suite 1, 673 Boronia Rd Wantirna VIC 3152 AUSTRALIA T 03 9800 3666 F 03 9800 3436 E info@amtil.com.au W www.amtil.com.au Copyright © Australian Manufacturing Technology (AMT). All rights reserved. AMT Magazine may not be copied or reproduced in whole or part thereof without written permission from the publisher. Contained specifications and claims are those supplied by the manufacturer (contributor)

Disclaimer The opinions expressed within AMT Magazine from editorial staff, contributors or advertisers are not necessarily those of AMTIL. The publisher reserves the right to amend the listed editorial features published in the AMT Magazine Media Kit for content or production purposes. AMT Magazine is dedicated to Australia’s machining, tooling and sheet-metal working industries and is published bi-monthly. Subscription to AMT Magazine (and other benefits) is available through AMTIL Associate Membership at $175 (ex GST) per annum. Contact AMTIL on 03 9800 3666 for further information.

1533AMTDEC/JAN2021

AMT DEC/JAN 2021

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FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

Let’s take the initiative on initiatives Boy oh boy it is hard to get a good handle on the Federal Government’s $1.5bn manufacturing assistance package announced in September! The objective to position Australia as a modern manufacturing leader, to energise the sector, build scale and lead us through a post-COVID recovery is indeed admirable and the sort of foresight, to be frank, our manufacturing industry has been looking for. The issue now is in the detail. The $1.3bn Modern Manufacturing Initiative is the centrepiece of the strategy, promising to enable businesses to access funds in order to transform ideas into commercial reality. I’ll come back to this later, but at present full details of the Modern Manufacturing Initiative are yet to be announced. Let’s change the subject back to some of the other aspects of the Government’s proposed funding. The Manufacturing Modernisation Fund (MMF) has $52.8m that is targeted at supporting roughly 150 companies that have a solid business plan to invest in new technology, upskill workers and create new jobs. Great idea. Great initiative. This is the second round of this Program and the early indications from the first round is that the majority of recipients have achieved revenue growth and job creation. So let’s get on with it. We are still waiting for this second round of the MMF to open. This is what I mean by getting a handle on the overall package. We are in unprecedented times, lots of post-COVID talk, great opportunities and strong verbal commitment from our leaders. These promises need to be delivered on as soon as possible. As welcome and needed as these funding grants are for the businesses that are lucky enough to get them, the ones that allocate time and resources to put proposals in and miss out have in a lot of cases put off investment decisions in the hope of securing funds. So the timing of the grant program and funding allocations is critical. I like the Supply Chain Resilience Initiative. Identifying existing capability, mapping that to future COVID-19 requirements and building these supply chains has a great deal of merit. COVID-19 has no doubt had an incredible impact on businesses. On a positive note, many have identified their ability to provide critical products and have taken advantage of this potential. Government support to help companies identify these opportunities, build scale and access global supply chains is welcome. We are far from resolving this pandemic and the early indication is that Australian companies have the intellect and ability to provide these critical goods and service. Why then, are we waiting until the middle of next year to get details of the funding available? As I have said, it’s hard to get a handle on the initiatives due to the lack of detail and timeliness of actions. Now I need to come back to the Manufacturing Modernisation Initiative, because as it has been promoted, it is the Morrison Government’s solution to unlocking the potential to deliver growth for our industry for decades to come. There is an indication that a road map needs to be completed for each of the six targeted sectors (Resources Technology & Critical Minerals Processing, Food & Beverage, Medical Products, Recycling & Clean Energy, Defence and Space). I’m sceptical about

“We are far from resolving this pandemic and the early indication is that Australian companies have the intellect and ability to provide these critical goods and service. Why then, are we waiting until the middle of next year to get details of the funding available?” roadmaps. Not because they are not important – more so because they inevitably have a use-by date depending on who has written them and who they have been commissioned by. We have Industry Growth Centres, funded by the Commonwealth, that have a mandate to advise Government on what is required to help transition Australia’s highly skilled manufacturers into global leaders. Surely they have most of the answers already. I hate the idea that roadmaps, commissioned reports and more industry consultation are going to hold up the details and rollout of this initiative. If that is the case, we will constantly be on this merrygo-round of industry-led, government-funded policy development that doesn’t produce the desired result. The Morrison Government and Industry Minister Karen Andrews have given us the shot in the arm. The adrenalin is pumping and we are ready for activity. Manufacturing, for a while, was front page news, and rightfully so given how important it is to our nation. We can’t let it disappear back to the middle pages by taking too long to put these initiatives in place.

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FROM THE MINISTRY THE HON KAREN ANDREWS MP – Minister for Industry, Science and Technology

Building optimism for the future One of the great things about Australians is that we are natural optimists. In difficult times we expect it to get better. This pandemic has been a long trial but there is a strong sense of a pent-up national energy just waiting to be released. This is particularly so in the private sector, which is bursting to get back to business. And it is the private sector that will lead our economic recovery. Our role as a Government is to create the conditions in which businesses can thrive and create the jobs we need now and for the future. As Industry Minister, I am delighted that the $1.5bn Modern Manufacturing Strategy launched in October will play a key part in our economic recovery and beyond. It is at the heart of our JobMaker plan, helping create jobs for Australians. We are working to create a stable and competitive business environment which will spur growth in the economy. Across Government we are working to get the economic conditions right for all businesses, by lowering energy costs, building our skills pipeline, and introducing new tax incentives, for example. Building on that solid base, the Modern Manufacturing Strategy will ensure that government, industry and the research community are all working together to advance the opportunities for our manufacturers. Our aim is to build scale in manufacturing through playing to our strengths, strategically investing, and boosting the role of science and technology in industry. By building scale we will open up opportunities to embrace new markets and take more of our quality products to the world. We need our small businesses to become medium enterprises and our medium enterprises to grow to larger businesses that are competitive and resilient. The centrepiece of the Strategy is the $1.3bn Modern Manufacturing Initiative, which will support projects within six priority areas: • Resources technology and critical minerals processing • Food and beverage • Medical products • Recycling and clean energy • Defence • Space We have made these choices because, as I have long said, we cannot be all things to all people. It is critical that we concentrate on Australia’s established competitive advantages and emerging areas of strategic priority. Having identified these priorities, we are already working with industry to develop roadmaps and identify opportunities for growth. These roadmaps will set clear goals and performance indicators over the next two, five and ten years so we can track our progress and guide our actions and investments. A key driver in our success is making science and technology work for industry to help businesses grow and create jobs. We are also providing nearly $460m in additional funding for the CSIRO, which plays a vitally important role helping businesses to translate their ideas into new products and services. The extra injection of funding in the 2020-21 Budget takes the Government’s total investment in CSIRO to $3.8bn over the next four years. The funding addresses the impacts of COVID-19 on the CSIRO’s commercial activities to ensure it can continue its essential scientific research.

AMT DEC/JAN 2021

Our Strategy also provides a further $52.8m investment for a second round of the Manufacturing Modernisation Fund (MMF). Earlier this year the Government invested $48.3m in a first round of the MMF to support about 200 projects worth $215m, which are expected to create 2,600 jobs. The second round of the MMF will open by the end of the year and is expected to support about 150 more businesses in the National Manufacturing Priority areas. This new funding will build the confidence businesses need coming out of COVID-19 and continue to help them harness technologies, upgrade equipment, create jobs and upskill their workforce to remain competitive. The COVID-19 crisis has also highlighted the need to better understand and address our supply chain issues and opportunities. We have worked closely with industry to help provide vital products and supplies at short notice, such as masks and ventilators, and industry has risen magnificently to the challenge. But for ongoing certainty of production and for protecting supplies in areas of national interest, such as personal protective equipment (PPE), we need to guard against shortages and vulnerabilities. Our Strategy’s $107m Supply Chain Resilience Initiative will work with industries to identify supply chain gaps and develop Sovereign Capability Plans to ensure we are prepared for future shocks. We will also be working very closely with like-minded nations to ensure reliable supply chains for ourselves and also creating opportunities for our manufacturers to feed into the supply chains of these nations. As a Government we understand it is industry, not governments, that create jobs. That’s why we have repurposed Innovation and Science Australia to Industry Innovation and Science Australia (IISA). The revamped organisation will play a crucial advisory role in implementing the Modern Manufacturing Strategy and overseeing the development of the industry-led road maps. In October we announced five new appointments to the board of IISA. DuluxGroup CEO Patrick Houlihan and Woodside Energy’s Lauren Stafford have both been appointed for three years. Fintech and consumer rights expert Scott Farrell, space technology entrepreneur Dr Alex Grant and internationally recognised agtech innovator Sarah Nolet have been appointed for two years. These appointments will ensure the Board has the necessary skills, expertise, and connections to the Australian business community that are needed to help advance Australian manufacturing. Our Strategy builds on the work across Government to improve economic conditions for business, including streamlining regulation, cutting taxes and red tape. We’ve improved the instant asset tax write-off and committed $2bn to the R&D Tax Incentive (RDTI) scheme. The Government is strategically investing in areas of manufacturing where we know we have an edge and that can deliver the jobs we need. We are improving collaboration and commercialisation, and supporting the development of highly skilled workforces. Our Strategy will deliver for the nation and rebuild the economic growth and jobs we need. Australians are right. We have every reason to be optimistic about the future.

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FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

National resilience and economic sovereignty In the early months of this year, when the lockdowns in China were suddenly upon us – followed shortly afterwards by more widespread interruptions to global production, the fracturing of supply chains and shortages of shipping and air freight – there was a good deal of talk about “economic sovereignty”. This was given a particular flavour by the sudden leap in demand – and expected demand – for a range of health, sanitising and protective equipment. However, concerns were not limited to these areas; they were felt across a very wide range of industries. All of a sudden, we could not source windows, packaging materials, and a whole range of components for this and that. These were global phenomena of course but we felt it particularly acutely in Australia because here we are at the other end of the world, tyrannised by distance and feeling all the more vulnerable by the decline in our manufacturing sector over recent years. While today our membership is drawn from across a broad spectrum of employers, Ai Group has a rich tradition in Australian manufacturing – and for well over a century it was our exclusive focus. We remain deeply engaged with the sector and we welcome the increased attention on domestic manufacturing. Nevertheless, from the outset, we were wary about some of the emphasis on “economic sovereignty”. Over recent decades, Australia has become an open economy. We have derived, and we continue to derive, very significant benefits from our engagement with the rest of the world. We are richer, more diverse and we face many more opportunities because of the exchange of capital, people, goods and services. From this point of view, it would be a strange reaction to the vulnerabilities we felt, when threatened by a breakdown in trade, if our solution was to close ourselves off from trade. That said, we certainly recognise the frailties exposed by those early months of the COVID crisis. And there are parallels with the need for us to have robust defence industry capabilities in Australia. There are also parallels with the prospect of further closures of uneconomic oil refinery capacity in Australia. While we remain firmly in favour of trade, and while we were wary, and we remain wary, of where an undue emphasis on economic sovereignty might take us, we also recognise the importance of the resilience of our economy. We think that framing the issue as one of resilience is a much better way to approach the issue than by a more whole-hearted embracing of economic sovereignty. But of course, there are many ways to build national resilience. One of the most important is by adopting much more through how we approach managing the risks of international supply chains.

“There are many ways to build national resilience. One of the most important is by adopting much more through how we approach managing the risks of international supply chains.” In some of these cases the sensible solution might be ‘economic sovereignty’ – bring it in house, or in country. But in others, that will not make sense and we can achieve the desired level of resilience at much lower cost (economists will quickly remind us that here we should be thinking “opportunity costs”). So instead of economic sovereignty we are attracted to the idea of “smart sovereignty”. That involves not just making sure we have desired levels of resilience in particular areas. It also, and more fundamentally, means that we should invest broadly in domestic capabilities. And I am not just thinking of manufacturing capabilities. These investments will contribute to the building of specific areas of resilience that will underpin our ability to meet unexpected contingencies.

Of course, none of these are new considerations. But there is certainly a case to say that we had lost sight of some of the risks we ought to have kept on our registers. And as at the level of individual businesses, so also we ought to recalibrate things at the national level.

On that note, it was impressive to see a very wide range of domestic producers put their hands up and, by calling on their existing capabilities – technical, managerial and those in their workforces – pivot to address some of the major areas of shortfall and areas of expected emergency demand in those early months of the COVID-19 crisis. As we look at how we build resilience, it is important that we remain mindful of being an open economy. It’s not always easy – particularly in the face of so many impulses in the opposite direction.

Defence capabilities – most obviously around sustainment – are clearly one area where increased regional and geopolitical risks are rightly giving rise to a reconsideration of our defence capabilities in co-opting those of our defence industry capabilities. Medicines are another area. Rare earths and petroleum fuels are others. And no doubt there are many more that should be examined.

Of course, we need to ensure continuity of supply and we need to appropriately manage the full range of risks we face. A key benefit of us being open is that we subject ourselves to competitive pressures. We make sure we remain exposed to global best practice. In the end, that is perhaps the most important step we can take to building and sustaining national resilience.

We have been very starkly reminded of the importance of diversified sources of supply. We have been jolted into a realisation of the vulnerabilities of just-in-time delivery and of the virtues of inventories.

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FROM THE UNION STEVE MURPHY – National Secretary Australian Manufacturing Workers Union

Poor managers are letting Australian businesses and workers down Australia’s managerial class must accept its responsibility for the decade of lost productivity that we’ve experienced since the Global Financial Crisis (GFC). The constant theme in reporting over the last decade or more is that these workers are being let down by managers who aren’t up to international standards. According to one recent study, “increasing management capability even at a moderate level has direct benefits for productivity and exports intensity” of around 13%. This would make a huge difference, not only to the bottom line of local businesses, but to our ability to compete on an international scale. In Australia, our GDP per hour worked (a key measure of productivity) hasn’t improved by more than 3% in a year since 2002 – indeed it has been below 1.5% per year for the majority of the last 18 years. This is a sad indictment on the ability of managers to bring our domestic industry into the 21st century at a time when numerous technological advancements should have made the work of improving productivity easier than ever. Other countries are taking advantage of the fourth industrial revolution to invest in new capital and improve productivity, that’s why our productivity sits below the OECD average. Our poor performance is not inevitable and we need to start focusing on what is causing our problems with productivity: managers. Improvements in labour productivity have been slow since the turn of the century, but it has continued to improve. The same cannot be said of capital productivity, which has been declining over the same period. While some of that can be attributed to the impact of the mining boom, the biggest driver of Australia’s historically bad productivity performance can be attributed to the poor performance of manufacturing businesses, according to Dr David Gruen. The failures that drive those poor national figures can be traced to poor firm-level decision-making. Australian managers fall behind their international counterparts in “operations, management of people and strategic planning, and workforce development and optimisation” according to Dr Gruen. If Australia, and in particular the manufacturing industry, is to achieve the productivity that we need over the next decade, we need managers that are better educated, more experience and who embrace innovation. Without these vital micro-economic reforms our local companies – and the workers that rely on them – won’t be able to compete on the international stage for the high skill, high wage jobs producing the goods and services that consumers need and want. Workers are already doing their part – two-thirds of working age Australians now hold a post-secondary qualification, the highest rate ever. There has never been a bigger pool of highly skilled, jobready workers looking to advance their careers in a whole range of professions. Despite the efforts of workers to invest in their own education, employers are not doing their part. There were over 130,000 fewer apprentices in 2019 than there were in 2013 – a shocking trend that should worry any employer who relies on skilled workers. Workers representatives haven’t been idle either – the Australian Manufacturing Workers Union (AMWU) and many other unions have engaged with employers and government during the COVID-19 period to talk about realistic solutions to the problems that are putting our members’ jobs at risk.

AMT DEC/JAN 2021

It was the union movement that pushed for a wage subsidy, which was vehemently opposed by the Government until the moment that it became their policy. Despite the obvious problems that let hundreds of thousands of workers fall through the cracks, JobKeeper has been instrumental in preventing the worst fears for economic ruin from being realised. The AMWU also worked with employer organisations and government in the NCCC process to chart a way forward for industry. We wanted to see manufacturing make it through this crisis and emerge from the other side stronger than ever. Sadly, many of the joint recommendations from that committee have been gathering dust on the shelf for six months with no concrete action to protect manufacturing jobs. This has led to 60,000 jobs being lost in the manufacturing industry since the end of last year – a disaster for our industry. Manufacturing has an important role to play in helping our economy get through the Covid crisis and arguably a bigger role to play in the recovery. We all want Australia to be a country that builds things, but it is just as important that we’re a country that invents, designs, maintains, and improves things. We’re only going to achieve a growing, dynamic and world class manufacturing industry if we’ve got support from government and investment from the private sector. But as long as Australia’s managers underperform their global counterparts, it will be hard to attract and retain the most talented workers. For too long the focus on improving productivity has been on cutting wages and conditions of workers, rather than developing their skills. Luckily workers have taken it on themselves to improve their education despite these obstacles. Unfortunately, we have not been so lucky when it comes to managers. What we need now is a plan to help our struggling mangers to better use the highly skilled, flexible workers and high-tech capital at their disposal. We need to expect better from our highly paid managerial workers, we need to support them, so that they can unlock the potential and attract the overseas investment that our industry desperately needs.

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INDUSTRY NEWS

IMCRC activate launches with rapid COVID-19 test Innovative Manufacturing Cooperative Research Centre (IMCRC) has launched its new funding initiative, IMCRC activate, with an Australian first — the development of a rapid COVID-19 test that uses optical technology. Designed to provide a much-needed stimulus to Australian manufacturing businesses in the wake of COVID-19, IMCRC activate stimulates and fasttracks R&D investment, offering access to valuable expertise and matched cash funding between $50,000 and $150,000. The first approved project of the initiative is led by Alcolizer, a Perth-based company developing a rapid saliva test for SARSCoV-2 virus antigens using its existing drug testing technology. Alcolizer’s partnership with IMCRC and research collaboration with the University of Technology Sydney (UTS) will see the project accelerate quickly in the face of the global health pandemic, evolving from a proof of concept to secure Good Manufacturing Practice (GMP) readiness in just four months. As Australia emerges from the worst of the COVID-19 crisis, providing valuable and strategic support for shorter-term research projects in advanced manufacturing and digital technologies is a priority for IMCRC. David Chuter, CEO and Managing Director of IMCRC, commented: “As the fourth largest industry in Australia, manufacturing is critical to rebuilding the health of our economy. COVID-19 highlighted some serious capability gaps in the industry, and now we must focus on using our Australian resources and R&D strengths for future growth. The IMCRC activate funding initiative has been designed to do just that — provide funding and pathways for manufacturers to recover and thrive. “We’re thrilled our first approved project has been so successful to date and has the potential to provide much needed health,

social and economic benefits in the fight against COVID-19. We hope this new funding initiative will shine a light on the need for broader investment in Australian manufacturing R&D.” Alcolizer General Manager Roger Hunt added: “The IMCRC activate initiative has been absolutely instrumental in our progress developing the prototype for this test. We have been able to boost our manufacturing capabilities and accelerate the diversification of our business into a new area of opportunity.” Laboratory trials using the Alcolizer COVID-19 test prototype are expected to begin within two months. IMCRC activate is a new initiative designed to help Australian manufacturers take action and gain a competitive edge in the post COVID-19 world. To be eligible for IMCRC activate funding, projects must: • Be industry-led, deliver clear manufacturing outcomes, and be completed within six to 15 months. • Be undertaken by one of IMCRC’s partner research organisations. • Apply Industry 4.0 technologies and digital business models. • Move the project through ideally two Manufacturing Readiness Levels (MRLs). • Ideally involve other Australian manufacturing SMEs as collaborators. • Address sustainability and/or national needs where possible. www.imcrc.org/activate

New report warns of gas industry decline A new report forecasts natural gas will inevitably decline as an energy source in Australia, calling into question the Federal Government’s “gas-fired recovery” and the prospect of cheaper energy for manufacturers. Prime Minister Scott Morrison has talked up a gas-fired recovery for manufacturing, raising expectations of big price reductions. However, the report from the Grattan Institute – entitled Flame out: the future of natural gas – shows that far from fuelling recovery from the COVID-19 recession, a combination of economics and environmental imperatives will place increasing pressure on the industry. “The evidence is clear: over time, gas will decline, economically and environmentally,” says Tony Wood, Grattan Institute Energy Program Director and the report’s lead author. “Rather than indulging in wishful thinking or living in denial, the Federal Government and the gas industry – and its customers – should start planning now for a future without natural gas, or at least with a dramatically reduced role for natural gas.” The report shows that eastern Australia faces inexorably more expensive gas. The east coast has already burned most of its low-cost gas and will not go back to the good old days of low prices, so gas will become an increasingly expensive energy source. If the Government intervenes directly in the market, taxpayers will pay the price via big subsidies.

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Even if the Government could significantly reduce gas prices, the benefits to manufacturing are overstated. The companies that would benefit most contribute only about 0.1% of gross domestic product (GDP) and employ only a little more than 10,000 people. Much of this gas-intensive industry is in Western Australia, which has low gas prices already. The report argues that the Government’s best role is to support the development and deployment of the low-emission alternatives that can replace natural gas in manufacturing, such as renewables-based hydrogen and renewables-based electricity. Australia must reduce emissions over coming decades to meet our international climate change commitments. The report also disputes the potential of gas as a ‘transition fuel’. As Australia’s coal-fired power stations retire over coming decades, it would be more expensive to replace them with gas than to switch to more renewable energy such as wind and solar. While gas will play an important backstop role in power generation, this does not require large volumes of gas.

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INDUSTRY NEWS

Dr Cathy Foley named as Australia’s next Chief Scientist Renowned physicist Dr Cathy Foley AO has been appointed Australia’s next Chief Scientist. Dr Foley, who has spent the last two years as the CSIRO’s Chief Scientist, will take over from Dr Alan Finkel AO, whose tenure comes to an end in December 2020. Prime Minister Scott Morrison said Dr Foley had the background needed to deliver during such a pivotal time in history. “As we recover from COVID-19 and look to rebuild a brighter future, the role of the Chief Scientist has never been more important,” Morrison said. “Dr Foley has a big task ahead to drive collaboration between industry and the science and research community, as we look to create jobs for the COVID-19 recovery and for the future.” Minister for Industry, Science and Technology Karen Andrews also thanked Dr Finkel for his service and said Dr Foley would bring a unique mix of experience to the role. “Dr Foley is highly regarded in the scientific community, has extensive experience working with government, but most importantly understands how to drive collaboration between industry and researchers,” said Andrews. “We know science will play a crucial role in helping to create jobs at this critical time, and Dr Foley’s skills as a talented science communicator will help sell that important message. “Like me, Dr Foley is also a strong advocate for women in science, technology, engineering and mathematics and her lived experience will make her an important role model for aspiring young scientists.” Dr Finkel praised the appointment, describing his successor as “an excellent choice.”

“I have known [Cathy] for many years,” said Dr Finkel. “I feel somewhat honoured to be followed in the role by such an esteemed person. I am confident in handing the Chief Scientist’s baton to her safe and experienced hands. Cathy is first and foremost a scientist – a world renowned physicist – and a leader in every aspect of her professional life.” Morrison also commended Dr Finkel for his time in his position: “I would like to thank Dr Alan Finkel AO for his outstanding contribution as Chief Scientist over the past five years. He has been a valued and respected voice to Government, and I know he will continue to make a significant contribution to the Australian and international science communities.” CSIRO Chief Executive Dr Larry Marshall praised Dr Foley on the appointment: “The appointment is testament to Cathy’s personal scientific excellence, her broad vision for Australia through her invaluable work at CSIRO, and her commitment and role-modelling for diversity and inclusion for the next generation of scientists. Cathy has been with CSIRO for nearly 36 years, beginning as a research scientist, working in manufacturing, and becoming CSIRO’s Chief Scientist in August 2018.” Dr Foley is the second woman to be named Australia’s Chief Scientist, after Professor Penny Sackett, who held the role from 2008-2011. Dr Foley is a Fellow of both the Australian Academy of Science, and the Australian Academy of Technology and Engineering. She is an accomplished scientist who has made significant contributions in the area of physics relating to superconductors. Her appointment as Australia’s Chief Scientist is for three years, starting in January 2021.

Wysiwyg 3D joins GoProto group in 3D scanning/printing merger In a new partnership, Wysiwyg 3D has joined forces with GoProto to create a unified laser scanning and 3D printing service bureau. By introducing scanning and digitising expertise into GoProto’s advanced manufacturing network, the merger enables a streamlined solution at every stage of the product development cycle. Shane Rolton, Managing Director of Wysiwyg 3D, sees the merger as a particularly beneficial opportunity for his clients, employees and business partners. “Our focus has always been on taking care of our customers by understanding what drives their business and providing solutions that affect the bottom line,” said Rolton. “We’ve already been working on a number of projects with GoProto. Combining our expertise and resources shortens the time-lag between scan data and production, putting ourselves exactly where our customers need us.” A recent project involving the repair of a rescue helicopter fuselage hatch served as a testament to the capabilities of these two

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companies and the potential for building greater manufacturing sovereignty within Australia. Traditionally, the NSW emergency service provider relied on overseas supply of spare parts, but with delays relating to COVID-19, the helicopter was going to be out-of-service for several weeks. By scanning the hatch and creating 3D printed patterns followed by carbon-fibre moulds, lightweight and durable replacement parts were installed within five days. Simon Marriott, Director of GoProto, sees the adoption of 3D scanning and product digitisation increasing as manufacturers adopt Industry 4.0. He described the partnership with Wysiwyg 3D as “a logical step in our growth strategy”. Wysiwyg 3D has been providing 3D scanning services since 2003. It will continue to provide laser scanning, photogrammetry and 3D CAD modelling service under the GoProto banner in Sydney.

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INDUSTRY NEWS

Australian Technologies Competition awards our best tech scaleups The Australian Technologies Competition held its National Awards Ceremony on 20 October, concluding a sevenmonth-long program designed to identify, reward and accelerate Australia’s best ‘deep tech’ scaleups. Electrogenics Laboratories was crowned overall winner for 2020 as well as the Medtech & Pharma winner for its medical radiation sensing technology that precisely measures radiation skin doses and rates in real time, helping to avoid organ and tissue damage. For Electrogenics Chairman Kim Lyle, the moleskin innovation is a personal one – having lost two family members as a consequence of radiation treatment. “Maintaining momentum has been the biggest challenge,” said Lyle, when asked about the commercialisation pathway. “Never give up; never surrender! There are a lot of hiccups along the way, but you just have to keep making it happen. Stay true to your vision and go for it!”. This year’s winners were: • Advanced Manufacturing Award – Contactile (NSW) • Cyber Security Award – Castlepoint Systems (ACT) • Disaster & Emergency Award – Helitak Fire Fighting Equipment (QLD) • Energy Award – Village Energy (WA) • Food & Agribusiness Award – Farmbot (NSW) • Global Social Impact Award – 4ize (NSW) • Medtech & Pharma Award – Electrogenics Laboratories (NSW) • Mining Technologies Award – NextOre (NSW) • Smart Cities Award – BindiMaps (NSW) • Space Award – HEO Robotics (NSW) • Alumni Achievement Award – AgriDigital (NSW) • Australian Tech Company of the Year – Electrogenics Laboratories (NSW) This year’s Ceremony commenced with an entrepreneurs panel discussing the role of the tech sector in rebuilding after COVID, after which the Minister for Industry, Science & Technology, Karen Andrews, delivered a keynote message. Highlighting the Federal Government’s recent commitment of an additional $460m to the

CSIRO and $2bn in R&D incentives to support the tech sector, Andrews congratulated the finalists: “In so many ways our future rests in the creative hands, critical inventions and trailblazing thinking that defines all of the ATC finalists.” Patrick Mooney, Executive Chair of Impact Technology Ventures, the organiser of the Competition, underscored the importance of a collaborative and supportive ‘deep’ technology ecosystem. “The shape of our re-emerging economy has to be different,” said Mooney. “Global market trends and capital markets are requiring more sustainable solutions and we can’t assume that our traditional sources of wealth can carry the same load. The scale-ups we see through this Competition in sectors like clean energy, smart cities, food and agtech, cybersecurity, manufacturing, emergency management, the circular economy and medtech are critical to this rebuilding. They deserve all of the support they can get from Australia’s tech ecosystem and government agencies.” The opening panel discussion featured four previous winners (Emma Weston of AgriDigital, Phil Hodgson of Calix, Anabela Correia of Livac and Giles Bourne of BluGlass), and venture capitalist Dr Michelle Deaker of OneVentures. The panel described how COVID-19 had significantly impacted their sectors and the ways they have adapted.

PM opens Military Vehicle Centre of Excellence Prime Minister Scott Morrison on 11 October officially opened Rheinmetall Defence Australia’s Military Vehicle Centre of Excellence (MILVEHCOE) in Redbank, Queensland, which will see hundreds of long-term jobs created. Rheinmetall will use the MILVEHCOE facility to build and assemble the majority of Boxer Combat Reconnaissance Vehicles, which are being delivered to the Australian Army under the $5bn LAND 400 Phase 2 project. The facility will also be used to conduct integration, support and heavy grade repair for the logistics trucks and modules being delivered under the LAND 121 Phase 3B and 5B projects. Morrison said the new defence industry facility in Redbank is part of the Economic Recovery Plan to create jobs as the nation recovers from the COVID-19 pandemic. “We are committed to keeping Australians safe, while protecting the nation’s interests in a rapidly changing global environment,” said Morrison. “This week’s budget has seen the Federal Government bring forward $1bn worth of capability projects and reservist days to support jobs, the Australian defence industry and the wider economy.

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“This Queensland centre will be where some of the most advanced armoured vehicles in the world will be produced by Australian workers. The MILVEHCOE will create more than 450 long-term jobs and become a national asset for military vehicles.” Morrison congratulated Rheinmetall Defence Australia for securing work to export at least 30 Lance Turrets from MILVEHCOE to Hungary. “This is a significant export order, and a clear demonstration of the Government’s commitment to supporting Australian defence industry to achieve export success,” Morrison said. “We make things in Australia. We do it well. And this is an example of how we are continuing to make things in Australia. Defence is one of six priority areas under our $1.5bn Modern Manufacturing Strategy and is backed by measures from Tuesday’s budget.”

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INDUSTRY NEWS

RUAG Australia lands US Navy Seahawk contract RUAG Australia has been awarded new contracts by the United States Navy for component maintenance, repair and overhaul (MRO) on MH-60R Seahawk helicopters. The contracts are authorised under the AUSMIN Defence Acquisition Committee (ADAC) initiative, a collaboration between the US and Australian Departments of Defence. This is the second consecutive contract with the US Navy for RUAG Australia in Q3 of 2020. First orders have been secured for the repair and overhaul of selected components on MH-60R Seahawk helicopters in the US Navy fleet. MRO support for the platform’s complex componentry requires specialized treatment and repair methods inherent to RUAG Australia’s proven aircraft component capabilities. The defence supplier is able to build upon its reliable performance and support in the componentry for the SH-60B Seahawk and to apply the full scope of its accumulated knowledge and experience therein. This is the second US Navy platform RUAG is set to support, in addition to the F/A-18 Hornet contracts awarded in August 2020. This new contract strengthens the existing collaboration between RUAG Australia and the US Navy and sees a foundation for future growth for the national Defence SME. “Earning the confidence and trust of the US Navy is testament to our highly skilled team of professionals who provided reliable MRO support for the B model Seahawk,” commented Terry Miles, General Manager at RUAG Australia. “Now awarded the first contracts for F/A-18 components and the MH-60R Seahawk proves our relationship with them continues forward, going from strength-to-strength.”

RUAG Australia is the first Australian company to receive an award under the ADAC initiative covering MRO of selected components for MH-60R Seahawk helicopter. This program designates the defence SME as an approved source of repair for Navy Supply (NAVSUP) within the APAC region. ADAC is a senior bilateral forum for cooperation between the US and Australian Military aiming to facilitate closer Defence and industry collaboration related to the acquisition, logistics and follow-on support of Defence equipment. “We are very proud to apply our vast technical expertise and knowhow in life cycle support on behalf of the US fleet and their aircraft availability,” said Stephan Jezler, Senior Vice President Aviation International, RUAG MRO International.

Australian Made teams up with AMGC The Australian Made Campaign has thrown its support behind the Advanced Manufacturing Growth Centre’s (AMGC) COVID-19 Manufacturer Response Register. Australian businesses registered on the platform can now highlight the local provenance of their products via the Australian Made logo. Businesses with products licensed to carry the logo will be able to incorporate the brand into their AMGC COVID-19 Manufacturer Response Register listings. Broad enhancements to the Register include the ability to: • Display the Australian Made logo. • Note Therapeutic Goods Administration (TGA) approval. • Upload a PDF for brochures, spec sheets or other key information. • Navigate with more powerful search and connection functions. Ben Lazzaro, Chief Executive of the Australian Made Campaign, said there has never been a more important time to consider buying local: “Australian manufacturers produce products made to some of the highest quality and safety standards in the world. AMGC’s COVID-19 Response Register is a great resource for local businesses to connect and identify local products and supplies relating to managing COVID-19, and we are happy to support the initiative via the use of the Australian Made logo.” Developed by AMGC in collaboration with the Department of Industry, Science, Energy & Resources, the COVID-19 Manufacturer Response Register brings together manufacturers, suppliers and customers via a self-managed platform to offer products and

services in response to the pandemic. The free platform allows companies to post a need, solution, or capability online, which is shared on a live community feed. Dr Jens Goennemann, Managing Director of AMGC, said the Register has proven its value during the crisis: “The Register continues to play a critical role in helping business shift focus to assisting the nation’s response to the pandemic, with manufacture of hand sanitiser to invasive ventilators aided by information from the Register. Now it is about supporting the economic recovery and COVIDSafe workplaces and businesses as we open back up through supply of products and services.” The supply matching feature helps suppliers connect with organisations looking for crucial items. Items available for purchase on the platform include hand sanitiser, sneeze guards, face masks, gloves, gowns, caps, booties and all manner of personal protective equipment (PPE), medical equipment and resources for operating a COVIDSafe business. “With the platform free to use for all Australian businesses, we encourage everyone to register and connect with manufacturers and suppliers,” Goennemann added. For further information about the AMGC COVID-19 Manufacturer Response Register, visit: www.amgc.org.au/covid-19-manufacturer-response

The advert by Intermach in the October/November issue of AMT contained an image of a LVD-HD press brake. Intermach is not an authorised agent of LVD and therefore cannot make representations of the LVD brand. LVD’s authorised agent for Australia and New Zealand is GWB Machine Tools. www.gwbtools.com.au

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GOVERNMENT NEWS

Victoria: No-cost service for Business Recovery & Resilience Mentoring The Victorian Government has established the Business Recovery & Resilience Mentoring Program, with the Victorian Chamber of Commerce and Industry as the auspicing body. Under the program, targeted advice and guidance is available to help small businesses navigate the economic challenges posed by the ongoing COVID-19 market changes. Through a panel of experienced Business Mentors, businesses can get help in the specific areas of business planning, strategy development and deployment, market transformation and supply chain diversification. Importantly, having been in lockdown for some months, this business recovery program is available at no cost to the participating business and is funded by the Victorian government. BizAdviser, a new association of business consulting professionals providing tailored advice to help SMEs become a cut above the rest, is an approved Business Mentor provider under the program. BizAdviser Principal Mal Clark said: “With around 90 years combined executive management experience in private industry and over 30 years collective experience supporting SMEs, our BizAdviser mentors have helped many businesses to grow and prosper across a broad spectrum of industries.” The program’s aim is to mitigate business risks and financial exposure. Where possible it will connect to other government support and local professional services. Through the program, eligible business owners can receive up to four two-hour mentoring sessions over a three-month period with an experienced professional from BizAdviser, who will help them make informed decisions about the future of their business. The program offers tailored guidance to help businesses in several areas: • Business recovery. To strengthen business recovery (cost reduction, debt and cashflow management). • Market transformation. To understand how COVID-19 has triggered or accelerated market changes. • Digital literacy and engagement. To help businesses reach new customers and markets. • Market and supply chain diversification. To reduce exposure to supply chain risks. • Reskilling and retraining. To help businesses upskill their existing workforce.

The BizAdviser team: Mal Clark, Rob Murphy and Phil Bourke.

Eligibility for the program has been kept as broad as possible; businesses must be located in Victoria and have fewer than 20 fulltime employees or turnover under $50m. BizAdviser can advise on your eligibility and guide you through the application process. Adviser Rob Murphy has a background of demonstrated management consulting expertise, assisting over 150 firms through Enterprise Connect and the Entrepreneurs' Programmes. Adviser Phil Bourke has an enviable record in international trade and export development. “Major disruptions like the COVID-19 pandemic present incredible challenges but also offer unique opportunities for businesses to recover, reposition and redesign their competitive advantage,” said Murphy. “Business leaders can navigate short-term uncertainty while accelerating needed transformation so the ultimate impact of COVID-19 will be defined by its role in driving constructive change.” Bourke added: “Whether in times of crisis or relative stability, leading with a vision and articulating a strategic path forward is crucial for long-term business success. While you can’t predict what’s coming with perfect certainty, now is a great time to consider what you could and should become, think about new customers or new markets, create a plan and then set it into motion.” Further information is available via the Victorian Government (https:// tinyurl.com/y52xlkau) or the Victorian Chamber of Commerce and Industry (https://tinyurl.com/y5cn7dk8). Businesses are advised to contact BizAdviser for guidance through the application process. www.bizadviser.com.au

NSW launches $100m Regional Job Creation Fund Regional businesses that can increase employment by expanding production lines or relocate operations to regional New South Wales (NSW) from interstate or overseas will have access to support grants of up to $10m. NSW Deputy Premier John Barilaro said the $100m Regional Job Creation Fund will provide businesses with money to fast track expansion plans, create jobs and stimulate the local economy. “NSW businesses have demonstrated remarkable resilience in the face of drought, bushfires and COVID-19 and this unprecedented funding program will help them thrive instead of just survive,” said Barilaro. “I have set an ambitious target for the Regional Job Creation Fund to create at least 5,000 new direct jobs across regional NSW in the next three years by providing businesses with the equipment, infrastructure and capacity to create new opportunities and attract new customers.” Barilaro said the Regional Job Creation Fund will provide grants between $100,000 and up to $10 million to undertake projects that create jobs, including those that:

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• Replace, upgrade or adapt existing plant or equipment, including technology or energy efficiency upgrades. • Enable existing regional NSW businesses to establish an additional production line. • Relocate a business from interstate or internationally to regional NSW, or onshore an activity currently undertaken overseas. • Develop new tourism experiences and attractions to create new demand in a region. Applications are now open and close on 14 May 2021 or when program funding is fully allocated. www.investregionalnsw.com/RJCFund

GOVERNMENT NEWS

New appointments to advise on manufacturing strategy Five new members have been added to a board of entrepreneurs, investors, researchers and educators who will advise the Federal Government in its effort to grow Australian manufacturing and create jobs. The newly renamed Industry Innovation and Science Australia (IISA) – previously known as Innovation and Science Australia – will advise the Government on innovation, research and science matters. DuluxGroup CEO Patrick Houlihan and Woodside Energy’s Lauren Stafford have both been appointed to the Board for three years. Fintech and consumer rights expert Scott Farrell, space technology entrepreneur Dr Alex Grant and ag-tech innovator Sarah Nolet have been appointed for two years. Minister for Industry, Science and Technology Karen Andrews said the new appointments would bolster industry experience within the organisation, particularly as it helps deliver the Government’s $1.5bn Modern Manufacturing Strategy. “As a Government we are getting the economic conditions right and backing our manufacturers to become more competitive, more resilient and to scale up,” Minister Andrews said. “But it is industry that will chart the course of our recovery and make this Strategy stick for generations to come. We know it is industry, not governments, that create jobs, so it’s essential that we have people from industry in these key advisory roles. “These appointments will ensure the Board has the necessary skills, expertise, and connections to the Australian business community to reshape and reignite Australian manufacturing – as well as delivering advice more broadly on how to innovate.” IISA is playing a crucial advisory role in implementing the Modern Manufacturing Strategy and overseeing the development of industry-led road maps that will guide future investment and action.

IISA Board Chair Andrew Stevens said he was keen to get to work with the refreshed Board. “These new appointments will bring a wealth of industry experience and fresh thinking to the Board,” said Stevens. “I look forward to working with our current and new members to further contribute to Australia’s economic recovery.” Andrews said changing the name from Innovation and Science Australia reflects an enhanced Government focus on making science and technology work for industry. More information on IISA is available at: www.industry.gov.au/strategies-for-the-future/innovation-andscience-australia

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Yes, we need to make things in Australia, but not like in the past Calls for a revival of Australian manufacturing have surged in 2020 as the COVID-19 pandemic showed our vulnerability as global supply chains broke down. However, we should be strategic in targeting areas of manufacturing where Australia can enjoy a comparative advantage, writes Richard Holden. Much of the focus of Opposition Leader Anthony Albanese’s budget reply speech was around Labor’s proposal to expand childcare subsidies – a policy with some flaws but which moves in the right direction. Labor’s plan to modernise the electricity grid by setting up a “Rewiring the Nation Corporation” with $20bn in government support was also met with general approval. What got less attention was the third pillar of Labor’s budget strategy – a big push toward more local manufacturing jobs. Albanese wasn’t shy about what he meant. He lamented the loss of Australia’s car-making industry: “Australians will never forget that it was this government that drove Holden, Ford and other car makers out of Australia, taking tens of thousands of jobs in auto manufacturing, servicing and the supply chain with them.” He then announced Labor would create a National Rail Manufacturing Plan to expand Australia’s boutique train-building industry: “We will provide leadership to the states and work with industry to identify and optimise the opportunities to build trains here in Australia – for freight and for public transport.” The economics of pillars 1 and 2 make sense. Pillar 3 involves trying to turn back the clock on the irrepressible, tectonic forces of globalisation and automation to pretend we should make things here we shouldn’t.

Understanding comparative advantage Countries benefit from trade rather than seeking to produce everything they need locally. This is due to the idea of ‘comparative advantage’, originated by David Ricardo in his 1817 book On the Principles of Political Economy and Taxation. One country (call it country A) might be more efficient than another (country B) in absolute terms at producing, for example, T-shirts and wine. It is tempting to think, then, that country A should produce both T-shirts and wine. But what if country B is really inefficient at producing T-shirts but reasonable at producing wine? If country A specialises in producing T-shirts and country B specialises in producing wine, they can trade and both be better off. Why? Because country A produces T-shirts much more efficiently than country B, and country B is only a little less efficient at producing wine. Overall, both economies get more efficient, raising living standards.

Making cars and trains in Australia Does Australia have any comparative advantage at producing cars or trains? With cars the evidence speaks for itself. Local manufacturing only survived for decades because of huge government subsidies. Without them Australian-made cars couldn’t compete. Only part of that was to do with labour costs – and we should be rightly proud of our comparatively high wages and good working conditions. Germany – home of BMW, Mercedes Benz and Volkswagen – also has high wages and conditions.

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What about trains? Some trains are made in Australia – by Downer EDI and Canadian multinational Bombardier. That’s good for a few thousand jobs. But the market is domestic, with the customers being state governments who buy with an eye on local jobs. There’s not a lot to suggest it can become an export industry, competing for example with Japan, which has been making bullet trains since the early 1960s. Or France, whose train builders have sold hydrogen trains to Germany and high-speed freight trains to Italy. With these competitors having such an edge, and the well-known phenomenon of “learning-by-doing”, are we really going to catch up? There are many other sectors in which Australian producers are internationally competitive, such as agriculture, services and areas of high-tech manufacturing. Building on and expanding comparative advantage in these areas makes a lot more sense.

The case for strategic manufacturing That said, the COVID-19 pandemic has taught us how fragile certain parts of our economy are. The same logic of comparative advantage that has done so much to improve living standards has also made us vulnerable in some areas. Having little or no manufacturing capacity in personal protective equipment (PPE) or pharmaceuticals like insulin, EpiPens and antibiotics is potentially very dangerous. Importing more than 90% of our pharmaceuticals puts us in a vulnerable position if a state actor that controls important parts of the global supply chain decides to cut supply. This is what economists call the “hold-up problem”. So it makes sense for Australia to have more presence in strategic manufacturing like pharmaceuticals and personal protective equipment, even if producing these goods locally is not as efficient as buying them from overseas.

From just-in-time to just-in-case The pandemic has taught us that we have, as a nation, moved a little too far towards the efficiencies of “just-in-time” supply chains. We need to move back somewhat, but certainly not completely, in the direction of “just-in-case” – to a little less efficiency but a little more insurance. That should involve a push for strategic manufacturing. We should at all times be looking to build on and expand our comparative advantage. But trying to go “Back to the Future” and build an Australian De Lorean makes no sense. Richard Holden is Professor of Economics at the Australia Business School of the University of New South Wales (UNSW). This article was originally published by The Conversation. www.theconversation.com www.unsw.edu.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Observation – The key to inspiring amazing, disruptive innovations The key to real innovation is in observing and identifying problems worth solving. Unfortunately many innovators are driven by the teaching that commitment and persistence will lead to success, even with ideas and products that may have little merit, writes Roger La Salle. Persist and you will succeed, we are told. But how true is this? Does persistence really win in the end? I have always lived by a saying I coined many years ago:

rises, resulting in thermal runaway or hot spots. For years the approach to identifying hot spots has included all of the ingredients that may qualify for an opportunity scan. Activities that were predictable, widespread and repetitious, with thermographers virtually worldwide annually taking single-shot thermal images inside electrical switchboards in an endeavour to find hot spots.

“Persistence is an important element of success; Persistence is an essential element of failure.” The underlying thinking here is that if the idea is fundamentally bad, no amount of persistence will make it good. Worse still, many are so enamoured with their ideas that they invest heavily in patents only to then fail and go broke at the same time. Persistence needs to be moderated with a high degree of common sense and objectivity, and the ability to let go and know when to stop. It’s not a failure if you stop before it’s too late. It is a failure if you persist beyond the point of sensibility. Having said that, capturing and holding the nub of a good idea is another matter as maybe it’s just a matter of time until the technology is achievable. A good example may be the concept of a wristwatch phone – conceived 50 years ago and a marvellous idea, but only recently possible. With that in mind let us explore the ways we can identify ideas or problems worth solving in the first place, before applying the tools of innovation and engineering to find a solution. Quite remarkably, the suggestion that you should explore your customers’ needs in search of a problem is somewhat new in the pursuit of innovation. This simple notion –of asking what the customer wants – is embodied in so-called “Design Thinking”, a movement that only swept the world during the past decade. The idea of exploring customer needs is of course excellent; the problem is that the means of exploring such needs was lacking. The secret to identifying possible good ideas lies in the art of not asking, but observing people’s behaviour. This is best done using the tools of “Opportunity Capture”, where there are only five things one needs to observe: • Predictable activities. • Widespread activities. • Repetitious activities. • Emerging trends in activities. • Comparison between groups. These are the seeds of opportunity capture, with the entire opportunity scan process being embedded in a five-by-eight matrix that gives some 40 ways to explore the opportunity horizon. However, the above seeds alone will suffice if we just use these to observe behaviour. Properly used, the approach of observation makes it easy to identify opportunities for innovation – in fact, disruptive innovation, since it focuses on common behaviours. This brings to mind a problem we observed many years ago, but have only recently resolved and brought to market. To put this into context, fires in electrical switchboards almost always occur at terminations as joints become loose and corrode and resistance

Unfortunately, as good as this may sound, a thermography can never be sure that when the picture is taken the load actually causing the hot spot is even operating. Who really knows what’s happening when the thermal image is captured? In fact the suggestion that a one-shot thermal picture of an electrical switchboard, with unknown loads operating, can give you peace of mind that a building is safe from fire until the next annual picture is questionable. Alternatives such as real-time radio I0T alert devices are available. So too are fibre-optic monitors that span many connections, or fixed thermal cameras or wired thermocouples, but these are simply not cost-effective for use across the myriad of switchboards and wires that populate every building in the country. It was the opportunity scan and observation of hot spots and the sheer population of switchboards that resulted in the development of a newly released technology. Costing only a few cents each, permanent colour change clips that change colour from purple to bright pink are now available and can be attached to every cable to indicate the presence of a hot spot, no matter when it occurred. Faults are now obvious the moment you open the switchboard. This is one simple example of what an opportunity scan can achieve on just one level. How many other safety-related events do we see only periodically monitored that could be monitored in a more thorough fashion and thus lead to breakthrough innovations? Examples might include: • “Tag testing” of trade power tools, only for the tool to become damaged and dangerous the very day after is passes all tests. • Vehicle tyre pressure. • Smoke detectors. • Life jackets in boats. • Electrical appliance connections. • Gas leaks. • CO monitors for domestic heaters. • Water leaks and dripping taps. The list is endless if we simply employ this opportunity scan approach of observing the way people work. Indeed, safety-related activities are a most fertile ground for identifying problems worth solving. www.innovationtraining.com.au www.safeconnectaustralia.com.au

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Collaborative automation key to Australia’s manufacturing revival As 2020 draws to an end, Australian manufacturing must face the challenges of operating in a new, post-COVID landscape. Collaborative robotic applications can help manufacturers emerge more competitive with greater production flexibility, higher output, and better output quality, writes James Taylor of OnRobot. In the midst of the COVID-19 pandemic, many of us have had to face once-in-a-lifetime challenges, perhaps both personally and economically. At the same time, geopolitical tensions have created uncertainty for some manufacturers with exposure to international markets. However, once-in-a-lifetime challenges also present significant opportunities for those who are willing to learn and adapt. With that in mind, new innovations in manufacturing technology are a key development for manufacturers seeking sustainable growth in this changing climate. For many years manufacturing played a significant role in Australia’s economic success and was one of the country’s biggest employment providers. In the 1980s, for instance, it accounted for roughly 16% of the country’s workforce—more than any other industry. So although Australia currently ranks last among Organisation for Economic Cooperation and Development (OECD) countries for manufacturing self-sufficiency, there is a history of success. The COVID-19 pandemic has impacted economies around the world, but Australian manufacturing can adapt, capitalising on international supply chain disruptions to meet growing domestic business demands. Driven by new technologies and capabilities, including modern collaborative applications and automation, now could be the time for manufacturing to make its welcomed comeback.

The rise and advantage of collaborative applications Collaborative applications – created when lightweight industrial robots and collaborative robots (cobots) are equipped with intelligent tools such as grippers, sensors, vision and the software that drives them – are the future of automation. These advanced technologies enable simple, rapid deployment and new processes while working safely alongside workers. In the past, automation was viable only for large manufacturers who had the space, cash, and technical resources for large investments in traditional industrial robots. Companies needed large runs of the same products and processes over long periods of time. Investments took years to pay for themselves. Collaborative applications provide a quick and easy entry-point to automation, particularly for smaller manufacturers whose businesses have lower-volume, high-mix production lines. These small-and-medium-sized enterprises (SMEs) can emerge more competitive with greater production flexibility, higher output, and better quality. Since SMEs are more vulnerable to supply chain disruptions and “black swan” events such as COVID-19, versatility and the capacity to quickly adjust manufacturing processes are hugely important. One such Australian company that improved its manufacturing processes is Designed Mouldings, primarily serving the pharmaceutical industry with plastic injection-moulded components. The company integrated OnRobot’s VGC10 vacuum gripper with a cobot at its factory in Caringbah, New South Wales, to automate the delicate, time-consuming task of picking and placing plastic moulded caps.

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Japanese contract manufacturer Sanmatsu used a collaborative robot to automate a machine tending application, eliminating the need to have a worker continuously stationed at the machine, reducing overtime and lowering production costs by 10%.

Equipped with a collaborative vacuum gripper, the cobot autonomously executes the task, reducing operational costs, increasing productivity, and delivering an expected return on investment (RoI) of just six months. Employees work safely in close proximity, feeding raw materials to the robot and removing completed products from the line.

Opportunity within disruption Supply chain disruptions caused by the COVID-19 pandemic have increased demand for domestic products and spurred policymakers to consider more manufacturing investments. Increasing Australia’s manufacturing self-sufficiency to 100% could add $180bn in new manufacturing output, boost GDP by $50bn a year, and create more than 650,000 jobs. Adoption of new manufacturing methods using collaborative automation will be a key enabler. Strategic consulting firm AlphaBeta estimates that automation could boost Australia’s productivity and national income by $2.2 trillion by 2030, while leading to the development of new products, services and business models . Collaborative automation can also help reduce manufacturing costs, which remain a roadblock in Australia. It can also relieve workers of dangerous, cumbersome, and otherwise boring tasks, freeing employees to take on higher-value jobs. This advantage is evident at Sanmatsu, a Japanese contract manufacturer. The company paired OnRobot’s RG6 Dual grippers with a cobot to automate a machine tending application. The RG6 extracts and sets parts simultaneously with its dual grippers, speeding up cycle time and lowering machine idle time roughly by half. This eliminates the need to have a worker continuously stationed at the machine, reducing overtime and lowering production costs by 10%. By offering greater flexibility and value, enabling onshoring capabilities, and helping produce higher quality results, I believe collaborative automation will help drive a resurgence of Australia’s once-potent manufacturing industry. James Taylor is the General Manager – APAC for OnRobot. www.onrobot.com

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Putting out fires with gasoline – Navigating changing supply chain dynamics amid COVID-19 The disruption to supply chains has been a business casualty throughout the crisis caused by the COVID-19 pandemic. Louise Bayliss, CEO of Setec, discusses the ways her manufacturing business has navigated the changing dynamics over the past six months. As a CEO in a manufacturing business with a history that spans more than 50 years, I know the balancing act that goes into guiding and leading a company. A successful enterprise always stands ready to redesign systems and operations in accordance with the current environment, and Setec is no exception. Our history proves a deft ability to remain competitive and strong. In the time now known as pre-COVID, it’s reasonable to say that most industries were cognisant of potential risks and how to mitigate against them. The risk of a natural disaster and its impact to business was well understood. Mitigating the risk of a misplaced shipment was equally recognised. Such potential risks were written into a business plan, ready for action in the event of such risks unfolding. It is, however, a fairly safe assumption that no business plan included a risk mitigation strategy arising from a once-in-100-year pandemic. No one saw this coming. And when we did see the virus creep across the seas in the early days, many believed it to be an isolated incident. Customers called for stock in substantial quantities, stockpiling materials to get through what was considered a small blip to trading. It was hard to gauge the full impact. There is no doubt that COVID-19 has left businesses scrambling. It’s increasingly difficult for CEOs and business owners to brainstorm the next risk point. There is a constant element of second-guessing, an ever-present need to be vigilant and agile against the next wave of coronavirus; its insidious threat vastly affects the supply chain across the globe, largely due to individual countries and their respective governments reacting with varied tactics. At a business level this takes decision-making out of our hands, held instead at the whim of governments, often with little transparency exhibited to industry and communities alike. And the ripple effect caused by these government edicts brings significant pressure to business owners as we struggle with a vagueness to supply chains. Routes that were previously known and reliable are now unknown and unreliable. Materials that might previously arrive within three or five business days can now take two weeks, sometimes three, as carriers are forced to alter routes to cross borders and enter countries in severe lockdown. The challenge this presents to CEOs demands a persistence to attempt to keep one step ahead; a resistance to accepting the status quo. This might take the form of asking the ‘What ifs’ regarding supply chain routes, and ensuring the leadership teams ask them too. It might be as simple as safeguarding multiple sources for your own suppliers or recognising alterations to the movement of your goods. Additionally, CEOs are placed under pressure just to “keep the shingle above the door”. We are left with little choice but to make more conservative decisions regarding investments, raw materials, and supply chains – all with a reduced revenue. Strategic planning and forward-thinking initiatives, seeking growth opportunities, have been paused to focus on something that is wholly unpredictable. It’s like we’re putting out fires with gasoline.

Setec shipped Australian-made BMPRO smart RV systems to a customer in the US in time in spite of supply chain disruptions during the COVID-19 crisis.

“There is no doubt that COVID-19 has left businesses scrambling. It’s increasingly difficult for CEOs and business owners to brainstorm the next risk point. There is a constant element of second-guessing, an ever-present need to be vigilant and agile against the next wave of coronavirus.” However, even during this insecurity Setec has been proud to be able to serve our customers. Throughout the pandemic, we have navigated blindly, in uncharted circumstances. We’ve split shipments to customers: one section by plane, one by truck, determined to get across the border and into our customers’ warehouses. We are privileged to maintain long-standing relationships with multiple suppliers of particular raw materials, leaving us the option of being able to use different sources as needed. We have invested heavily in building stock so we are equipped and ready to supply our customers consistently and at their need. There will always be gaps, particularly in the current climate, where plans slip and fall. But agility in leadership demands a necessity to rebalance the business. At Setec, we focus on building a rapport with our suppliers, customers and people. I believe it is through the channel of connections that we’ve weathered the most unpredictable and volatile risk in our time. Louise Bayliss is the CEO of Setec Pty Ltd, a designer and manufacturer of custom-made power supplies for automotive, medical, communications and gaming industries based in Knoxfield, Victoria. www.setec.com.au

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TECH NEWS

Germany: Leaner, greener fire-resistant glass

Australia: Cement-free concrete beats corrosion and fatbergs

Although fire-resistant windows already exist, they contain a carcinogenic gel, and their production generates a lot of waste. A new technology is much safer and less wasteful. By rights, this glazing should not work. However, it does - in a way that exceeds expectations. During a fire-test, the glass withstood flames and heat of over 1,000°C for up to 120 minutes. The panes do not contain the carcinogenic acrylamide and it generates just 20kg of process waste a day – far less than the 150kg produced in the past. The glazing contains a transparent gel rich in water and electrolytes between two glass panes. If a fire breaks out, the pane facing the flames does not withstand the heat for long and shatters. This actuates two mechanisms: For one, the water in the gel evaporates and cools the intact second pane. For the other, a heat-insulating salt layer forms.

Researchers have developed an eco-friendly cement-free concrete, which all but eliminates corrosion. Concrete corrosion and fatbergs plague sewage systems around the world. However this zerocement concrete can withstand the corrosive acidic environment found in sewage pipes, while greatly reducing residual lime that leaches out, contributing to fatbergs. The concrete eliminates free lime – a chemical compound that promotes corrosion and fatbergs. Portland cement is widely used in the fast-paced construction industry, but it poses long term durability issues in some of its applications. Making concrete out of this composite blend – rather than cement – significantly improved longevity. The zero-cement concrete achieves multiple benefits: it’s environmentally friendly, reduces concrete corrosion by 96% and totally eliminates residual lime (instrumental in the formation of fatbergs).

Fraunhofer/New Atlas

RMIT

Australia: Translating thoughts to actions World-first and Australian-developed; a human trial has been conducted of a paper-clip-sized device (Stentrode™) which was inserted into a vein in the skull of a paralysed person. This picks up infrared brain signals and wirelessly transmits them so that the person can operate computers and phones with their minds (directed by eye-tracking software). Reading brain signals to operate devices isn’t new (ie EEG head caps). But the Stentrode is placed in a blood vessel. Unlike electrode brain-implants, which produce an immune response that leads to scar tissue around the recording electrodes, the Stentrode™ is biocompatible and is incorporated in the wall of the blood vessel and isn’t in direct contact with the brain, meaning it can keep operating permanently. Synchron Australia was founded as the vehicle to translate the technology from research to commercial product. University of Melbourne

USA: 3D printable, self-healing, recyclable polymers By tweaking the chemistry of a single polymer, researchers have created a family of synthetic materials that range from ultra-soft to extremely rigid. The materials are 3D printable, self-healing within seconds, recyclable, have shape memory and naturally adhere to each other in air or underwater. Researchers focused on the molecules involved in “crosslinking”. First, they chose a prepolymer, and then chemically studded these prepolymer chains with two types of small crosslinking molecules — furan and maleimide. By increasing the number of these molecules, they found that they could create materials stiffer. Crosslinks are reversible: furan and maleimide pairs can “click” and “unclick” depending on temperature. By modifying the hardware and processing parameters in a standard 3D printer, complex 3D objects were printed, with the layers of vastly different stiffness. Texas A&M University College of Engineering

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Left: highly-corroded Portland cement concrete. Right: Zero-cement concrete

Japan: Metal–plastic 3D printing Scientists have developed a novel and surprisingly simple method to print 3D structures made of metal and plastic, paving the way for 3D electronics. It a major improvement over the conventional metallization process, in which the plastic object is 3D-printed and then submerged in a solution containing palladium (Pd) and then submerged in an electroless plating bath which produces a metallic coating that is non-uniform and adheres poorly. In contrast, in the new hybrid method, a printer with a dual nozzle is used; one nozzle extrudes ABS whereas the other extrudes ABS loaded with PdCl2. By selectively printing layers using one nozzle or the other, specific areas of the 3D object are loaded with Pd. Then, through electroless plating, one finally obtains a plastic structure with a metallic coating over selected areas only. The technique does not require any roughening or etching of the ABS structure to promote the deposition of the catalyst, unlike the conventional method. Waseda University

Australia: Affordable solar cells using copper Sydney startup SunDrive is aiming to produce affordable solar cells in Australia from common materials by replacing silver (which is in limited supply) with copper, which is 1,000 times more abundant and 100 times cheaper per kg than silver. The company, securing $8m in funding, is commercialising its technology and to improve the efficiency beyond the levels attainable with silver. SunDrive is not the first to tackle the problem, but its unique copper processes put it at the forefront. Late last year, the team produced the most efficient commercial-size solar cell ever made in Australia. The business originated from co-founder Vince Allen's PhD at the UNSW, where he was developing a way for copper to stick to the surface of solar cells; creating a method of electroplating the copper, in which it is deposited using an electric current instead of a paste. Arena/ABC/Fin Review/Smart Company

TECH HEADING NEWS

UK: Wind turbine repair “blade-walker”

Italy: World's first 3D-printed fibreglass boat

BladeBUG and the Offshore Renewable Energy Catapult have announced the UK’s first blade walk by a robot on an offshore wind turbine. The six-legged inspect-and-repair robot repeatedly scaled blades at a demonstration turbine off the coast of Fife. The robot is said to represent a 30% cost reduction based on lifetime blade maintenance and is predicted to reach up to 50% for next generation turbines. These costs have been a primary concern for offshore operators, as sea conditions and faster tip speeds can lead to significant blade damage. During the demonstration, the robot walked 50 metres on a vertically positioned blade (a length of 84 metres with the tip reaching 195 metres above the sea when upright). Capabilities demonstrated were the ‘perfect’ adherence of its vacuum-packed feet to blade surfaces in offshore conditions, the ability to navigate the varying curvature of blade surfaces in a variety of scenarios, and transmission of data from blade scans and live video feed to technicians.

Moi Composites has unveiled the MAMBO (Motor AM Boat), which is reportedly the world’s first genuine boat 3D-printed in continuous fiberglass thermoset material. It is 6.5 metres long by 2.5 metres wide; includes a navigation system and 113-horsepower engine. The various sections were printed using two Kuka Quantec robots at Moi Composites’ headquarters in Milan, and in Autodesk's Advanced Manufacturing Facility in the U.K. The boat was digitally crafted with patented CFM. This allows the creation of fibrereinforced products with mechanical characteristics comparable to those of unidirectional fibreglass, without the aid of models and moulds. It is thereby possible to obtain real products in small lots or unique pieces, efficiently and cost-effectively with customisation and high mechanical performance not available through traditional manufacturing. The material makes products durable and lightweight, and the robotic system allows for scalability in print size. The Fabricator

The Engineer

Redirecting lightning Australia: Loyal Wingman drone completes taxi test Partnering with Boeing Australia, Queensland will be the production home for unmanned defence aircraft – the first military aircraft to be designed, engineered and manufactured in Australia in more than 50 years. The first aircraft prototype, the Loyal Wingman drone, unveiled last May, has completed its milestone low-speed taxi test in October where it successfully demonstrated the ability to stop and manoeuvre on command. This is part of preparations for the first flight, which is expected by the end of the year. This aircraft and the other prototypes will be unmanned with fighter-like performance and the ability to fly 3,700 nautical kms. Mirage News/mixed

UK: New technique for producing biocompatible glass

“We have an invisible thread, a pen with which we can write light and control the electrical discharge to within about one tenth the width of a human hair" Prof. Andrey Miroshnichenko, UNSW, speaking about new laser tractor beam technology developed by an international team including the UNSW and ANU. The team used a laser beam that mirrors the same process as lightning and creates a path that directs electrical discharges to specific targets. It works by trapping and heating graphene microparticles in the ambient air and heating those particles trapped in the beam; thereby creating the necessary conditions for electric breakdown and transmission along the laser's path. The team used a laser intensity a thousand times less than that in any previous attempts, meaning any potential technology to control lightning could be much cheaper, safer and more precise. The discovery also has potential for the micro-scale control of electrical discharge in medicine and manufacturing.

Researchers have applied a new low temperature (<250°C) processing technique to bioactive glasses which could be used to repair human tissues in a safe, sustainable way. The idea came from the concept of the cold sintering of ceramics. In addition to densifying a range of specialist glasses, cold sintering is of particular interest for bioactive glasses such as Bioglass®, which are biocompatible and widely used in the medical sector. The advantages of using this process to densify Bioglass® are many - including the potential for drugs to be embedded in the Bioglass® before densification. Cold sintered glasses can be used to coat surfaces and stick together a wide range of materials, including other glasses, ceramics, composites and metals. The potential of this technology will hopefully allow the exploration of new functional glass and polymer composites hitherto thought impossible to manufacture. University of Sheffield

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PRODUCT NEWS

Walter Innotime – From component to tooling, at high speed Walter has introduced ‘Walter Innotime’, a new digital design wizard for accelerating the consulting and ordering process for its cutting tools. Engineers at Walter Engineering have been working with Walter Innotime, a web application that links existing Walter systems to the Engineering Kompetenz of Walter employees. Based on a 3D model of the component drag-anddrop uploaded to the Walter website by the customer, Walter Innotime analyses which cutting operations are required and suggests to the engineer dealing with the enquiry (in future versions, directly to the customer) the appropriate machining tools with cutting data and prices from the Walter portfolio. This digital search at component level is currently unique in the market. The engineer checks the proposal and optimises it, if necessary, according to the customer’s needs. As a result, the design process for complex enquiries is fast-tracked considerably – and the customer receives the most economical tailored tooling solution and a valid quote in the shortest time. Walter field service

employees and engineers benefit from the preliminary work done by the system: in the physical design and the development of the optimum machining strategy for the customer component. “For our engineers and technical distributors, but primarily for our customers, Walter Innotime represents a milestone,” explains Dr Michael Hepp, Vice-President – Digital Business at Walter. “We deliberate intensively over the component and can deal with enquiries so much faster – for our customers, that’s something directly tangible. By combining the Engineering Kompetenz of our employees with the virtual intelligence of our software systems, we can assist our customers in quickly and easily finding, purchasing and employing the most economical tooling solution for them. In future, our customers will have to do nothing more than upload their 3D component – quick and easy.” www.walter-tools.com

Lang Technik stamping technology now available for round parts Leading workholding manufacturer Lang Technik has added a new product to its highly regarded Makro-Grip range: the Makro-4Grip. This innovative clamping system allows Lang’s stamping technology to now be utilised for round parts. The Makro-4Grip employs a patented form-closure technology, which provides the highest holding power for five-face machining in the world. Often referred to as pre-stamping, it involves the workpiece being stamped outside of the machine tool with up to 20 tons of hydraulic pressure. Clamping scenarios that require high holding power, no work stop in the machining area, or where the danger of workpiece deformation exists can be mastered with the stamping process. “Makro-Grip stamping technology provides tremendous material savings due to minimal clamping edge requirements,” says Paul Fowler, Managing Director of Dimac Tooling. “The new Makro-4Grip means that any company that is involved with workpiece milling of round parts can now benefit from this technology easily and costefficiently. Lang’s stamping technology is still the benchmark when it comes to processing raw parts in five-axis machining.” The Makro-4Grip consists of universal stamping jaws with inserts for individual positioning as well as matching clamping jaws suitable for all sizes of Makro-Grip vises. The jaws grip the pre-stamped part in four indentations at a clamping height of just 3mm and covers a range from 36mm to 300mm. “For five-sided machining, where optimal accessibility has to be achieved, stamping technology in connection with a Makro-Grip five-axis vise provides the ultimate solution and most importantly the highest holding power for five-face machining worldwide,” Fowler explains. “Makro-Grip five-axis vises are the perfect solution for all challenging clamping tasks and are simply unbeatable in fivesided manufacturing.”

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The Makro-Grip vise range includes the Dual-Clamping vise, the Makro-Grip Automation and the Profilo Clamping vise; a clamping system for all shaped parts allowing for the use of different types of profile jaws on one vise body. The Universal Avanti vise offers great handling characteristics and enormous set-up time savings thanks to a quick jaw exchange system. The Vario-Tec Centering vise is a convenient and versatile clamping solution for semi-finished parts while the Ino-Grip 3-Jaw chuck is an automatable chuck for milling round parts. Another unique product in the Lang Technik range is the Cleaning Fan. The fan automatically cleans the machine table, pallet and/or workpieces after the machining process is complete. “This well known German company is recognised as the leading manufacturer of workholding solutions for almost any clamping requirement from raw material to the finished workpiece,” adds Fowler. “Every month thousands of clamping set-ups are delivered to customers all over the world to help them increase their production efficiency. “Because all Lang Technik’s extensive products come from the one place they are perfectly matched and interfacing problems with other systems do not exist. The modular building system and the multitude of combinations and capabilities are the reason that their workholding systems can be used in almost any machining centre.” www.dimac.com.au

PRODUCT NEWS

Integra Systems’ DigiSMART Collection – Transforming i4.0 processes Integra Systems has released the DigiSMART Collection, a newly designed touchscreen kiosk technology created to help other manufacturers in achieving digitisation and Industry 4.0 ambitions across their operations. Developed as part of Integra TransForm – a special division of Integra Systems where performance-enhancing proprietary products are conceived, designed and produced – the DigiSMART Collection offers a degree of versatility that goes beyond the manufacturing space, adapting to the many demands of other industry sectors such as retail, defence, logistics, transport, medical and so on. As an example, Integra Systems founder and Managing Director Paul Hughes says that the i4.0 DigiSMART Kiosk in the DigiSMART Collection integrates with various data sources across an organisation to create streamlined, smarter ways of operating. “It combines everything so you’ve essentially got a virtual ‘job bag’ so that everyone can open the job via a touchscreen and see all the information they need in one place,” says Hughes. “Utilising artificial intelligence, the I4.0 DigiSMART Kiosk accommodates absolutely every aspect of the manufacturing process and collaborates virtually and visually between the factory floor, design office and client. “For instance, it links with videoconferencing like Zoom, so the client can be there beside the machine with you as you complete the prototyping – perfect for managing manufacturing during a pandemic. It provides detailed analytics so you can see how a job is tracking against KPIs and time-estimates. It’s customisable so the specific requirements of any manufacturing process can be accommodated. And the interface is intuitive and very user-friendly, not to mention visually stunning kiosk enclosures.”

Integra’s DigiSMART Kiosk is non-discretionary in its data sources, which means it can easily be applied to sectors outside manufacturing. Basically, anything can be inputted, which means the different applications for these kiosks are virtually endless. For example, a supermarket could use this technology to access backend data and enhance the customer interface and service experience. “We’ve already deployed ten 43-inch DigiSMART touchscreen kiosks across Integra’s own offices and manufacturing facility,” says Hughes. “Only once we were confident the technology was meeting the rigours imposed on it by our own business, and impacting positively on our finances and efficiencies, did we commit to commercialising the technology and taking it to market. We’re very proud to say that time has come.” www.integrasystems.com.au

www.integratransform.com.au

MTI PE200 SWING DOORS The most robust solution for food industry, retail and logistics The new PE200 HDPE double acting impact traffic door, exclusively available from MTI See-Thru, offers the perfect solution for insulation, functionality and durability. Benefits of the MTI PE200 Swing Door; • Made of solid polyethylene – non breakable • Hygienic (EU/FDA approved) • Maintenance-free • Made to measure • Short production time • Easy installation • Long service life • PVC finger protection • 10 year guarantee on door leaves • Stainless steel hinges

MTI PE200 AMT_HalfPage.indd 1

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• Kraft Foods, Bahrain • Nestlé, Germany • Aldi, Ireland • Lidl , Germany, England • Edeka, Germany • Kaufland, Germany • IKEA, Turkey

INDUSTRIAL DOOR SOLUTIONS www.mtiqualos.com.au Free call: 1300 135 539 sales@mtiqualos.com.au AM AMT25/10/2018 DEC/JAN10:55 2021

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Epicor ERP – Release helps manufacturers adapt and innovate amid COVID-19 Epicor Software Corporation has announced the 10.2.700 release of its enterprise resource planning (ERP) solution. The new release helps global manufacturers to adapt in the everchanging workplace with reliable cloud enhancements and higher security access to data and order creation remotely. Epicor ERP 10.2.700 empowers remote workers and companies, especially those deemed essential, to thrive in an all-new territory. This release essentially completes the investment that Epicor has made in modernising and updating the Epicor ERP user experience. There are hundreds of new forms, reports, processes, trackers and flows now available to simplify daily work and enhance

productivity. In addition, Epicor Application Studio, a powerful toolset that enables users to create their own experience in an intuitive and streamlined way, is introducing enhancements including a new Application Studio home page, embedded websites, and reusable component design. Another significant feature is Advanced Unit of Measure (AUOM), which offers new levels of traceability in inventory management to meet requirements of the metals services industry. Users will be able to see and transact inventory in two separate units of measure, including when there is no constant conversion.

“We’re excited about our partnership with Epicor,” said Ian Morris, Head of Business Systems at Barrett Steel Limited, the UK’s largest independent steel stockholder. “One of the reasons we selected Epicor was for the introduction of AUOM – for us this will be instrumental to the way our teams measure and transact inventory. We have over 43 companies operating from 30 locations across the UK and keeping up with the latest ERP technology will help to ensure we are in a great position to continue growing as we embrace the future.” www.epicor.com/australia

ABB expands small robot family with fast, powerful IRB 1300 ABB has extended its family of small six-axis industrial robots with the launch of the IRB 1300, designed to meet demand for a faster, more compact robot able to rapidly lift heavy objects or loads with complex and irregular shapes. Building on the success of ABB’s IRB 1600 robot for payloads up to 10kg, the IRB 1300 offers a 27% improvement in cycle times and is nearly 60% lighter and 83% smaller than the IRB 1600. With a footprint of just 220mm by 220mm, the IRB 1300 is designed for use in small spaces, enabling more robots to be deployed in a confined area. “The IRB 1300 is an exciting addition to our portfolio of small industrial robots and means we can now offer an even greater breadth of capability and performance”, said Adrian Shore, Robotics in Manufacturing Sales Specialist for ABB Australia. “We’ve designed the IRB 1300 to help our customers achieve new standards of speed and accuracy as they develop solutions to lift heavy, complex or irregular shapes, even in small workspaces.” With improved payload and reach for materials handling, machine tending, polishing, and assembly and testing applications, it is aimed at manufacturing, electronics, food, beverage, pharmaceutical and consumer packaged goods processing, case packaging and logistics applications. The IRB 1300 is available in three main versions: 11kg with a 0.9m reach; 10kg with a 1.15m reach; and 7kg with a 1.4m reach. The 11kg payload for the 0.9m reach

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variant is higher than any other competing robot in its class. Powered by ABB’s OmniCore controller, the IRB 1300 offers advanced motion control and best-in-class path accuracy, allowing it to handle an expanded range of applications such as polishing and machine tending. To maximise the versatility of the IRB 1300, the OmniCore controller can be equipped with a range of additional equipment, including fieldbus protocols, vision solutions and force control. OmniCore also offers a simple user interface on the intuitive FlexPendant, which features a large multi-touch display with standard gestures such as pinch, swipe and tap, allowing users to quickly get to grips with

programming and operating their robot. The IRB 1300 offers 20 Input/Output ports, 50% more than the IRB 1600, to enable the IRB 1300 to be used with more sophisticated grippers or end-effectors, allowing users to improve productivity by handling an increased number of work pieces simultaneously. Supplied with IP40 ingress protection as standard, the IRB 1300 has the option of IP67 protection against solid particles and water ingress, or Foundry Plus2, designed to protect against the extremely harsh conditions in foundries and other metal processing plants. It can also be supplied to IPA Clean Room protection standard. www.abb.com/au

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Hyster – Nimble, driver-focused four-wheel electric lift trucks Engineered for driver control and comfort, Hyster’s new four-wheel electric forklifts are being introduced to the AsiaPacific region for cost-efficient use across multiple warehousing and logistics applications. The UT series of four-wheel electric forklifts, in capacities from 1 to 3.5 tons, complements the broader UT series range for customers seeking Hyster toughness, quality and strong service backing to cost-effectively tackle simple everyday materials handling needs. It also brings the performance of electric forklifts to a new market sector seeking optimum cost-efficiency for their needs. Features of the new machines, which provide an ideal solution to meet users’ needs for less frequent usage, include an ergonomically designed operator compartment laid out to enable operators to work comfortably across a range of applications, including food and beverage, frozen produce, manufacturing, distribution and truck and transport centres. “UT series four-wheel electric lift trucks are engineered for drivers, with an outstanding range of compliance, performance, comfort and easy service features,” says Mark Chaffey, Hyster Area Business Director, Pacific. “Power options including wet cell batteries with single point watering or maintenance-free Lithium Ion technology. “Smooth, progressive high performance is provided by AC traction and hydraulic motors with electronic control. European designed AC controllers are coupled with AC traction and hydraulic motors to allow for precise controllability. A small steering wheel facilitates fine control, with eight degrees of adjustment and low steering effort for operation in confined spaces. The low steering effort without kickback facilitates precise positioning.” Further features include: • High strength profiled steel overhead guard for added protection coupled with low step height for easy access. The secure overhead guard has passed CE drop test and safety standards. • Wide view mast to enhance operators’ forward view field. The high-vis mast provides soft landing technology as standard

to absorb shocks. Controlled mast lowering speeds help to avoid damage. LED lighting is standard. • Full suspension seat that reduces driver fatigue, which, like the steering wheel, is adjustable to suit a wide variety of operators. Safety features also include an Operator Presence System. • Performance features include simple and clear display of speed, power, error code and working hours to keep operators fully informed. Colour displays integrated with functions such as performance selection to configure the truck for different applications. • Integrated motor, transmission and axle provide compact performance and accessibility for maintenance. Precision cut gears provide reduced wear and lower noise levels. The use of high-quality, robust components, complemented by outstanding filtration and cooling, helps to provide driver-oriented comfort, reliability and low cost of ownership. These elements, combined with fast availability of cost-effective replacement parts, help to curtail maintenance requirements and costs. The new machines’ value proposition – “Meets the Need. Makes the Move” – relates to customers who don’t need particular advanced functionality features, but prefer proven materials handling solutions backed by a supplier which they can trust. Hyster can also offer the support of a reputable service network extending across Asia Pacific, including Australia and New Zealand. www.hyster.com

Ximea CB654 PCIe – High-performance industrial camera The new CB654 PCIe industrial camera from Ximea GmbH offers 65 Megapixels at a remarkable data rate of 70 frames per second when streaming at 10 Bits of RAW image format. The CB654 utilises the GMAX3265, the latest CMOS sensor from Gpixel, which has picture parameters close to sCMOS performance. The 8K sensor consists of 9,344 by 7,000 pixels, which is the world’s highest resolution sensor with a Global shutter. The sCMOS level of picture quality is reflected in low noise and Dark current of 2e-/s that makes the cameras suitable for both industrial and demanding scientific applications, such as flat panel inspection or printed circuit board (PCB) examination. There are various grades of GMAX3265 available and Ximea is capable of supplying multiple camera versions to provide different levels of quality and prices. For overall heat dissipation reduction and even better noise results, the cameras are equipped with a fan cooler which can be removed and replaced with a heatsink or water cooling system.

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The high-grade sensor is matched by an equally impressive interface in the form of a PCI Express Gen3 with a bandwidth of 64 Gbits and real data throughput of 7,000 MB/ second – or more than any other conventional industrial camera can compete with. This comes without the need for bulky and expensive frame grabbers or special software. Additional benefits of the PCIe interface are Direct Memory Access (DMA) with a low CPU load and practically zero latency. The cable length can reach up to 300m with fibre-optics, and bonus GPIO connectors ensure triggering and synchronisation. The supplied active EF-mount lens interface enables remote control of aperture, focus and image stabilisation. This all comes in a robust housing of 60mm x 70mm and 40mm, at a weight of 250 grams. www.scitech.com.au

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TMTS 2020: Utilising remote technology to establish a new model of smart manufacturing Over the past 10 years, with the joint efforts of government and industry, Taiwan’s machine tools industry has earned a place in international markets through outstanding manufacturing quality and performance. Taiwanese machine tools serve as a brand and express the spirit of “High-tech, precision, innovation, global service, advancement and flexibility” in the international markets. The short-chain revolution and the US-China trade war have caused manufacturing industries to migrate. The previously expected economic recovery was delayed by the coronavirus pandemic, which has forced global manufacturing industries to move towards digitalisation. Taiwan’s machine tool manufacturers, such as YCM, Goodway, Campro and others, use Internet of Things (IoT) technology to transfer real-time information in the workshop, including data such as production progress and machine operation status. Advanced applications such as monitoring dashboards and mobile devices are employed to achieve remote control and management (RCM). Personnel can solve real-time problems without frequently entering the workshop. Meanwhile, by browsing in split-screen, more machines can be managed with less manpower. In addition to RCM, the use of augmented reality (AR) under a 5G technical environment also provides the industry a non-contact management model. Via remote AR, manufacturing support experts can provide online troubleshooting or repair assistance for the equipment via visual instructions, which can replace physical inspection in the workshop. For manufacturers, preventative and predictive maintenance not only reduces unnecessary daily maintenance costs, but can also improve the inspection accuracy or predict when a production bottleneck or machine failure will occur. The way to achieve smart manufacturing not only depends on an unmanned environment. Instead, it requires various intelligent tools and equipment, software, and human-machine interfaces. It also needs enhanced integration of personnel and automated devices to meet requirements, which has an irreplaceable position in the manufacturing field. Today we are in a special era where

establishing a new management model for any manufacturer is especially important. Building on an already solid foundation, Taiwan’s machine tool industry has seized the opportunity to quickly transform to smart manufacturing, occupying an important position in the global industrial chain with the advantage of combining the resources of supply chain and the markets. As the coronavirus pandemic spreads around the world, the Taiwan International Machine Tool Show (TMTS 2020), hosted by the Taiwan Machine Tool and Accessory Builder’s Association (TMBA), will be held as an online exhibition, TMTS Virtual. Having opened on 10 November, TMTS Virtual will showcase the latest products, allowing global buyers to interact with exhibitors without the constraints of time zone and boundaries. Visitors can try the virtual experience of TMTS Virtual by visiting the show anywhere, anytime. www.tmts.tw

Kennametal introduces HPX solid carbide drill Kennametal has introduced an expansion to its solid carbide drilling portfolio, the HPX drill for high performance, large volume drilling in steel. Designed to quickly and efficiently punch holes up to 8 x D in any ISO-P steel material, the HPX drill provides up to twice the tool life and three times the productivity compared to competing products, even in dry or minimum quantity lubrication (MQL) applications. Steels are used for a wide variety of automotive, commercial and industrial applications, often in production volumes where maximum tool life and throughput is critical. Yet steel creates a high degree of mechanical loading during drilling operations, resulting in forces that lead to rapid tool wear and chipping of the tool’s more vulnerable corners. Kennametal has eliminated this failure point by applying a small corner chamfer and straightening the HPX drill’s cutting edges. Together with the rounded margin lands running down the length of the flutes, this serves to stabilise the drill while reducing friction. Built-up edges are another common problem when drilling alloy steels. The HPX drill’s straight cutting edge helps eliminate some of this, but the real clincher is the drill’s optimised edge preparation. This gentle hone further reduces the friction that leads to built-up

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edge, as do the tool’s highly polished flutes. Couple that with a carbide grade designed specifically for steel – KCP15B – and a proprietary multilayer AlTiN coating, and the HPX drill sets a new standard for tool life in high-volume ISO-P drilling. Special gashing on the HPX drill improves the chip formation and curls a smaller chip. The material specific HPX point geometry creates significantly lower cutting forces, which works great for machines with lower spindle capabilities, unstable cutting conditions, or unstable workpiece clamping. A continuous cross section makes the HPX drill more resistant against tool breakage, and the ultrahigh polished chip flutes ensure superior chip evacuation. Manufacturers wishing to turn off their high-pressure coolant pumps in favour of dry cutting or MQL systems, efficient chip evacuation along with low-friction cutting is a must, and the HPX drill delivers on both counts. The drill comes equipped with a leakproof MQL interface that meets DIN 6535 and 69090-03 standards, meaning no more special orders or in-house modifications. www.kennametal.com

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SET TO

CHARGE AUSTRALIA AND THE EV REVOLUTION

The global automotive market is undergoing a radical transformation, with electric vehicles rapidly gaining market share – but Australia is in danger of falling behind. Nonetheless, a small group of Australian manufacturers are bucking the trend and taking on the world. By William Poole. Around the world, a mobility revolution is gaining speed. Just as the early 20th century saw the automobile replace the horse-drawn carriage, we are now witnessing a similar change as the internal combustion engine makes way for the electric vehicle (EV). A decade ago, the number of electric cars on the road was negligible – around 20,000 worldwide, according to the International Energy Agency (IEA). By 2019, worldwide sales had soared to 2.1m, bringing the global stock to 7.2m vehicles. EVs made up 2.6% of global car sales and about 1% of global stocks – a 40% year-onyear increase. Early figures for this year are pointing to even bigger gains. Australia, however, is stuck in the slow lane. In 2019, EVs made up to 0.6% of new vehicles sold here, putting us well behind almost all other developed nations. The market in Australia is growing, but we are lagging. “There’s a chasm there, but it’s a surmountable one,” says Behyad Jafari, CEO of the Electric Vehicle Council of Australia (EVC). “In most of the developed world the market share for EVs usually sits around 5% to 10%. We reached 6,700 EV sales in 2019, whereas if we were up to par with the global average, we would have sold about 50,000. So for us it’s: how do we get to 5%? And then from there we work out how we solve every other problem and work our way up towards 100%.”

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The EVC is an industry body that represents the EV sector in Australia. Established in 2016, today it has around 60 members, including automotive manufacturers; electricity generation, distribution and retail companies; and businesses involved in developing charging infrastructure and other innovative technologies. While much of the EVC’s work entails representing the array of businesses with an interest in the sector, a big part is also highlighting e-mobility’s enormous potential for Australia. “We look at that value chain in this global shift towards EVs,” Jafari explains. “What opportunities does it present for our country? How can we develop that industry? We’ve got some of the world’s richest mineral resources for developing batteries – how do we capitalise on that, and go down the value chain towards battery production, vehicle production, and associated infrastructure?” The EVC’s activities cover three broad categories. The first is policy development and advocacy, working with governments to develop policies that support the EV industry. Second is market facilitation, growing the market for the EVs, particularly through corporate and government fleets. Finally a third category is industry co-ordination. EVs are a ‘convergence technology’, drawing in sectors with little engagement previously with the automotive industry: battery manufacturers, infrastructure providers, electricity companies, and so on. The EVC seeks to bring these groups together to solve problems, develop products, and formulate industry standards.

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Jafari talks optimistically about the opportunities the EV industry represents, and the advantages Australia enjoys. “There are two things Australia is really well known for having: mineral resources; and people resources,” he says. “We’ve got the rocks in the ground to make batteries that go into EVs. How do we go from what unfortunately we’ve always done – digging rocks up, sending them overseas to be value-added, and buying them back – to keeping more of that here and doing the refining, the processing, the battery manufacturing, the vehicle manufacturing? “But we also have some really great innovators and entrepreneurs doing unique things. In some cases there are globally leading companies, founded and based in Australia, serving the EV industry. There are projects we’re doing, in vehicle-to-grid and fast charging, that are occurring in maybe three places globally, and one of them is in Australia.” A notable factor about EVs is they are simpler to manufacture than conventional cars; the drive train in particular requires significantly fewer parts than an internal combustion engine. For Australia, this creates the prospect of a new automotive industry emerging that is more agile and less capital-intensive than traditional car manufacturing. “You need far fewer inputs to get a new manufacturing plant up and running,” says Jafari. “Setting up the old Holden plants back in the day, you’d need about 300,000 to 500,000 vehicles produced out of the factory to justify building it. Today we have companies saying ‘We can start with 10,000 or 20,000 vehicles, get the returns we need at that level, and scale up from there.’

Behyad Jafari, CEO of the Electric Vehicle Council of Australia (EVC).

“Because of how manufacturing has shifted, the benefit of being in Australia has also shifted; it’s advanced manufacturing with a highly skilled workforce. And Australia’s a great location to service the region from because we’ve got good trading relationships. These advantages give Australia a leg up. We can get started, and if successful, ramp up production to service the region.” Continued next page

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AUTOMOTIVE & ROAD TRANSPORT Right: The Tritium team with the new RTM75 DC Fast Charger. From left: Dr David Finn, Founder and Chief Growth Officer; David Toomey, Chief Revenue Officer ; James Kennedy, Founder and Chief Growth Officer; Jane Hunter, Chief Executive Officer; and Michael Hipwood, Chief Financial Officer Contined from previous page

However, there are obstacles. One of the biggest, according to Jafari, is a culture of pessimism: a mindset that, because we’re a small country with a small domestic market far removed from the big export markets, pursuing these opportunities is pointless. Often it’s government who are the most apathetic. “We get lots of investors from around the world who see benefits in putting operations here,” he says. “But other countries are competing harder than we are. We speak to international investors who say they stopped by Singapore or Malaysia or Thailand on their way to Australia, and in those countries they roll out the red carpet. Their presidents are waiting at the plane, saying ‘How do we get you guys to invest here?’ We don’t see that enthusiasm here. If companies don’t see that, that gives them less confidence. So it’s this crazy situation where we’ve got the rocks, we’ve actually got an edge over the competition; we’re just choosing not to do anything with it.” Jafari thinks government could do more to support the sector, starting with promoting Australia’s own EV market through measures such as fuel efficiency standards and tax exemptions. Jafari also favours subsidies to help in the building of charging infrastructure. Steps like these would in turn inspire confidence among investors. “Countries around the world are providing generous subsidies to start preparing their markets and accelerate that growth. They see that the more you start feeding this today, the more you get the businesses being set up in your country, as opposed to somewhere else. “If you look at technologies over the past century, as you hit that tipping point, a technology goes from being 5% to 90% market share very quickly. That’s why you’ve got countries confidently saying ‘We’re going to ban internal combustion engines’ and setting targets for 100% electrification. They’re doing the work now to prepare. If we don’t do that work, that big shift will come and we’ll start preparing in the midst of it.” Jafari believes the potential size of an EV industry in Australia is really down to us. We have the means to compete across the value chain globally; it is just a question of how much we prioritise it. “It’s not something that’s out of reach for any other reason than us choosing to not pursue it. Can Australia become a significant base of operations for the global e-mobility sector? Certainly. Are we currently taking the steps to realise that? No, we’re not. “The ingredients are there. We’re not imagining a scenario of ‘What if we had these businesses here?’ They’re already here. Support them, help them grow, and help more of them come up.”

Tritium – Super-charging innovation When considering e-mobility, it’s easy to just picture the cars themselves, but there’s a whole lot more to it than that. Just as with traditional, internal-combustion vehicles, EVs cannot be viable without a plethora of supporting equipment and infrastructure, all of which create opportunities for innovation. And despite us lagging behind in the global EV revolution, many Australians might be surprised to learn we do already have at least one world leader in this area. Tritium produces some of the world’s most advanced charging equipment for EVs, controlling about 20% of the market in Europe, about 15% in the US, and more than 90% here in Australia. Moreover while the company has a truly global footprint with facilities in the US and the Netherlands, it still designs and manufactures its products from its headquarters in Brisbane.

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Tritium designs and manufactures almost all of its products from its headquarters in Brisbane.

The company was founded in 2001 by Dr David Finn, James Kennedy and Dr Paul Sernia. As engineering students at the University of Queensland, the trio’s SunShark solar racing car took third place at the 1999 World Solar Challenge, and they established Tritium initially to sell motor controllers based on the SunShark technology. Today it has exported more than 4,500 chargers to more than 38 countries. Finn and Kennedy are now Chief Growth Officer and Chief Technology Officer respectively, while Sernia remains involved as a Non-Executive Director. Former Boeing executive Jane Hunter came on board this March as CEO. On 17 November Tritium held an event in Brisbane, streamed online to a global audience, to mark the launch of its new MSC (Modular Scalable Charging) hardware platform. MSC is the first platform to enable truly scalable EV charging networks, overcoming a key bottleneck in the roll-out of charging infrastructure by allowing charging systems’ power levels to be increased as capabilities advance. Previously, operators of charging networks had to install chargers from a set of prefabricated charging options; often set at 50kW (fast or rapid chargers), 175kW or 350kW (high power or ultra-fast chargers). MSC allows quick installation of additional modules within compatible chargers so power can be increased in 25kW increments, from 25kW to 350kW and beyond. “This has been something the industry and our customers have asked for over the years, and we are the first company in the world to deliver it,” said Hunter. “With our MSC platform, 50kW DC chargers can quickly be upgraded to 75kW, 100kW and beyond, without a rip-and-replace required. This solution is future-proofing governments and network operators across the globe; something they have been crying out for.” The company also unveiled the first charger built on the MSC platform – the next-gen RTM75 DC Fast Charger. Capable of adding 75km of range to an EV in ten minutes of charging, the slim charger also allows simultaneous charging of two vehicles at once.

AUTOMOTIVE & ROAD TRANSPORT

Tritium’s PK350 high power charger makes up the majority of IONITY in Europe, the world’s largest and fastest charging network.

“The electrification of transportation is at a tipping point, so our customers want to know how they can easily extend their charging site capacity over the coming years,” said Finn. “Tritium’s MSC Hardware Platform allows our customers to scale their charging sites for half the price and configure their charging sites for a desired reliability.” The MSC platform and the RTM75 charger build on Tritium’s existing flagship products. Its RT50 fast charger is used in the NRMA NSW-wide fast charging network and the Queensland Electric Super Highway, as well as many locations overseas. Meanwhile the PK350 high power charger dominates IONITY in Europe, the world’s largest, fastest charging network, and is being rolled out as part of nationwide networks in Australia. Tritium has also launched a range of products in the software space this year, as well as a US-specific charger, the RT175-S. To maintain its position in an increasingly competitive global market, Tritium invests heavily in research & development (R&D). With more than 300 employees globally, its R&D and engineering teams are the same size as its executive, sales and marketing teams combined, and at times it has been adding an engineer to the payroll every week on average. To accommodate that growth, Tritium in April completed a major expansion of its Brisbane headquarters with the opening of the E-Mobility Innovation Centre, a state-of-the-art new R&D facility. The company is now building what Hunter says will be “the world’s most high-powered test & certification facility” – again in Brisbane. With the market for its products tipped for rapid growth worldwide, it’s an exciting move for a company that remains committed to manufacturing in Australia.

“It is actually a world first,” says Hunter. “There’s nobody else in the world who can test at 720kW power. So this is an absolutely key critical advantage for us in the market. And we’re just terribly excited to bring that to Brisbane, because it is going to attract other industry to the state.”

ACE EV – A new Aussie car manufacturer? Even though the EV sector encompasses more than just the vehicle itself, for many in Australian manufacturing, what truly fires the imagination is the idea of actually making cars – or trucks or buses – here in this country. In this regard there is already a lot of activity. October saw news of the purchase of 51 hectares of land in Moss Vale, NSW, by clean-tech investment group TrueGreen and its bus subsidiary Nexport to establish a dedicated EV production facility. Meanwhile, Melbourne-based SEA Electric recently secured a $20m investment from the US, amid growing international interest in its power-system technology for commercial vehicles. Continued net page

The Urban small car is one of three vehicles ACE EV will initially be releasing, along with the Cargo, a light van, and the Yewt, a utility vehicle.

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ACE EV has a contract partnership with Adelaide-based Aldom Motor Body Builders, which will produce the vehicles in South Australia. Contiued from previous page

Perhaps one of the most interesting examples is ACE Electric Vehicles, a Queenland start-up with an ambitious plan to produce EVs in Australia and export them. But first and foremost, the team at ACE EV do not think of themselves as vehicle manufacturers. “Everyone thinks we’re a vehicle manufacturing business,” says Greg McGarvie, Managing Director of ACE EV. “We’re not really; we’re an energy management solutions manufacturing business. It just happens to be a smart energy pack on wheels with seats that moves people around inexpensively – and cleanly. You’ve got this nice quiet vehicle that is a pleasure to drive and less than a third of the running cost of an equivalent fossil fuel smoker.” ACE EV is initially bringing out three vehicle models. The Cargo light van and the Yewt utility vehicle, are already online for reservation. The third, the Urban small car, will be available in early 2022; further down the line there is also a sports car in development. However, the strategy with the Cargo and the Yewt is to find niches where a product like this can swiftly find a footing. “We’re looking at the light commercial, last-mile, urban deliverystyle vehicle,” says McGarvie. “Our focus is at the market point that we think will work, and that focus is really on fleet and groups like that. If you’re going for the general population there’s all sorts of different tastes and expectations. Our vehicle is a working vehicle. It’s a low-risk strategy, but it might actually accelerate.” The smart energy management adds a further dimension to what ACE EV is doing, with ongoing trials in bidirectional charging and vehicle-to-grid technology – which would see the vehicle’s battery doubling as an energy source and grid-storage device when the vehicle is not in use. It’s just one way that ACE EV is taking a different, innovative approach. The company is working with AI solutions company SenSen to develop autonomous driving capabilities, and that partnership will also see the development of plug-in packs that enable owners to personalise their vehicle in the same way as we do now with mobile phones. The innovation is most prominent in the vehicles themselves. Built on a carbon-fibre skeleton, they offer greatly reduced weight while

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being easily customisable to meet customers’ requirements. The panelling is made from ABS plastic, with parts glued together like the adhesive bondings on the Boeing 787 Dreamliner, and the vehicles can be shipped as smart-packed kits for assembly closer to the target market. “What we have here is a technology that’s world-leading,” says McGarvie. “It’s a 100% composite vehicle, and the whole idea behind it is its long life. The skeleton should last as long as you do. But people get sick of the look of a vehicle and they need change, so you can change the skins on our vehicles after five years and have a different looking vehicle.” The distinctive, unconventional nature of much of what ACE EV is doing is reflected in the company’s origins. Formerly a marine biologist, McGarvie emphasises that concern over the environmental impact of fossil fuels was a key motive when setting up the company. He and co-founder Will Qiang were originally developing a solar farm when they were introduced to engineers Dr Charles Kung and Gerhard Kurr, based in Taiwan and Germany respectively. Kung and Kurr had developed the concept for ACE EV’s vehicles, and with them as technology partners, the company was established in 2016. ACE EV has a contract partnership with Adelaide-based Aldom Motor Body Builders, who will produce the vehicles in South Australia. Initially a trial batch of 20 vehicles are being brought in in smartpack form and assembled at Aldom’s plant in Wingfield. While that trial is underway, the team will be setting up the full production line, using the initial vehicle stock to attract further investment and recruit supply chain partners. The aim is to use local suppliers as much as possible. “Effectively we want to aim for an assembly process with at least 25% Australian content,” says McGarvie. “Then, when we’ve got the full factory in place, more than 50%. And it can escalate from that – already there are some battery manufacturing facilities starting up.”

AUTOMOTIVE & ROAD TRANSPORT Going forward, the ACE EV concept is built around a lean, efficient manufacturing process that is highly agile and flexible. “The beauty of our vehicle is it takes one-third of the energy to build, so that’s a saving straight off. It’s about 50% lighter than its equivalent – that’s important with EVs. And we can do a model change in less than 20 months, from concept to prototype. The auto industry would still be thinking about it in that time.” ACE EV is setting ambitious targets for exports, with plans for 70% of its product to go overseas. While the Australian operation will serve as the global manufacturing centre, final assembly will be undertaken in the destination markets. “Effectively it goes offshore in six boxes, and we bring people from the destination country and train them on our production line,” says McGarvie. “They set up a climate-controlled workshop in the partner country, we ship the vehicle in, and they assemble it. It’s a win-win: for them it’s creating jobs, creating new technology opportunities; for us there will be a pipeline. It’s a big win for Australia.” There have been difficulties: securing investment hasn’t been easy, and government support has been limited. But going forward McGarvie is optimistic, and he sees enormous potential for Australian manufacturers as the business begins to scale up. “We’re being approached by many now: for the wiring harnesses for the vehicles, even power trains down the track. Batteries are another one. The battery is roughly 30%-40% of the cost of the vehicle at the moment, and Australia’s got some of the best resources with lithium. The more we can do in Australia and value add here the better. And with robotics, people can be put to much better use in other areas of the process.” As well as the benefits for those manufacturers, there are gains to be made for the broader economy and indeed Australia as a nation. “It’s just a job multiplier,” says McGarvie. “Our original financial modelling showed we would be producing well over 24,000 vehicles by 2025, and it’ll create over 500 jobs. Now, with levels of offshore demand, it has become prudent to budget for double the production and jobs. And this will create close to one billion dollars in revenue to the state. Australia is in a really good position if it’s quick and smart to take a global technology lead. It just needs government to really get on board and support what we’re doing. “Our goal is to get as many EVs in the place as possible, as soon as possible, and running on renewable energy. Everybody could see the difference during the peak of the pandemic; when cities were no longer running vehicles, suddenly we had sunshine and clean air. That’s possible with EVs.” www.electricvehiclecouncil.com.au www.tritiumcharging.com www.ace-ev.com.au

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Greg McGarvie, Managing Director of ACE EV, (left) with Shadow Treasurer Jim Chalmers.

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Bentley Group invests in versatile all-rounder from MaxiTRANS Hauling more than 60 state-of-the-art residential suites to a new cabin park in South Australia is one of the many freight tasks Bentley Group will be assigning its new purpose-built Freighter Drop Deck Semi. Manufactured by MaxiTRANS, the multi-purpose trailer is later planned to make its way around the company’s other business divisions, providing great versatility for its varying operations. Following the success of its Port Pirie venture, Bentley’s Cabin Parks will soon be opening its new fully self-contained accommodation park at Port Augusta. Part of the Bentley Group, the cabin park division was first set up in 1995 when Hayden Bentley, founder and Managing Director, set up four cabins inspired by his travels around Australia with his family. Bentley Group is a diversified business that is involved in farming, hospitality and construction. The new cabins for the Port Augusta site are being built at the company-owned construction yards based in South Australia. To transport those cabins, Hayden recently invested in a new Freighter Drop Deck Semi with ramps, from MaxiTRANS. “We have bought aluminium tippers from MaxiTRANS previously and in February we picked up a new multi-purpose Freighter Drop Deck Semi trailer,” said Hayden. “We had the trailer purpose-built to suit our specific needs. “The cabins we transport with the trailer are one or two-bedroom, with the longest of them around 10.3m long, so we wanted the base of the deck to be 10.5m so the cabin could fit on it. Its bi-folding ramps were made removable to make it easier to put the cabins on and off. We even had it colour-coded to match our new prime mover so it looks nice on the road as well.” Although this trailer was made to suit the specific purposes of Bentley’s Cabin Parks, it is a general-purpose trailer as well. As a result, it will also be used to transport various types of loads including heavy machinery for the company’s other farming and construction equipment such as bulldozers, loaders and graders. The Freighter Drop Deck Semi-Trailer is capable of delivering low tare weight and carrying high loads, machinery and silage. Featuring a short, extra-strong gooseneck, it can be engineered to optimise pallet capacity and spacing on both upper and lower decks, based on specific freight requirements. The wide-spaced main beams combined with low profile frames, deliver complete stability and centre of gravity. Meanwhile, the use of durable cross members

provides a more robust and reliable trailer. Hayden chose to include the optional pull out ramps to allow the load to be driven between the lower and upper decks. “The quality of the workmanship is fantastic,” he explained. “Unlike some of the other trailers with ramps that we have used in the past, the ramps of the new Freighter trailer have shown no signs of rusting or physical damage. We have had good experience with MaxiTRANS before – we bought aluminium tippers from them and we’ve been very happy with them. It was an obvious choice for us to go to them again. We knew we had to stick to what we trusted and what we knew, so going with the Freighter Drop Deck Semi was an easy decision. “We have been using products from MaxiTRANS for nearly 10 years and it was good to work with them again. They made the trailer exactly like how we wanted. The finished product is excellent. They’ve thought of everything and finished it on time. We trust Australian manufacturing and we like quality. We understand that cheap is not always the best so we are willing to pay for quality.”

Boosting manufacturing to meet demand MaxiTRANS is the largest supplier of locally manufactured, highquality heavy road transport trailer solutions, including trailer repair and service, in Australia and New Zealand. In August, despite the impact the COVID-19 pandemic had had on many industries, the company moved ahead with plans to increase production to support an uplift in demand for its leading semi-trailer brands. In addition, the company sought to fill approximately 60 roles across its Victorian and Queensland manufacturing facilities to meet market demand and support this growth. “The support of our customers during these challenging times has been fantastic, while there will still be difficult times ahead, it is great to see confidence in and support of local manufacturing show positive signs of growth in the short term,” said Dean Jenkins, MaxiTRANS CEO and Managing Director.

Bentley Group’s new Freighter Drop Deck Semi trailer from MaxiTRANS.

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AUTOMOTIVE & ROAD TRANSPORT

MaxiTRANS has seen a significant uplift in demand for its semi-trailer brands.

While Government support programs have allowed Australian businesses like MaxiTRANS to keep operations going, the increased demand for new equipment is a demonstration that there is an increased confidence from some sectors of the economy. This in part has come off the back of improved rainfall across many parts of New South Wales, Victoria and South Australia, which has acted as a catalyst for increased demand for tipper product across these regions. “It is fantastic to see many regional and rural areas, which have been ravished by extended drought over recent years, seeing better rainfall in the lead up to this year’s harvest season,” said Dean. “We have had a number of our customers discuss their tipper needs much earlier than usual to ensure they have the equipment they need, which really shows a boost in confidence for the agriculture sector.” Despite the challenges that the ongoing pandemic is presenting for many industries, especially when Melbourne entered tougher Stage 4 restrictions, MaxiTRANS looked to keep up with the overall

increase in demand by filling approximately 60 roles across two of its manufacturing facilities – in Ballarat, Victoria, and Richlands, Queensland. Of these, approximately 70% were at the Ballarat facility, which was a real positive for jobs in this rural Victorian community. The varied roles and employment opportunities the company sought to fill included qualified welders, painters and labourers. The recruitment drive also presented the opportunity for up to 15 apprentices to join the company’s apprenticeship program. “We have already been able to fill a number of roles within the manufacturing business, which is especially great as some of these roles were filled by people who had been recently displaced due to COVID-19 restrictions,” said Dean. “This latest recruitment drive is another demonstration of our ongoing commitment to our customers and the wider transport industry. Our customers can have great confidence that we are here to support them as much as they are here to support local Australian manufacturing.” While MaxiTRANS has been adding more people to its team, the company has also sought to reassure new employees that it places great emphasis on the safety of all of its people and has been following strict COVID-19 guidelines to maintain the health and wellbeing of all members of the MaxiTRANS family. “I would like to take this opportunity to again thank all of our customers, employees and suppliers for their ongoing support throughout what has really been a challenging year,” said Dean. “While there are still tough times ahead, we have seen just how important this industry is for our community and Australian manufacturing. “At MaxiTRANS, all our employees pride themselves on knowing they play a vital role. Particularly at this time. It is about providing the support and access to equipment our customers need so they can get on with doing what they do best and delivering the needs of the nation.” www.maxitrans.com

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HSP 4x4 Accessories: Australian-made, competing globally For the founders of HSP 4×4 Accessories, with more than two decades of experience in the automotive industry, it was an obvious choice to create cutting-edge ute accessories that give people a significantly better experience with their vehicle compared to what was already on the market. Based in Noble Park, Victoria, HSP 4×4 Accessories is an Australianowned business specialising in the design, prototyping, manufacture and sale of high-quality, cutting-edge accessories for 4×4 and ute lovers across the country and around the world. HSP’s mission is simple: to create and distribute beautifully engineered products that create an effortless collaboration between the vehicle and the user.

The entrepreneurial trio have received international acclaim for their innovations. Since founding the business, they have designed and manufactured world-first products that maximise the potential of a ute by creating solutions, not just products. As a result they have amassed a number of industry awards for their cutting edge designs and innovations.

Innovation is at the core of the business, and inspires HSP Accessories to constantly strive to achieve advancements in all facets of the industry. According to co-founder Massih Aimaq, HSP’s commitment to setting new benchmarks is one of the reasons behind the company’s prompt rise to become a frontrunner in an industry that he believes had been innovatively stagnant for far too long.

In addition to being 100% Australian-owned, HSP’s major products are also 100% designed and manufactured in this country. Boasting a number of world-firsts, the company’s products are highly sought after both here in Australia, as well as abroad. Due to the company’s increasing market share, HSP is currently expanding its regional production plants in order to keep jobs in Australia while servicing its growing customer base.

“The traditional tub cover industry has become complacent,” Massih explains. “As part of the automotive industry it was frustrating to see the lack of creativity coming out of the big brands, so we knew we had something unique to offer ute junkies like ourselves when we launched HSP 4x4 Accessories. Since our launch, the response has been out of this world.”

“Being Australian distinguishes our brand from competitors because we have exceptional quality control and complete power over all after-sales policies,” says Massih. “At our core, we put Aussies first – keeping locals employed and ensuring we are able to constantly evolve our products to cater to the needs of all Australians.”

Growing up in Melbourne, Massih spent his early years completing a Bachelor of International Business at RMIT. His passion for the car industry, and the 4x4 sector in particular, led to him to start working with his older brother Masood Aimaq and life-long friend Omer Dost from a young age at a crash repair business – which they later became co-owners of. With more than 20 years of experience in the automotive industry, the close-knit three started creating ute products with the sole goal of giving the user a better experience with their vehicle – and so HSP 4 x 4 Accessories was born. Today Massih, Masood and Omer remain the co-directors of HSP. Together they work hand in hand to manage, grow and develop the business domestically and globally. Massih is the spokesperson for the business and is responsible for sales and business development; Masood manages research & development; and Omer takes care of operations.

The company supplies products to Australia’s burgeoning aftermarket sector as well as to a number of vehicle manufacturers in Australia and overseas. HSP’s products are sold in many countries throughout the world. Massih cites the HSP Premium Hard Lid as one example of some of the innovations the business has brought to the market. “Our HSP Premium Hard Lid is without a doubt the most advanced hard lid on the market,” he remarks. “When designing this product we knew we needed to breathe new life into the traditional hard lid, to make it more user-friendly, secure, and at a more accessible price. Our HSP Premium Hard Lid has been engineered to feature a unique pin release for easy removal, twin-seal weather protection, as well as the latest technology in painting and detailing for clean aesthetics. The central locking system is also an exciting exclusive feature, offering additional security and peace of mind for 4x4 owners that when their vehicle is locked, so is their lid.”

The founders and directors of HSP 4x4 Accessories: from left, Omer Dost, Massih Aimaq and Masood Aimaq.

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AUTOMOTIVE & ROAD TRANSPORT

HSP 4x4 Accessories’ range of products suits most vehicle brands.

The company’s range of products suits most vehicle brands, and as well the Premium Hard Lids includes Silverback Lids, Electric R Roll Covers, canopies, load slides, tail gate assist and central locking, HSP load racks, SmartGuard tub liners, SmartBar Bull Bars, HSP Rack Clamps and Roll R Draws. “Our HSP SilverBack range was designed for customers who still want a multipurpose cover offering outstanding security, visual aesthetics, and load carrying capabilities, but at a cost-effective price,” says Massih. “We recognised that there are a lot of people who do not want to spend upwards of a tenth of their vehicle price on a tub lid, which is why our pricing is so competitive – especially in our SilverBack range. “The HSP Roll R Cover pushed the boundaries of the 4x4 industry again with our one-of-a-kind secure, versatile and practical electric roll top. Unlike anything else on offer, the HSP Roll R Cover is

compatible with Android and Apple devices as well as voice command through Siri, Apple Watch and Air Pods. We also have our HSP Load Slide, which employs an advanced engineered purposebuilt retractable bed slide that provides a 75% extension, and 250kg weight capacity. Massih, Masood and Omer inject their energy, passion and vision into all aspects of the business, designing and manufacturing world-first products that maximise the potential of a ute by creating solutions, not just products. Their focus on detail and quality is exemplary. The company continues to push boundaries in the local and international 4x4 industry – making the most innovative, best-priced products on the market. “At HSP 4x4 Accessories we are innovators through-and-through, and we are not slowing down” says Massih. “It is incredibly humbling to see our products getting put to the test around the world. We will continue to push against the conventional limits of the 4x4 industry and designing products that will exceed the expectations of ute owners. The HSP 4x4 Accessory difference is that we believe in constantly challenging the status quo.” www.hsputelids.com

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3D printing electric vehicles: Pipe dream, or the future of automotive? While it has already demonstrated immense value across many fields, 3D printing has still not been entirely embraced by the automotive industry. That, however, may all be about to change. As part of the manufacturing process, 3D printing can help reduce costs enough that major carmakers and other industry participants have started exploring the technology. Electric vehicles (EVs) – one of the more tech-forward fields in the transportation industry – are pushing the technology in a completely new direction. While most efforts to integrate 3D printing with manufacturing focus on using the technology to substitute certain components and parts during the process, the EV sector takes 3D printing a step further. Most recently, the industry stirred excitement following one company’s announcement that it planned to commence selling 3D-printed vehicles. A success on that scale could transform 3D printing from a luxury to a major necessity across the automotive industry.

From components to complete cars The automotive industry is no stranger to 3D printing (also known as additive manufacturing due to the layered manner in which components are constructed). Late in 2018, BMW announced that it had printed more than one million components, with the automaker applying 3D printing techniques for more than 25 years. Yet, 3D printing is still not completely used for mainstream component production, despite growing momentum in that direction as the technology improves. For many automakers, 3D printers represent an excellent strategy for prototyping components, constructing full vehicles, and even creating models of new ideas. The sector has obliged, with companies like Stratasys creating tools that employ cutting edge technology for greater ease of use. However, the biggest advantage the technology supplies to automakers is its multifaceted upgrade of the manufacturing process. Principally, it cuts down production time significantly, as parts can be 3D printed (in metal, no less) in a fraction of the time needed for traditional casting and manufacturing. Additionally, 3D printed components tend to be more lightweight and easier to repair. Other major producers are also exploring the field for new implementations of 3D printing. Daimler, EOS and Premium AEROTEC have partnered to build a fully automated line for serial 3D printing that could be deployed seamlessly in most manufacturing operations. Nevertheless, the goal – or until recently a pipe dream – of a fully 3D printed vehicle has remained just out of reach, primarily because finding replacements for sensitive components like engine parts is difficult. Now, the EV sector may be on the brink of sparking another wave of innovation. Italian manufacturer XEV took the industry by storm when it unveiled its design for its LSEV, promises that outside of some key components, the entirety of its vehicle is 3D printed. According to the company, the vehicle has reduced the number of components from 2,000 to slightly over 50 and manages to reduce costs by nearly 70%. Impressively, the car would weigh just under 500kg, which is significantly less than most vehicles on the roads today. XEV also claims that the production time for each car would be reduced from three to five years to just three to 12 months. XEV isn’t the only company hard at work on a 3D-printed EV. USbased firm Local Motors has been developing a prototype for a self-driven minibus named the Olli, which is meant to help reduce the traffic congestion plaguing many of the world’s largest cities.

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It’s also 3D-printed, but it is marketed as a public-transit solution as opposed to XEV’s private cars. Local Motors has also noted that it has perfected its 3D printing process to the extent that it can fully manufacture an Olli in just about 10 hours, marking a notable achievement for such a complex task. It is worth noting that while both the LSEV and the Ollie are almost entirely 3D-printed, they still rely on some traditionally manufactured components. In the LSEV’s case, that is the main chassis, the windows and the car seats. The Olli’s windows are also not 3D-printed, but the rest of the vehicle depends on these rapid advances in printing technology. Moreover, the Olli is not meant to be a replacement for buses and other large vehicles – its top speed is only 40km per hour and it only has roughly 1.5 hours of battery. Even so, it marks an important first step towards constructing more sustainable transportation solutions.

The future is bright, but not here yet While the LSEV and Olli are promising hints at what the future holds for both 3D printing technology and EVs, they are still first and early attempts. It remains to be seen whether they will be embraced over the long run. Nevertheless, it’s a promising development, and one that could significantly alter the way we view EV technology and sustainability, and manner by which we handle issues like pollution, traffic congestion, and rapidly expanding urban populations. These projects are likely only the beginning, as well. As 3D printing matures and becomes more viable, we’ll likely see many more disruptive projects emerge. www.tclhofmann.com.au www.tclh3dprinting.com.au

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Carbon Revolution – Automating to gain an edge With its advanced composite wheels attracting growing demand from some of the most prestigious car manufacturers in the world, Carbon Revolution worked with Automated Solutions Australia to streamline its manufacturing operation. Growing from a small engineering start-up to a world leader successfully manufacturing to the exacting quality standards of leading original equipment manufacturers (OEMs), Carbon Revolution is exactly the kind of high-tech, innovative company that the Australian manufacturing industry needs more of. The Carbon Revolution story began at Deakin University in the mid2000s, where a group of engineering students, staff and industry mentors had begun developing carbon-fibre wheels for teams entering the Formula SAE student motorsports competition. In 2007, a group of them decided to try to commercialise their work, and the company was formally established. Today Carbon Revolution operates from a purpose-built facility on Deakin’s Waurn Ponds campus, in the suburbs of Geelong, Victoria. The company made its ASX debut on 29 November 2019, with its lightweight carbon fibre wheels now being used by some of the premier car brands in the world including Ferrari and Ford. Automated Solutions Australia (ASA) has built a strong relationship with Carbon Revolution over the last four years, collaborating on multiple projects to automate the company’s manufacturing processes. ASA has been a well-matched partner, drawing on years of specialisation in automated paint applications for the automobile industry and applying this expertise into other dispensing and machine-tending applications in Carbon Revolution’s production process. Automation and industrialisation of manufacturing processes are helping Carbon Revolution to meet the exacting demands of its customers. Carbon Revolution is meeting this challenge by increasing its throughput and constantly honing and redeveloping its production methodologies. This has been possible by analysing current processes and identifying areas that cause bottlenecks in the overall manufacturing process, as well as pre-empting potential future bottlenecks as production output increases. One of those bottlenecks identified is the Manual Deflash process, which is where the excess resin and fibre are removed from the wheels after the moulding process. Prior to automation, the process involved manually removing excess resin and fibre with files and sandpaper. Manual removal is very labour-intensive; in addition it poses significant potential for injury as the resin in certain parts of the wheel is thick and sharp. Carbon Revolution decided that it required a process development robot cell that would enable its engineering staff to develop best practice around automatic removal of the resin and fibre. It was a challenge that ASA resolved with a cutting-edge solution using six-axis force sensing and profiling of the part for path generation. A M710iC/50 robot was employed for the task, complete with Fanuc’s Severe Liquid and Dust Protection (Foundry) option, which provides IP56 protection on the main body and IP67 on the outer arm and wrist. The robot and a Fanuc single-axis positioner table controlled as an integrated axis of the robot were mounted to a common, heavy skid base to provide rigidity and the ability to relocate the cell within Carbon Revolutions’s ever-evolving plant. The cell is a polycarbonate enclosure construction with sub-floor dust collection and a dust extraction system integrated into the base structure. The robot was fitted with Fanuc’s integrated Force Sensor coupled to a Pushcorp Spindle tool with automatic tool changer (ATC). The ATC allows the robot to change tools using industry standard BT30 toolholders. The cell features a seven-position tool rack with interlocked access doors for both the robot and operator, allowing

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Carbon Revolution required a process development robot cell that would allow automatic removal of resin and fibre from its wheels after the moulding process.

tools to be changed by the robot in the middle of the process depending upon the current cut profile and whether it is a roughing or finishing cut that is being undertaken. Tools can also be serviced or changed over by the operator and returned to the tool rack. Those tools are subsequently measured with the robot using the Fanuc force sensor to automatically recalibrate the tool. The Fanuc Force Sensor solution is a highly fine-tuned piece of equipment, which serves more purposes than recalibrating the tools; for new path programming, the robot is directed to a spoke “window” and then set to create its own path by moving to an adjacent edge and then profile tracing the window. This method is used to create the nominal path, which is traced in production with the actual cutting tool applying force feedback provided by the integrated force sensor. Before machining, the force sensor allows the robot to accurately probe the wheel by touching several pre-defined locations to judge if the wheel loaded corresponds to the program that it is about to perform and to accurately measure the orientation of the wheel, adapting the process to the actual orientation. During machining, the force sensor performs a contouring function to accurately machine high-tolerance sections of the wheel.

AUTOMOTIVE & ROAD TRANSPORT

Carbon Revolution’s lightweight carbon fibre wheels are now used by some of the premier car brands in the world including Ferrari and Ford.

Automated Solutions Australia’s solution featured a Fanuc M710iC/50 robot, complete with Fanuc’s Severe Liquid and Dust Protection (Foundry) option.

To deliver the best outcome for Carbon Revolution, ASA sent two of its team to the USA to undergo specialised training on the use and implementation of Fanuc’s Force Sensor technology and to bring this highly advanced programming technology back to Australia for this project. The cell is controlled by an Omron NJ programmable logic controller (PLC) with integrated safety to provide communication to the robot, to the plant part traceability system for product-related data, and to the plant’s Ignition-based supervisory control and data acquisition (SCADA) system to report process feedback in an effort to meet the latest Industry 4.0 standards. A touch-screen Ignition human-machine interface (HMI) was also included to provide a control interface for the cell, also acting as a diagnostic terminal.

The main benefits to Carbon Revolution of this deflash process, using cutting-edge force sensing technology, has been the increased throughput that the company has managed to achieve as a result. By removing the bulk of the resin and fibre robotically, it has provided a significant reduction in the time and effort required to finesse the wheel. The successful results achieved by this technology has meant the development cell is now just another step in the process that delivers world’s best wheels – from Australia to the world stage. www.automatedsolutions.com.au www.carbonrev.com

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ViscoTec revolutionises dispensing applications in e-mobility manufacturing The application and injection of TIMS or gap fillers on and into battery modules or other electronic components in electric vehicles (EVs) requires an absolutely process-safe handling of one- or two-component materials. Precise, fully automated, easily adjustable and endless dosing is the prerequisite. Purely volumetric dispensing systems like ViscoTec dispensers enable exactly that: continuous, repeatable, materialfriendly dispensing of TIMs, gap fillers, sealing materials and adhesives – regardless of their viscosity. A specially developed rotor in the ViscoTec dispensers ensures long service life, even when using highly abrasive materials. For example, a long-term test with a two-component gap filler, with aluminium-oxide fillers, showed a nine-fold service life compared to the standard rotor. By using a special coating on the rotors or more specifically by using a ceramic rotor, customers can achieve even greater process stability due to a much longer lifetime of the dispenser components.

Battery cell assembly The thermal connection of the electronic modules or battery modules to the heat sink is crucial to dissipate the generated heat via the heat sink and therefore prevent overheating. For this purpose, heat-conducting pastes and adhesives with increasingly higher thermal conductivities are used to eliminate the air gap. Up until now, the usual heat-conducting pastes only had thermal conductivities of 0.8 to 2.0 W/mK. Thanks to higher proportions of thermally conductive solid particles and the specific selection of particle size distributions and different filler types, values of up to 7 to 8 W/mK have now been achieved. These mostly ceramic fillers, such as aluminium oxide or aluminium nitride, have a remarkably high thermal conductivity combined with electrical insulation. However, due to their high Mohs hardness of up to 9 or 10, they are generating challenges for the dispensing technology with regard to wear and maintenance intervals. These highly filled materials must be dosed without bubbles. Only then optimum thermal conductivity can be guaranteed. However, implementation is made more difficult because the liquid gap-filling material is applied in large quantities. In addition, the material is very abrasive, and the dosing system can wear out quickly. Nevertheless, in order to significantly increase the service life of the dispensing components, the proven stainless-steel rotor has been further developed through the use of special coatings based on Diamond Coating. More specifically, a new type of rotor, made from a technical full ceramic, revolutionises the volumetric dispensing of heat conducting pastes: in numerous internal long-term tests as well as field tests carried out in existing customer systems, a clear optimisation could be demonstrated. The special coating can already double or triple the service life of the core components. However, according to current experience, the ceramic rotor version achieves a service life of the core components that is approximately 9 to 10 times longer. The various long-term tests with running times ranging from several months to over a year and dispensed material quantities of several hundred to thousand liters show hardly any signs of wear on the ceramic rotor to date. A stable and process-safe dispensing is still possible, which makes a much longer period of use conceivable. Therefore, the cost-in-use can be significantly reduced. “Fight fire with fire - this is the motto of the ceramic rotor,” says Manuel Paintmayer, Relationship Manager – Material Manufacturing at ViscoTec. “Due to the three to four times stronger surface hardness compared to the previous hard chrome-plated stainless steel version of the rotor, long-term tests with state-of-the-art gap

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fillers have not yet shown any measurable wear or damage to the surface of the ceramic rotor.” The counterpart to the rotor in the dispenser is the stator, which is made of special elastomers. The stators also have a much longer service life thanks to the undamaged surface of the rotor. Ceramic rotors for shot sizes from 50µl showed no signs of malfunction or wear after more than 100 litres of dispensed gap filler. This corresponds to more than 2,000,000 individual shots. Identical results were shown for larger dispensers with shot sizes from 1.7ml. After more than 4,000 litres of dispensed material, no signs of wear on the rotor could be measured and precise and stable dispensing was still possible. These results were even achieved by using one single stator only. The use of ceramic rotors therefore results in numerous advantages for customers: • Maximum process reliability through unchanged dispensing precision of the volumetric dispensing system. • Minimal set-up and downtime. • Cost reduction due to minimal spare parts requirement and minimal cost in use. • Easy to integrate into existing systems. ViscoTec has achieved its goal of the highest quality and greatest process reliability. Customers are enthusiastic, as shown by one who remarked: “The dispensing system did not have to be recalibrated once during a complete production year in order to compensate for possible wear and tear.” www.viscotec.de

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Jayco Australia – Safe working with Smart Badge Like most manufacturers, Jayco Australia has faced enormous challenges due to the COVID-19 pandemic, but it has gradually found ways to get its operations back on track – an innovative safety technology from Smart Badge. As the country’s leading producer of recreational vehicles (RVs) and caravans, Jayco is is an iconic Australian manufacturing business. Since commencing operations in 1975, the company has built more than 200,000 RVs, all manufactured in Victoria. Still a locally-owned family business, Jayco today employs 900 staff, most of them at its manufacturing base in Dandenong South, Victoria. When the COVID-19 pandemic reached Australia early in 2020, official measures aimed at containing its spread had a significant impact on Jayco’s operations. There was also understandable concern among staff about the risks posed by the virus, both for their safety and that of their dependants. The situation worsened in August, as a second wave of infections surged in Victoria. With the State Government imposing Stage Four restrictions to combat the outbreak, Jayco was forced to close down its manufacturing plant for eight weeks. “Stage Four restrictions were pretty tough,” says Gerry Ryan OAM, Jayco Australia’s owner, founder and CEO. “We had to close our Dandenong-South factory, and over the eight-week period, we have had a significant loss of production.” Jayco has been pragmatic and proactive in the steps it has taken to enable safe operations as the crisis has gone on. A range of safety measures have been put in place, including the provision of sanitisation stations in all work areas, extra toilets, and additional personal protective equipment (PPE). Automatic, touchless doors have been installed to reduce touch points; start and break times are staggered and movement around the site is restricted; and strict cleaning regimes have been established. In addition, Jayco has become one of the first manufacturing companies in Australia to roll out Smart Badge, an innovative new technology that manages contact tracing and social distancing between workers, and assists with maintaining capacity limits. For Ryan, the safety and wellbeing of employees is Jayco’s top priority and Smart Badge’s wearable technology is helping his company give staff and the wider community peace of mind. Jayco Australia’s manufacturing base in Dandenong South.

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“We are extremely COVID-conscious, and in our large-scale manufacturing environment, diligently managing capacity limits for anyone on site is crucial,” says Ryan. “From the factory to the front office, Smart Badge’s technology helps us do this using real-time data.”

Smart safety The Smart Badge consists of a wearable device – available as a lanyard, wristband, clip or pin, with a hard hat version also available – that can sense if another device is within 1.5m. With everyone at a work site wearing the devices, the device will beep and vibrate if anyone strays within social distancing limits, reminding the wearers to move apart. The Smart Badge also connects wirelessly to node points positioned at key locations in the work site, providing a record of a worker’s movements and any colleagues that he/she may have been in close contact with. In the event of a worker testing positive for COVID-19, this enables rapid contact-tracing. Moreover, it allows businesses to control room or area capacity to comply with government limits. The installation of the system at Jayco’s plant illustrates how it works in practice. Simon Finlayson, General Manager at Smart Badge, explains what the process at Jayco entailed. “Jayco has issued all of its staff at the plant – manufacturing floor staff, office administration, security – with a wristband,” says Finlayson. “It looks a lot like a FitBit (fitness tracker), it’s IP67 waterproof and dustproof. Those wristbands are worn each day to work by the staff, and the close contacts that they might accumulate during their normal daily duties are automatically uploaded through a node point in each of Jayco’s warehouses or manufacturing buildings. “So it’s very straightforward. It doesn’t require staff to remember to go and tap off or download their contacts, or any manual process. It just automatically scrapes the close contacts off their device and stores them in case they need to review for a positive case being identified. It’s as simple as that. There’s no complex installation; just pop a node up in each building and issue the badges registered to each employee.”

AUTOMOTIVE & ROAD TRANSPORT Smart Badge can be worn as a wristband, lanyard, clip or pin, with a hard hat version also available.

Gerry Ryan OAM, owner, founder and CEO of Jayco Australia.

The Smart Badge system was developed more or less from scratch over the course of this year. The company is a spin-off from Harry The Hirer, a Melbourne-based company specialising in providing equipment for the events industry (many in Australian manufacturing will know Harry the Hirer through its longstanding involvement in AMTIL’s Austech exhibition). When COVID-19 hit at the start of 2020, it rapidly brought the entire events industry to a standstill. The team at Harry’s immediately set about exploring ways to get back into operation as quickly as possible once the pandemic was brought under control and enable events to be held safely . “Our entire industry literally turned off overnight,” Finlayson recalls. “And very quickly a couple of us looked to find ways to help businesses in our industry get back to work sooner rather than later. At the time our focus was on social distancing, because that was all the talk from government and the media, so we started to look at ways to develop a social distancing alert that would give event managers the confidence to get people back in a space and know that they would stay apart.” Finlayson had worked for several years at Harry The Hirer as General Manager – Productions, where his work was largely focused on developing and deploying technology for large mass gatherings, so he and his team were well qualified for the challenge ahead. “As our R&D process went along in April and May, it started to become apparent that contact tracing – certainly in Victoria – wasn’t up to scratch,” he adds. “We were lucky enough to have in-house software developers who were able to add that functionality into our devices. “We ran some trials in different cities, and it started to get much wider interest than we first intended, from market sectors as broad as food-processing, manufacturing, health, resources ... It was pretty obvious there was real demand from businesses to take control of their own outcomes, rather than rely on a third party or a government department to respond to a positive COVID case. Businesses could do it there and then, and minimise their shutdowns.” The Smart Badge is not a universal panacea: Jayco is still implementing a full range of measures to keep its workplace safe. Staff are still wearing masks, shifts are staggered, and social distancing and sanitisation are taking place. But as Finlayson stresses, the Smart Badge system helps minimise the fallout on the business in the event that an employee is diagnosed with COVID-19. “If you were to get a positive case, our system allows you to select that person’s contact records,” he says. “So in Jayco’s case, you can clearly see which building that person has been in and out of. So say that person had been in building five, but not in buildings one, two, three, four, six and seven; you would only need to deep-clean building five. The contact tracing records show you that activity. And that just goes back to minimising shutdowns and productivity losses.”

Opening up for business Jayco’s eight-week closure came to an end in late September, with the company entering its partnership with Smart Badge just as employees were returning to work. “Seventy percent of our production goes interstate so all our customers and dealers are keen for us to re-open,” says Ryan. “The safety measures that we’ve implemented, including the roll-out of Smart Badge, will help us remain safe and socially distant, so that we can fulfill our customer orders and get people back to enjoy caravaning as quickly as possible.” The implementation of Smart Badge coincided with Jayco’s announcement of more than 250 new job opportunities. The company plans to hire new employees over the next three months as demand for RVs continues to skyrocket – a situation likely to continue as international border restrictions see more and more Australians holidaying within its borders. “We have had record interest and sales in caravans, camper trailers and motorhomes over the past few months,” Ryan adds. “There has been a near-65% increase in sales nationwide since the start of the COVID-19 pandemic, and this has opened up a range of new opportunities at our head office and factory. Our facility and production lines have never been busier. We have hundreds of new RVs to deliver to our customers and we’re accelerating our production to ensure travellers can get on the road as soon as possible.” Finlayson remarks that while Jayco benefits as a business from the safety that Smart Badge helps to provide, it has also been welcomed by staff, providing them the reassurance that they can work more safely. “I had an opportunity to talk to a few of the staff, and they quite appreciate the social distancing alerts, when the wristbands vibrate or beep, reminding them to step back. A few of them said to me ‘We can come to work knowing people will stay back, and I’m not going to potentially take a virus home to my family because we’re all remaining socially distanced.’” Meanwhile, the team at Smart Badge is busy working on further development, both in terms of what its product can do, and the settings in which it can be used. The company has a large pipeline of additional functions and feature sets that it intends to add over the next few months, taking Smart Badge beyond contact tracing and social distancing. Meanwhile, the list of industries looking at adopting the technology continues to grow: the team recently installed the system in two pubs in Melbourne CBD, in readiness for restrictions to be eased and hospitality venues to be able to reopen. “We’ve been very humbled by the interest from market sectors we’ve never really had any involvement with,” says Finlayson. “So my thinking is that anything we can do to help any business operate with confidence, we will certainly do it. We are more than happy to supply any number of market sectors and help them get that activity and confidence back into the workplace.” www.jayco.com.au www.smartbadge.com.au

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Iscar – Stainless competence Stainless steel has long been one of the main engineering materials. Stainless steel products are common everywhere: in turbomachinery, cookware, aerospace engineering, surgery, oil & gas, and food industries. Such a wide use of stainless steel is explained by the most important property of this material – its resistance to corrosion. “Stainless” and “corrosion” steel are generally used synonymously, along with other terms such as rust-resistant steel, inox steel, and non-corrosive steel. Stainless, originally meaning “free of red rust stains”, was developed as a result of iron oxidising. Corrosion is caused by chemical and physical-chemical reactions. There are different types of corrosion. Stainless steel can be divided into the following groups, according to their main functional features: • Corrosion-resistant steel: resistant to corrosion under normal conditions. • Oxidation or rust-resistant steel: resistant to corrosion under high temperatures in aggressive environments. • Heat-resistant or high-temperature steel that does not change its strength under high temperature stress. Therefore, corrosion-resistant steel can be considered a type of stainless steel. The functional features of these stainless-steel groups determine the choice of a steel grade as a material for cutting tool design. For a manufacturer involved in machining stainless steel, the key parameter is machinability. The machinability of stainless steel relates to a steel content and structure. Accordingly, stainless steel is classified by the following types: • Chrome stainless steel – Ferritic – Martensitic and ferritic-martensitic • Chrome-nickel stainless steel – Austenitic and super austenitic – Duplex (ferritic-austenitic) In addition, there is a separate category of precipitation-hardening (PH) stainless steel, which can be both martensitic and semiaustenitic. Stainless-steel belongs to one type or another, which enables estimating machinability and selecting the required cutting tool. In cutting tool design, the type of stainless steel is a major factor for forming cutting geometry, choosing tool material (particularly carbide grade), and deciding about coolant supply. From a machinability point of view, ferritic and martensitic stainless steel are very similar to high alloy steel. Therefore, standard ISO 513, which specifies the main groups of cutting tool applications, classifies ferritic and martensitic stainless steel as ISO P. However, the situation with austenitic, duplex, and PH steel is totally different. These types of stainless-steel feature poor machinability and their machining is specified as ISO M. Machinability is also influenced by heat treatment. When cutting ISO M stainless steel, due to the low machinability of this material, a cutting tool edge works under heavy load conditions. • When beginning with poor heat conduction of such steel – a high temperature causes thermal cracking. • Self-hardening, due to material deformation during machining, leads to plastic deformation and a fracture. • High-material strength results in intensive fatigue wear and breakage. • The tendency of material sticking contributes to a built-upedge formation. The ISO S group of applications considers machining hightemperature super alloys (HTSA), titanium, and titanium alloys.

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Among a wide range of HTSA, there are iron-based alloys that, in fact, are heat-resistant stainless steels and their machinability leaves much to be desired. Hence, stainless steel is a whole class of engineering materials, which differs by content, property and machinability. Machining stainless steel requires tools, varied in cutting geometry and tool material, that cover three main groups of application: ISO P, M, and S. The metalworking industry needs more and more effective tools for stainless steel machining and cutting tool producers are in constant search of an appropriate answer to the growing industrial demands. Despite a long history of stainless steel machining, cutting tool manufacturers contrive to find new sources for innovative developments and improved existing solutions. The latest products from Iscar clearly support this conclusion.

Turning tools Based on accumulated experience, Iscar has developed three new chipformers for ISO turning inserts. The chipformers, which determine the profile of an insert rake face, are designated R3M, M3M and F3 and specify the main fields of application: rough, medium-duty, and finish turning stainless steel. They are used in both negative and positive turning insert designs. Typical features of the chipformers are a specially shaped deflector for better chip control and a wavy surface to prevent chip hammering. The 3D modeling of the chip flow greatly contributed to forming the deflector during the design stage. To help identify the chipformer, there is an engraved contour around the hole of the insert and each chipformer is characterised by the number of contour curves. According to Iscar experts, the new chipformers – in combination with the most advanced carbide grades that feature Iscar’s post-coating treatment technology SumoTech – provide higher performance and increase tool life. In the metalworking industry, Swiss-type machine tools are very popular for manufacturing small-sized stainless steel parts, particularly for aerospace and medicine products. The recently introduced inserts for grooving and turning with a new NX chipformer, which enriched the Iscar SwissCut Innoval Line, were developed specifically for these machining tools. The new chipformer considerably improves chip control in machining stainless steel. As in the previous case, 3D modelling of a chip formation facilitated in finding the optimal chipformer shape.

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In parting and grooving, Iscar launched two new carbide grades with PVD TiAlN coating for machining stainless steel: IC1010 for medium to high cutting speeds; and IC1030 for low to medium cutting speeds.

Rotating tools The technical capabilities of a cutting tool are largely determined by its properties. In drilling stainless steel, many of the latest Iscar developments have been aimed at creating better tool material, which has resulted in two new carbide grades: IC806 and IC5500. IC806 with PVD coating is dedicated mainly for deep drilling difficultto-cut heat resistant stainless steel (ISO S and ISO M groups), while IC5500, which features both new a substrate and a CVD coating, ensures high performance in drilling ferritic and martensitic stainless steel (ISO P group). The impressive results of the carbide grade IC5500 in drilling had a direct impact on expanding the application range of the grade, and was later adopted by the indexable milling product line. The family of milling cutters with round inserts has recently expanded with new tools intended for machining profile surfaces, especially the working surfaces of blades in turbomachinery. The new inserts are available in two design versions. The first version, produced from grade IC5820, is directed to machining austenitic, duplex, and precipitation-hardening stainless steel (ISO M and ISO S groups). The second version, made from carbide grade IC5500, is intended for milling ferritic and martensitic steel (ISO P group). Using grade IC5500, well-proven in drilling, as the material for the round insert, provides considerably increased cutting speeds. An interesting solution of improving performance in machining austenitic, duplex, and precipitation-hardening stainless steel (ISO M and ISO S groups) is represented by the recently developed family of five-flute solid carbide endmills. The endmill concept utilises the vibration-proof principle and gained successful recognition of Iscarâ&#x20AC;&#x2122;s ChatterFree products - variable angular pitch and different flute helix portions. A new element is a sub-flute wear control mechanism. The endmills are made from a new PVD coated hard submicron carbide grade IC608. The combination of the chatter-free approach, the subflutes, a reinforced taper core, and the advanced wear-resistant grade in the endmill design brought about a noticeable increase of tool life.

Effective cooling â&#x20AC;&#x201C; A stepping stone to success When machining difficult-to-cut stainless steel, in many cases, effective coolant supply is a factor in performance optimisation. Introduced over the past few years, the TangSlit slitting cutters with coolant channels directed to each cutting edge provide a reasonable solution for the customer. The cutters, suitable for either low (up to 10 bar) or high (up to 340 bar) coolant pressure, reach increasing cutting speeds of up to 50% and ensure efficient chip disposal and improved surface finish. Following the growing demands for machining with high pressure coolant supply, Iscar added new adapters with inner coolant channels to the threading tools. The adapters carry highly economical inserts with ten cutting corners. Demands for more and more efficient tools for machining stainless steel require an appropriate response from the cutting tool manufacturer. High competence and expertise, multiplied by an innovative initiative, is the decisive point here and the way to progress. Iscar remains determined and will continue following this practice in future developments. www.iscar.com.au

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Tooling manufacturer rewarded with shift to sustainability Dormer Pramet aims to lead a change in the metalworking industry by making sustainability integral to its business. At the core of this strategy is the use of new technologies and ways of working that deliver value for employees, customers and suppliers, brought together under a program called ‘Make the Shift’. This encompasses a wide range of initiatives and targets under four key headings: Circularity, Climate, People and Fair Play. A list of key actions and objectives are now in place with the aim to deliver all by 2030. This includes increasing recycling of its products and packaging material, reducing waste, lowering its greenhouse gas emissions, halving the total recorded injury frequency rate, developing a diverse and inclusive workforce and engaging in community involvement projects. An example of the very tangible results already achieved by this initiative comes from Dormer Pramet’s production and R&D department. Through international collaboration, a project team has made innovative technological developments which have enabled significant reductions in energy consumption and, at the same time, improved product quality. By implementing new insulation on its furnace coating, the manufacturer improved the heating of its CVD coating reactor, significantly shortening cycle time. This not only improved the deposition conditions, which affects the evenness of the coating on inserts, but it also generated a positive environmental impact, reducing emissions by 25 tonnes per year. Dormer Pramet also modified the sintering cycle during the production phase. This involved a redesign of the gas flow passing through the charge, enabling a more efficient furnace. The project succeeded in shortening the length of a single sintering cycle by 100 minutes (10% of the total length of the cycle), while maintaining the quality of the process.

The sintering furnace at Dormer Pramet’s indexable production unit.

A gradual introduction of this new technology began in 2019 and has continued this year, with an expected reduction in emissions of 14.7 tonnes per year. This activity resulted in the company being shortlisted in Sandvik Groups’ inaugural Sigrid Göransson sustainability award. The new accolade is given to employees who have contributed to a particularly innovative solution, which has a measurable and lasting impact on environmental, economic or social sustainability projects within the company or the local communities. www.dormerpramet.com

Mapal introduces additive manufactured PCD tools Mapal is now utilising additive manufacturing processes to realise the benefits of lightweight cutting tools. The process is also providing complete design freedom for ever more innovative solutions. As a general rule-of-thumb, if the weight of PCD cutting tools is reduced, then significantly higher cutting data can be achieved. As 3D-printed cutting tool structures can be designed and manufactured to minimise weight without compromising strength or integrity, Mapal engineers are increasingly pushing the boundaries of cutting tool design and development.

The honeycomb structure inside the tool can be realised thanks to additive manufacturing.

An example of how Mapal uses the advantages of 3D printing can be realised in the company’s new bell tools with brazed PCD inserts. Bell tools are frequently used in the hydraulic and automotive sectors, with examples being the external machining of hose connections on turbochargers where complex contour requirements must be met with precision. This means that cutting tool production must be equally precise to ensure customers can achieve their cost-effective, precision machining requirements. To meet the needs of the end-users, Mapal has optimised the existing, conventionally manufactured bell tool by integrating selective laser melting process into its manufacturing processes. This allows the inside of the cutting tool to be modified. Instead of utilising tools with a heavy solid material design, the new Mapal tools have now been specially designed with a honeycomb structure. As a consequence, the tool is at least 30% lighter and the tool life is increased by upwards of 40%, credit to the enhanced vibration damping characteristics of additive manufactured tool designs. It is therefore possible to machine at higher speeds and feeds while retaining the quality that end users require. Customers using Mapal’s additive manufactured tools are witnessing productivity improvements in the region of 50%. Additionally, Mapal

experts are using the 3D printing technology to optimise the cooling channels, ensuring that cutting fluid is delivered to the cutting area via the most efficient possible route. The new bell tool is a hybrid design that can be specified by the end user to meet their exact machining requirements. Using selective laser melting, the new tool geometry is printed on a highly precise tool body with an HSK-63 connection. The additively manufactured tool body is subsequently machined to provide the precise platform for the PCD inserts to be brazed into place and then cut to shape using a laser. www.mapal.com.au

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Overcoming process uncertainty to reduce scrap and rework Product quality is a key performance indicator for manufacturing businesses. Many workshops believe that achieving quality-standard certifications such as ISO, NADCAP and API affirms the quality of their work. In reality, the standards do not fully focus on how to make acceptable finished workpieces, but rather concentrate on establishing procedures for rejecting bad parts. By Patrick de Vos, Corporate Technical Education Manager, Seco Tools. A true picture of a manufacturer’s product quality comes from a look into the shop’s quality control area, especially where there are parts with stickers or tags calling for “re-inspection.” The tags indicate that for some reason the workpieces were rejected or must be returned to production for rework. Scrap and rework result when manufacturing processes do not meet expectations. Some processes, especially machining, are based on the interaction of many variables and thereby are subject to uncertainty and some degree of unreliability. It is essential that manufacturers recognise the sources of uncertainty, understand how they arise, and find ways to resolve them. In many cases, however, the sources of process uncertainty are not recognised or are ignored and accepted as standard practice. In the end, overcoming uncertainty and limiting scrap and rework comes down to the awareness, knowledge and motivation of those on the shop floor.

Sources of uncertainty Competitive pressures prompt manufacturers to perform costreduction analyses. The analyses include examination of spending for materials, tooling and machining time. Seeking out and eliminating the many instances of lost time offers significant opportunities for controlling costs. Methods used in cost analyses include overall equipment effectiveness (OEE) and Lean programs. Such analyses, however, often are based on a view of the manufacturing process as a kind of self-contained, simple box. A shop puts raw material or a semi-finished product into the box, machining processes occur, then a certain number of workpieces exit the box, either as finished products or as semi-finished workpieces destined for another box. What is often missing in the analyses is recognition that in the real world, it is not totally certain that every product that leaves the box

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will be acceptable. Unacceptable products must be reworked or scrapped. The number of unacceptable workpieces produced depends on how closely the variables in the manufacturing process are controlled. Processes such as forging, for example, are not extremely complex and do not require an extreme level of precision. These processes therefore are relatively controllable, reliable and capable of consistently delivering the expected number of acceptable workpieces. In contrast, other manufacturing processes involve multiple variables that can reduce the predictability of the outcome. The number of acceptable workpieces coming out of the box is not reliably predictable. It is an exaggeration to call all machining processes unreliable, but describing them as not entirely predictable is quite accurate. Machining involves many variables. It subjects cutting tools and workpiece materials to strong cutting forces and high temperatures. The combination of forces and temperatures creates a complex and fluid situation. The hardness of a tool determines its ability to cut effectively, and hardness will vary between room temperature and the 800˚C temperatures generated in machining. Heat also affects the machining characteristics of the workpiece material. The effects of the variables are unpredictable. Even if machining parameters are specified for a certain application, the exact values that exist during operation will be unknown. Varying results in surface finish or dimensions can make a part a candidate for rework or the scrap bin. When parts are unacceptable, two areas need to be examined. One area is technological: a manufacturer needs to know what is actually happening, recognise which variables caused the unexpected result, and decide how to resolve the problem. The other area for examination involves determining the financial effects of producing

CUTTING TOOLS unacceptable parts. That includes calculating the unexpected cost of rejection or rework and deciding how the company will account for it. Mass production scenarios generally compare the number of unacceptable parts statistically with the hundreds or thousands of parts produced overall. Over long production runs, the shop can analyze the operation, note the factors that resulted in the unacceptable parts, and update machining parameters to minimise uncertainty and maximise reliability. In high-mix, low-volume manufacturing scenarios, however, there is minimal time to examine unacceptable parts and change machining processes to eliminate them. The challenge is greater if a production run consists of only a single item. The issue is multiplied further when the shop is not familiar with the workpiece material and the end customer requires the finished part immediately. An unacceptable result on a job involving a single part demands machining of another part, increasing cost and disappointing the customer. In the case of mass production, eliminating the production of unacceptable parts is relatively simple. Technological staff review and update the process, make trial runs, and arrive at a solution. In true mass production scenarios, the number of unacceptable workpieces is relatively very small compared to the total production output, and the costs are negligible. But in the case of high-mix, low-volume or even single-part production, the cost of unacceptable parts can severely depress profit margins or even result in an operating loss. The manufacturer has just one opportunity to make an acceptable part in an extremely limited amount of time.

Hidden or ignored costs Some costs that should be included in the total cost of manufacturing may be hidden or ignored. An example is the cost of deburring. A workpiece is considered complete when its machined surface finishes match specifications and its edges and geometries match blueprint requirements. A part with a burr is not complete. Although a burr represents a lapse in machining quality, burrs often are accepted as a normal consequence of the process. In any case, burrs must be removed and the cost of accomplishing that can be significant. In a real-world example, a highly-automated shop with five-axis milling machines produced a family of parts that required manual deburring. Ultimately, the time and labour involved in deburring represented 20% of the cost of a finished workpiece. In some cases, the cost and price calculations for a part are based on machining processes without considering the cost of deburring or other secondary operations. Such costs may not be negligible. To

gain an accurate picture of total manufacturing cost, hidden costs must be recognised and mitigated.

Tool selection Use of appropriate production equipment and tooling will minimise variability in machining operations. Large, rigid machine tools can resist the forces of heavy machining that cause inconsistent workpiece dimensions. Machine tool features such as glass scales, linear guides and thermal management systems maximise accuracy. Cutting tool selection plays a major role in limiting variability. Over the last two or three decades, the approach to tool selection has evolved. Previously, tool choice was basically divided between highperformance tools that offered the greatest possible output rates and economical tools that provided the lowest possible cost per part. In some cases, however, the highest-performing tools were relatively fragile. When they worked well, they worked brilliantly, but careful application was paramount. The lower-priced tools did not match the speed and output capability of the high-performance tools, but the price advantage came at the expense of lower output. When choosing tools today, a key consideration before choosing geometries, speeds and feeds is what a user requires in terms of tool performance. For mass production operations, there remains a need for tools that maximise metal removal rates and tools that offer maximum tool life. Extremely high-precision applications require tools whose manufactured dimensions, wear characteristics, and application parameters have been developed with extreme accuracy in mind, albeit at a premium tool cost. In the present era of frequent high-mix, low-volume production scenarios, it is extremely important that the quality of the finished workpiece meets expectations the first time the part is machined. The focus is on tools that work in a wide variety of situations with minimal process development time. When put to use by production engineers and operators who know the toolsâ&#x20AC;&#x2122; capabilities and limitations, tooling engineered to be reliable and versatile is the answer for many applications. Working with a limited number of versatile tools enables an operator to learn and understand tool performance over time while adapting to machining of variety of different workpieces. Knowledgeable application of versatile tooling can minimise production of rejected workpieces, and increased process reliability can help management gain an accurate picture of costs and profit margins. www.secotools.com

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CUTTING TOOLS

Deep hole drilling with high pressure MQL Single flute drilling is the method of choice for the reliable drilling of high-precision and deep holes. In many cases, however, users cannot fall back on single flute drilling because the necessary prerequisites are not fulfilled using a deep hole drilling machine with an oil cooling lubrication. Thanks to adapted tools and a new, high-pressure-capable minimum quantity lubrication (MQL) system, botek and Bielomatik have succeeded in using deep hole drilling tools with small diameters in a reliable process even under unfavourable conditions. Deep hole drilling is considered to be a reliable and cost-effective process that is significantly better than other drilling methods in terms of machining quality. These advantages can be exploited in many applications where often only a small bore centerline deviation is permitted. In addition, surfaces with very low roughness values may be required, for example if they have to be cleaned afterwards without leaving any residues. Here, deep hole drilling is often the only method that enables such results without subsequent machining of the hole. Optimal conditions for their implementation are a special deep hole drilling machine, deep hole drilling oil with HP additives, coolant pressure of up to 160 or even 200 bar for the smallest diameters as well as an efficient filtering system.

Challenging conditions Numerous machines now enable production with cooling lubricant pressures of up to 80 bar, in individual cases up to 140 bar. However, machining centres and lathes are often operated with emulsion, which sets limits for deep hole drilling because the lubricating effect on the guide pads of the tools is insufficient. In addition, with small bore diameters, even a pressure of 80 bar can be insufficient due to the small cooling channels of the tools. For users who do not primarily drill deep holes, an investment in special deep hole drilling machines or cooling lubricant systems for higher pressures is usually not worthwhile. Last but not least, the use of deep hole drilling oil is not permitted in certain production processes or at some locations. In order to still be able to drill high-precision and deep holes on existing machines, botek and Bielomatik have now combined their know-how. In their new deep hole drilling processes, sufficient lubricant reaches the cutting edge and guide elements of the tool thanks to the MQL-compatible, optimised high-performance solid carbide gundrill type 113-HP-M. A specially adapted cutting edge geometry produces a chip shape adapted to MQL machining even at high feed rates, which prevents the chips from jamming in the chip flute of the single fluted drill.

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Deep hole drilling of stainless steel on a TBS200 deep hole drilling machine.

Bielomatik’s MQL system uses aerosol under high pressure to provide the necessary amount of oil for spot lubrication and cooling on the cutting edge and guide pads of the tool. Because the air-oil mixture has a higher compressibility than waterbased emulsions, a larger volume flow is achieved, so that the chips can be removed from the bore hole quickly and reliably. Consequently, bore diameters of 2.5mm or less can now be realised on machines that do not have a high-pressure system with deep hole drilling oil.

Additional cooling effect thanks to high pressure Like the other process parameters, the MQL pressure provided can be adapted to the respective machining task. This way, the compressed air and energy consumption can be kept within application-optimised limits. The pressure increase from the level of the house network, approximately 6 bar, up to 25 bar is achieved by pressure amplifiers known as boosters, which are connected upstream of the Bielomatik system. Due to the higher compression and the increased expansion of the MQL aerosol as it exits the tool, an increased cooling effect also occurs, which influences the chip formation. For example, this cooling effect leads to significantly shorter chips when machining high-purity copper materials, which are generally very long-chipping when machining with oil – an effect that decisively supports reliable chip removal. This can be

seen clearly in the processing of electrolytic copper and small drill diameters. In a customer application, a 40mm deep hole with a diameter of 1.5mm was drilled into this material. The required quality criteria were a Ra-value of 0.2μm and a centerline deviation of less than 0.03mm. With the generation of significantly shorter chips during this machining under high-pressure MQL, it was not only possible to achieve process reliability, but also to increase the feed rate by up to 70% compared to oil. “We knew that with copper we had a problem with chip formation,” says Jürgen Deeg, Manager of the Testing department at botek. “But we also knew we were in a diameter range where there was not much scope for different tool geometries. The tools are simply too delicate. But now we were able to drive the process parameters upwards. Because with this intervention in the chip formation we suddenly had very small chips.” Another application that botek and Bielomatik were able to design with process reliability is the deep hole drilling of small diameters into stainless steel. In this process, bore wall surfaces were created with a roughness that is very close to the qualities achievable under deep hole drilling oil and significantly undercuts the Ra values achieved under emulsion. Here too, small diameters could be reliably drilled in with single flute gundrills designed for MQL and high-pressure MQL, once again thanks to particularly short chips.

CUTTING TOOLS The new 1-channel MQL system from Bielomatik.

Particularly short chips were produced with the MQL system under high pressure, even when drilling stainless steels. The chips are quenched by the expansion of the air and break clearly better.

Next technology step possible The process limit, which botek and Bielomatik were able to shift in this way, is currently at a diameter of 1.2mm. Only now, materials such as stainless steel with diameters below 2.5mm can be deep hole drilled under MQL using single fluted tools. For larger diameters this was already possible with 10 bar. With up to 25 bar this limit has now been significantly lowered.

Based on these developments for deep hole drilling with high pressure, botek and Bielomatik are the contact partners for new applications, be it in terms of process design, quality or economy. The degrees of freedom for the user have been increased. It is now up to the user to decide how to explore them. Thanks to experienced specialists and application engineers at botek and Bielomatik, users have access to highly

qualified contacts to test the possibilities of deep hole drilling under MQL in their company. Not only is drilling fast one of botek‘s strengths, but also the shortterm availability of the tools. To this end, the stock program has been successively expanded in recent years and an express production line has recently been set up for solid carbide gundrills, pilot drills and special tools such as step drills. www.botek.de www.bielomatik-schmiertechnik.de www.teco.net.au

The Surftest SJ-210 is a user-friendly surface roughness measurement instrument designed as a handheld tool that can be carried with you and used on-site

Easy to use • 2.4-inch colour graphic LCD with backlight • Simple key layout The Surftest SJ-210 can be operated easily using the keys on the front of the unit and under the sliding cover.

Highly functional • Advanced data storage capabilities • Optional memory card • Password protection • Multilingual support • Stylus alarm An alarm warns you when the cumulative measurement distance exceeds a preset limit.

Contact MTI Qualos today to learn more about the SJ-210 Series.

Extensive analysis and display features • Complies with many industry standards The Surftest SJ-210 complies with the following standards: JIS (JISB0601- 2001, JIS-B0601-1994, JIS B0601-1982), VDA, ISO-1997, and ANSI. • Displays assessed profiles and graphical data In addition to calculation results, the Surftest SJ-210 can display sectional calculation results and assessed profiles, load curves, and amplitude distribution curves.

M.T.I. Qualos Pty. Ltd. 1300 135 539 or email sales@mtiqualos.com.au

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COMPANY FOCUS

Renner Auto – Modernising classic vehicles with advanced manufacturing After 30 years working in the global automotive supply industry, from R&D to senior management, Renner Auto’s owner and founder Jason Ferraro is now following his passion – building and restoring classic vehicles with innovative high-tech chassis and drivetrain systems. By Carole Goldsmith.

Renner Auto builds its vehicles in small batches to realise economies of scale.

Excitement was at an all-time peak at Renner Auto this October, when the first of four Renner Auto Speedsters rolled out for inspection and testing. These updated classic vehicles are being built using the latest in advanced manufacturing at the company’s workshop in Melbourne’s eastern suburbs. Proudly standing beside these four Speedsters – open with chassis, engine and internal components on display – Ferraro says that the first two Speedsters will be ready before Christmas, with the other two completed early next year. Nearby, team member and fellow engineer Kevin Reich performs general assembly work on another of the Speedsters. The vehicles are all replicas of the classic 1956 Porsche 356A Speedster, but with modern high-tech mechanical and electronic systems. Ferraro points to the PWR radiator and turbo charger intercoolers in each of the four cars and advises: “PWR is a tremendous partner in our Speedster recreations and one of the many excellent local suppliers we use.” Ferraro uses a wall display of 3D-printed Speedster models for clients to choose the vehicle’s external colour and upholstery. “We commenced the Speedster development project one and a half years ago and all of these vehicles are pre-sold to clients,” he says. “Components for the next four Speedsters are being procured now and we plan to produce up to eight of them each year. “Although we modelled and designed the vehicles to closely resemble the original item, we sell it as a Renner Auto Speedster. You can’t recreate a vehicle from scratch and call it a Porsche, and it can’t leave our workshop with Porsche badges on it. We can however restore a Porsche from scratch and it can retain the Porsche badging, as a restored vehicle. “An original classic Porsche Speedster can sell for more than $700,000. Currently, we have an original Porsche 356 Coupe in the workshop, which we are completely modernising internally, so it can keep its Porsche badges on it.” Ferraro speaks with great enthusiasm for his business: “Renner Auto is celebrating the high point of automotive design, the period

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between 1950 and 1970, through the building of new cars, that pays tribute to that period’s styling. These vehicles possess the styling that make them an instantly recognisable classic. By using advanced manufacturing, we build a modern chassis, engine and electrical system that makes them as advanced in technology and up to date as new vehicles.” He shows an AC control unit for the Speedster that he had just printed on the Raise 3D Pro2 Plus machine: “I purchased the 3D printer two years ago for around $11,000. We 3D print prototype and select production parts using this equipment, and it has enabled us to implement OEM (original equipment manufacturer) solutions at volumes that were not previously viable. As well as the 3D printing and supporting CAD design work, I do a lot of general workshop operations, such as TIG/MIG welding and composite work.”

Dream machines How it works at Renner: most clients are local and after scheduling an appointment, they’ll come into the workshop for a site visit. Ferraro says that some clients have even ordered their vehicle build on the spot. Several of Renner’s custom vehicle projects have seen clients investing over one million dollars to create their dream vehicle. “I provide an estimated price and time frame to the client, and we often run on an open book costing model,”says Ferraro. “We use 3D scanning equipment to digitise the vehicle structure and then commence the 3D CAD design of all the vehicle systems. Then we install the modern internal components in the body, so that it resembles the original vehicle with a high-tech engine and a modern internal operating system. The recreation of a classic vehicle takes between 1,000 to 2,500 hours to build and there are usually up to six cars being built at a time. Significant time is spent on vehicle R&D and fit-out. “Clients are involved during the build both via Zoom, regular newsletters and now face to face, post COVID-19 lockdown. They get very excited, like we do, when their custom-built vehicle is nearing completion.”

069 In-house 3D-printed components are used for prototype and final production components, using a Raise 3D Pro2 Plus supplied by Bilby3D.

A fully digital design process has enabled Renner Auto to package a complex vehicle system within an authentic Speedster body shape.

During the Melbourne COVID-19 lockdown, Ferraro had two of his four-person Renner team assisting him on the job: “I also engage RMIT undergraduate mechanical engineers to spend time in the workshop, as we have a great mix of theoretical and hands-on engineering tasks, on a daily basis. We plan to employ extra full-time staff as we are getting very busy in the workshop.” Ferraro adds that the Federal Government’s JobKeeper grant has assisted the business weather the COVID-19 crisis, while the R&D Tax Incentive program has helped to support an innovative automotive project.

Driven by passion Before founding Renner Auto, Ferraro had worked in senior management roles at several large global corporate automotive supply companies, including Air International Thermal Systems, Futuris Automotive and TE Connectivity. After 30 years, he decided it was time to move on and take on new challenges, doing exactly what he enjoys. “I was nearing 50 and had enough behind me to start my own business,” he recalls. “So, I launched Renner Auto, enabling me to follow my passion, working with advanced manufacturing and technology, applying a unique skill set in the construction of custom cars from the 1950s to the late 1970s.” While the Renner team specialises in producing the Renner Speedster as an important sideline, its main business is to custombuild classic cars of this same era. The iconic Ford GT40 and Jaguar XJ13 replicas are two builds that Ferraro is very proud of. The skyblue coloured GT40 replica had been his hobby project for after work and weekends until he started Renner Auto. It’s also one of his favourite creations to date, which he proudly built over seven years. “That’s my own car, so it’s not built for clients,” he says. “And my 12-year-old daughter has already claimed it for when she is old enough to drive. We also have a four-year-old daughter, whom I will probably build an electric Speedster for when she’s older.” Ferraro writes a comprehensive blog on his website and describes the build and modifications of some of Renner’s classic custom car replicas. The Jaguar XJI3 build’s progress are among these blog reports. The Jaguar XJ13 replica includes a V12 engine and the same transaxle as used in a Lamborghini Gallardo. Ferraro advises that only one XJ13 was ever built and the dashboard layout was not that functional. “The client was happy for us to create a dashboard that had as many original details as possible,” he says. “However he wanted the speedometer and tachometer behind the steering wheel.”

“If you are undertaking true R&D activities there is some great support out there from government.”

Data driven Ferraro graduated with a degree in mechanical engineering from RMIT University in the early 1990s. “As an engineer, you become a data driven person,” he remarks. “The engineering degree made me the person I am today; however, I was also very fortunate to start my career as a graduate engineer at Air International Thermal Systems. “I started work in the R&D area and moved to managing and running the climatic tunnel. I had access to the machine and pattern shop, and had the good fortune to learn from people with years of skill in these disciplines. This provided invaluable experience and skill development that I use today, and can pass on knowledge to apprentices and contracted employees. In recent corporate roles, I learnt a lot about innovation and advanced manufacturing, such as 3D printing and CAD systems, which we now use extensively.” Ferraro’s plan for Renner is to build vehicles equipped with electric drivetrains within the next two years. He explains that the electric drivetrain is a far more elegant and efficient system, with far fewer components than a combustion engine. “We will employ an engineering graduate who is interested and trained in that technology and start developing the electric drivetrainpowered classic vehicle. We are also looking at the maturity of the technology in the automotive aftermarket. There are already companies that can supply businesses like mine, restoring classic cars with electric ,drivetrains and I look forward to working with them in the near future. “Over the years I have learnt what motivates me,” Ferraro adds. “At the top of this list is to be working in a company where innovation and technology are core to the business success. Working with new technologies is my passion and at the centre of everything I do, at a professional and personal level.” www.rennerauto.com.au

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MATERIAL REMOVAL

Hargo Engineering: Remaining positive, pushing ahead Based in Croydon, Victoria, Hargo Engineering has been providing specialist precision and repetition engineering services since 1976. Hargo’s CEO Frank Gogol spoke about his company and its recent purchase of a Nakamura-Tome WY 100II lathe supplied by Headland Machinery. AMT: How long has Hargo been in business? Frank Gogol: My dad Heinz Gogol started the business in 1976. Dad came from a watchmaking background in Germany, and he started the business as an engineering shop specialising in small components. I joined in 1991 after I completed my apprenticeship in electrical fitting with Siemens, manufacturing high and low-voltage switchboards. AMT: How has the business grown over the years? FG: Like a lot of family businesses, Hargo has grown conservatively over the years. When I joined in 1991 Hargo employed around eight people including the family, and by 2015 we had grown to 20 staff. In 2015 Hargo established an advisory board to help with expansion and direction of the business and has since doubled in size, in both turnover and staff. Up until 1995, Hargo’s machinery still consisted of sliding head cam autos. The purchase of our first CNC, a Start SR16, was made, the benefits were soon realised, and the transition to a modern CNC machine shop began. By 2005 Hargo had become purely CNC, retiring all of the cam autos. AMT: What industries do you service? FG: We cover a large range of industries; we currently make components for model trains right through to the Space X and Starlink programs, and everything in between. At the moment, our specialty is complex, high-quality components at production volumes, which we are supplying to automotive and second-tier aerospace and defence, both in Australia and the USA. AMT: What are the keys to your company’s success? FG: Not being scared of the difficult jobs, investing in the right technology and getting the technology to work for you, to its full capacity and capability, is key. We’re not afraid to try new things, and spend a lot of time developing tooling to get parts from the machine complete. We empower our people to think about the best, most efficient way to manufacture the component. We also have a strong training program. I think getting the right people is a big

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Hargo Engineering’s workshop in Croydon, Victoria.

struggle for many Australian manufacturers. We have focused heavily on overcoming this through our apprenticeship program. We get a new apprenticeship every year and we train all the way through. We select people based on their attitude and always select someone who is keen and open and willing to learn. We also open our doors to schools and have lots of work placements, giving students the chance to experience engineering before they look for a job. We always have a new face starting. Everyone in the business has a responsibility to train – that way we share the knowledge from all the people in the business. AMT: How you do remain ahead of the competition?

looking to set up a small manufacturing plant over there. We already have a brand for ourselves over there which is fantastic – it gives us a foot in the door. AMT: What are Hargo’s greatest strengths? FG: Relationships – both customer and supplier relationships – are key for us. Working closely with our customers, as most of our work is repeat and doing it ontime and to high-quality standards is critical. We are also big communicators; we are actively communicating with the customers on how we can manufacture parts most efficiently. We help them to manufacture the part most cost-effectively and talk to them about how they make their parts. We don’t hide pricing and keep everything very open and transparent.

FG: We have a strong focus on our people and supply chain. Hargo currently exports up to 40% of sales and have had to become globally competitive. Hargo has had to develop a supply chain within Australia and the USA focusing on value and quality; it’s been hard work to find a supply chain that you can trust to deliver a high-end product that you export competitively. We have spent a lot of time visiting key suppliers in the USA to foster and develop those relationships early.

AMT: You recently purchased and installed a Nakamura WY 100II lathe. What problem were you trying to solve with this investment?

We are also looking to expand our footprint into the US market. But of course, this has all been put on hold for now. We are still

The key for us was getting the cycle time down on a complex part with many variations that are used by a number of

FG: We have been growing our export business consistently and needed a machine that would reduce our cycle times and maintain a high capability. We were focused on a particular range of material and size. We have experience with other brands, and the Nakamura became the obvious choice.

MATERIAL REMOVAL customers that we have and are targeting. The very first mil spec housing we machined on the Nakamura had a 30% quicker cycle time, so we’ve definitely made the right decision. We are confident that future quoting reflecting this reduction will grow this business more.

The newly installed Nakamura-Tome WY 100II lathe at Hargo Engineering.

The capability of the machine is most critical, but for us the level of service, support and training from Headland themselves was also an important factor. We have dealt with Headland in the past and have been comfortable with them – they are a good company to work with. AMT: What’s the real value of the machinery you have in your factory? FG: Cycle times and repeatability – this machine was more about our customer, some of our customers are using the Nakamura in their machine shops, and with our efficiencies we knew we could get cycle time down significantly and be competitive. We’re currently manufacturing shell blanks for the SpaceX program, which is highly competitive and demanding in quality standards. We’ve had Headland’s CNC programmer Gurav working on the installation and training on the software, and he’s been pretty flexible working around the restrictions of COVID adapting to our split shift no-contact policy.

AMT: What’s your view on the current state of manufacturing in Australia? FG: I’m receiving mixed feedback from the market. While some sections of the industry seem to be doing quite well, and some manufacturing seems to be coming back on-shore, we need the whole end product to come back to Australia, for the industry to truly benefit. AMT: What’s the outlook for Hargo Engineering going forward? FG: I took over a great business from my dad. He was more conservative than me and we were in for slow, but sustained growth. I’m a bit more aggressive and

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we’ve doubled in size over the last five years. During COVID-19, I’m happy to say none of our staff have lost any hours and we have still hit all our budgets, putting us on track for our best year ever. However, we are very cautious in the next few months ahead to see what happens. But overall, we’re remaining positive and pushing ahead. And no matter what, we’re always willing to have a crack, so I think that helps in times like these. www.headland.com.au www.hargo.com.au

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MATERIAL REMOVAL

Bremont – Luxury watchmaker doubles capacity British luxury watch manufacturer Bremont Watch Company made the most of Sandvik Coromant and DMG MORI’s strategic partnership as it introduced a turnkey manufacturing cell to double capacity at its factory. Bremont is a true manufacturing success story. Founded by brothers Nick and Giles English in 2002, the company specialises in the manufacture of certified chronometers for the aviation sector. These watches are assembled, as well as shock- and qualitytested, at the manufacturer’s dedicated headquarters in Henley-on-Thames, Oxfordshire, in the UK. Production of the main components, such as stainless steel backs and casings, takes place just a few minutes’ drive away. High demand and the launch of six new watch designs meant that Bremont’s production capacity had to be increased. To achieve this, the company purchased an NTX 1000, a state-of-the-art five-axis machining centre from DMG MORI, which came equipped with tool packages from Sandvik Coromant. The project was six months in the making, explains Mathew Bates, a machine tool investment specialist from Sandvik Coromant’s UK Machine Tool Solutions team. “From the beginning, the objective was to deliver a ‘right first time’ solution,” explains Bates. “We wanted Bremont to be able to use the new system straight away.” Close collaboration with application technicians from DMG MORI was needed, with regard to the selection of suitable tools. “We knew that we had to produce six new watches,” says Bates. “As soon as the drawings were ready we met with specialists from DMG MORI to compile a list of standard tools and to determine which special tools would be needed.”

Integrated automation for 24/7 operation The DMG MORI NTX 1000 is equipped with a magazine for 38 Coromant Capto tools, with the option of expanding the capacity up to 76 tools. The turn and mill machine is suitable for turning and high-speed milling in five axes, simultaneously. Thanks to the bar loader, the machine produces the different stainless steel components around the clock without any operator intervention. The NTX 1000 is designed to offer a perfect combination of maximum turning and milling performance. Key features include: • Six-sided complete machining — Production turning through synchronous machining with the B-axis and the lower ten-station turret at the main and counter spindles.

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• A direct drive motor (DDM) on the B-axis for five-axis simultaneous machining of complex workpieces. • Thermo-symmetrical headstock structure with coolant circulation.

Everything from a single source Even before the installation of the machine, Frederick Shortt, an application technician at DMG MORI, and his development team created and simulated the numerical control (NC) programs with the Vericut computeraided manufacture (CAM) system. “Together with Sandvik Coromant we optimised all programs in such a way that as few tools as possible are needed,” says Shortt. In other words, Bremont only bought what it really needed. As this all took place before the installation, Bremont was able to start producing from day one. “This joint optimisation meant that any teething problems were reduced to a minimum and the investment quickly paid off for Bremont,” explains James Rhys-Davies, Strategic Relations Director, Northern Europe at Sandvik Coromant. “The call for such turnkey solutions will increase steadily. Although the preliminary costs are sometimes a little higher, the

benefits of a fast return on investment (ROI) and maximisation of machine availability make such turnkey production cells a very attractive option, as cost per part is generally much lower.”

Tolerances between three and five micrometres Exactly as planned, Bremont was able to start full production of the watch components immediately after installation of the new machine. Malcolm Kent, Production Manager at Bremont, has been extremely satisfied with the results. “We were surprised at the speed and high quality to which we can now produce the individual components,” he says. “We produce very complex parts with tolerances of 3µm to 5µm, where quality and precision are of paramount importance. Thanks to the NTX 1000 in combination with the Sandvik Coromant tools, the processes are absolutely trouble-free.” Bates adds: “Thanks to the collaboration between Sandvik Coromant and DMG MORI, it was possible to start production on the NTX 1000 on the very first day.” www.dmgmori.com www.sandvik.coromant.com www.bremont.com

MATERIAL REMOVAL

Mazak unveils next-gen compact five-axis vertical machining centre Yamazaki Mazak has unveiled a new high-accuracy simultaneous five-axis vertical machining centre, the Mazak VARIAXIS C-600, suitable for a wide range of industry sectors including the aerospace and automotive markets. The Mazak VARIAXIS C-600, which is the successor machine to the highly successful Mazak VARIAXIS j-600/5X, is being marketed at an attractive price point to provide a high-performance and costeffective five-axis solution. The VARIAXIS C-600 is characterised by its highly agile performance, with no compromise on rigidity. The compact machine, capable of machining workpieces up to 730mm in diameter x 450mm in height and 500kg in weight, has been designed with a large machining envelope and a highrigidity structure, featuring a 600mm fullysupported trunnion table, with roller gear cam on the B- and C-axes. Exceptional high-speed performance is delivered with 42 metres/min rapid traverse rates in the X-,Y- and Z-axes, and a chip-to-chip time of just 4.5 seconds to reduce non-cutting time for faster cycle times. Most importantly, the new Mazak VARIAXIS C-600 comes with a class-leading range of specification options, enabling users to configure the CNC machine tool to match their specific application. The machine’s high-rigidity spindle can perform heavy-duty cutting of steel, as well as the high-speed machining of other non-ferrous materials such as aluminium, as it can be configured with four different spindle options. These range from a 12,000rpm standard spindle, up to a 15,000rpm high-torque option, or 18,000rpm high-speed and 20,000rpm high-power spindles. In addition, the Mazak VARIAXIS C-600 features a 30-tool magazine as standard, complete with a double-arm automatic tool changer, which can drastically reduce chip-to-chip times. Alongside this standard specification, 60-, 90- and 120-tool magazine options are also available. The VARIAXIS C-600 also employs Mazak’s SmoothAi Spindle function, featuring AI adaptive control (patent pending) that suppresses milling spindle chatter by intelligently adjusting cutting technology based on feedback from sensors built into the machine. The modularity of the Mazak VARIAXIS C-600 extends to the variety of coolant packages that are available for different applications up to 70 bar pressure. Dedicated packages for cast iron, aluminium and composite, and casting machining are also available as options.

As well as offering excellent operator access and ergonomics, the Mazak VARIAXIS C-600 has been designed to integrate easily with a range of automation solutions, such as MPP and Palletech. Optional extras such as a side loading door, and preparation for hydraulic and pneumatic fixture interfaces are available to support bespoke automation projects with articulated robots. Integration of automation is further enhanced with the new Smooth RCC (Robot Cell Controller) adding advanced capabilities, such as tool and fixture capability check, tool set-up and fixture set-up, while the Robot Setup Assist enables efficient programming of the robot in the same co-ordinate system as the machine. The Mazak VARIAXIS C-600 is equipped with SmoothAi, Mazak’s new artificial intelligence control, which has in-built learning capability to continually improve machine performance. Smooth Machining Configuration Plus allows operators to easily adjust features including cycle time, finished surface and machined shape on the CNC display, according to material requirements. This is especially effective for complex workpieces with contours defined in small program increments. Specific settings can be saved and stored to allow them to be easily used for future cycles. The Smooth Project Manager also allows for easy management of data required to execute machining programs such as tool data, fixtures, co-ordinates, parameters and workpiece 3D models. Further machining accuracy is guaranteed by the new Ai Thermal Shield function, which uses algorithms to automatically determine the volume of compensation needed according to changes in temperature. www.johnhart.com.au

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New MultiSwiss helps SPM progress medical turning As changing demographics, an ageing global population, technology and innovation transform the medical sector, US manufacturer Swiss Precision Machining (SPM) counts on Tornos in its pursuit of excellence. As a key supplier to the medtech industry, SPM’s recent purchase of two new MultiSwiss machines advances its legacy of precision and boosts its productivity. Based in Wheeling, Illinois, much has changed since Mike Haupers, the son of an instrument maker specialising in dental instrument making, founded SPM in 1979 with just two machines and two employees. Mike’s daughters grew up with the business, and today Cassandra Haupers is SPM’s Vice-President of Operations, while Jennifer Haupers Adair is the company’s Quality Assurance/ Continuous Improvements Manager. “My dad started manufacturing dental components, then people started hearing the name and recognising the quality and competitive pricing, and SPM became a job shop,” Cassandra explains. “Manufacturing has been in our family for three generations. My sister Jennifer and I started working at SPM in high school. When I was in college, I worked two days a week in the office and ran the machines for an entire summer. My dad taught me how to tackle challenging parts, and I understand what it means when equipment is down.” “My dad is the boldest and most daring businessman I have ever met,” Jennifer adds. “He takes risks and knows he will fail at times but look at what he has created. We did not grow up like your ordinary girls with him. We were taught how to use tools, fix things and put them together, how to make things and never rely on anyone else – always carve out your paths. I have always had an eye for spotting imperfections and always want things looking their best. I am just lucky enough to get to do this daily with a team of 140 people that I get to call my second family.”

Swiss Precision Machining (SPM) Directors Jennifer Haupers Adair and Cassandra Haupers with one of the new Tornos MultiSwiss machine.

That passion for quality underpins SPM’s success and its reputation among customers. Jennifer says SPM was built on Tornos cam machines, including the R10, R125, RR20, MS7 and T4. “Back when SPM started 40 years ago, Tornos had a reputation of quality and precision—two values that SPM lives by,” she says. “Still to this day, Tornos builds quality machines that hold precision tolerances and has the support needed. That alignment of values is the foundation of SPM’s relationship with Tornos. When core values align in companies, there’s no doubt that a partnership will flourish - and that’s what’s happening here with Tornos.” SPM recently purchased two MultiSwiss multispindle machines from Tornos. The MultiSwiss range, launched in 2011 when multispindle technology was still considered extremely complex, is renowned for its superb ergonomics and machining performance. SPM counts on its MultiSwiss machines to machine parts for robotic surgical operations. “We knew that the quantities in demand for medical parts were increasing considerably,” Cassandra explains. “To stay competitive, we needed a machine that could keep up with our customer’s demand, could produce a quality part and allow us to charge a price to compete globally. The Tornos MultiSwiss was our answer.” The MultiSwiss answers that concern and more. Featuring independent mobile spindles with Z axes, barrel indexing using torque motor technology, and a container housing for all of the peripherals needed for machine operation, these capabilities position SPM for success well into the future. Marking a departure from conventional multispindle machines, the MultiSwiss range bridges the gap between a single-spindle sliding headstock lathe and multi-spindle machining. Additionally, its onboard technology means a MultiSwiss can deliver cycle times equal to those of cam-operated multi-spindle turning machines.

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Some of the parts manufactured at SPM.

A key differentiator between SPM and its competitors is its willingness to invest in anything that will help the company improve product quality. Another differentiator is the company’s focus on aesthetics. Even when aesthetics aren’t on the blueprint, SPM knows that doctors and dentists want instruments that are not only functional but pleasing to the eye. With this commitment to both quality and aesthetics, SPM produces parts and instruments that their customers cannot get anywhere else. “We chose the Tornos multi-spindles because we know that Tornos will keep us turning,” says Cassandra. “There are a few product lines SPM manufacturers need in tremendous quantities. However, we needed a machine that can achieve a high rate of production while producing quality parts. We knew Tornos could do both.” SPM’s new MultiSwiss 6x16 and MultiSwiss 8x26 will produce parts for a robotic surgery platform. Cassandra explains: “These parts require tight tolerances being held to ± 0.01mm. The challenges these machines help us overcome are the ability to produce highly sophisticated components, at a high production rate, resulting in a competitive price.” With the global medical device manufacturing market poised to exceed US$600bn by 2025, SPM is ready with an enthusiastic and highly skilled workforce, an 7,600sqm facility, and 90 of the latest CNC machines running six days per week on two shifts. This includes the two new MultiSwiss machines, delivering on Tornos’ brand promise: We keep you turning. www.tornos.com www.spmswiss.com

Real Business Real People Real Members I have been associated with AMITL as a member since its inception and have known most of the AMTIL staff for considerable years therefore I feel that I can say the organisation is of the quality the members should be very proud of. AMTIL conducts its activities with the enthusiasm and direction needed to promote Australiaâ&#x20AC;&#x2122;s manufacturing industry across all appropriate sectors of government and industry alike. Their methods are generally of a consultative nature as they seek out inputs from all concerned and then having done so their feedback is informative. Most certainly confidentiality of matters discussed is paramount for the competitive industry we are in and there is never a concern with regards to such matters where AMTIL is involved. Anyone who has ever attended or participated in a AUSTECH exhibition could only attest to the quality of the exhibition and this is as a direct result of AMTILâ&#x20AC;&#x2122;s overall co-ordination of the event and their methods of working closely with all involved. Dean McCarroll, OKUMA Australia Pty Ltd

Since 1999, AMTIL has been connecting business, informing of opportunities and growing the manufacturing community. To be become an AMTIL member contact our Corporate Services Manager, Greg Chalker on 03 9800 3666 or email gchalker@amtil.com.au

amtil.com.au 1311AMTIL/DM

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New fibre laser gives JC Butko total quality control of production process Based in Wodonga, Victoria, JC Butko Engineering has experienced continual expansion since it was established in 1976, particularly over the last 10 years. Having just built a new second factory to help it service ever-increasing customer demand, the company recently invested in a new Yawei fibre laser from Applied Machinery, allowing it to bring more of its operations in-house. JC Butko was set up 44 years ago by John and Carolyn Butko. Born to Ukrainian immigrant parents, John Butko serves his apprenticeship as a fitter and turner in Melbourne before returning to Wodonga and joining Milos Metrol & Sons. In 1972, he was named as Albury & Wodonga’s top apprentice. Soon afterwards, John rented a small shed in Kendall Street, Wodonga, and began investing heavily in machinery, including a lathe, guillotine and a set of rollers. The rest is history. Now employing 128 tradespersons and 30 contractors, the team at JC Butko consists of boilermakers, sheet metal workers, pipe welders, fitter/machinists and apprentices. The management team comprises project managers, mechanical engineers, certifying engineers, project supervisors, estimators, drafting personnel, quality assurance, health, safety & wellness, and administration. A significant part of JC Butko’s recent growth has come about as a result of working on larger projects throughout Australia (mostly the East Coast) and overseas (including the USA, New Zealand and Papua New Guinea). The company undertakes a diverse range of projects, including large structural steel, tanks, pipe spooling, conveyor systems, food/materials handling systems and pressure vessel work, in either mild steel or stainless steel. The company’s work is a 50/50 split between mild and stainless steel, as well as a 50/50 split between fabrication and site installation. JC Butko prides itself on its one-stop-shop service, covering the entire process from design, through 3D modeling to installation, and then ongoing maintenance. “This is our bread and butter,” says JC Butko’s Commercial Manager, Paul Butko. “We work with clients from the beginning to end of a project, providing a sense of reassurance.”

Investing in capacity Due to a growing need for additional space and the desire to separate its mild and stainless steel operations, the company has recently built a new factory dedicated to its mild steel production. Combined with the existing factory which now focuses entirely on stainless steel production, the entire facility now covers an impressive 7,000 square metres – maintaining its status as the region’s largest general engineering company. “The new factory has been a big investment for us,” Paul adds. “But splitting the steel operations was something the industry demanded and will ensure we maintain the highest quality and service levels.” This additional space allowed the company to look at purchasing a new Yawei fibre laser, joining the company’s existing line-up of Yawei pressbrakes. The ability to perform plate cutting operations in-house, which had previously been outsourced, was a key reason for JC Butko to look at a fibre laser. Crucially it now allows the company greater control over the production process. “In conjunction with our Yawei pressbrakes, the new fibre laser allows us to have total quality control of the entire process from start to finish – especially important with our stainless division,” says Paul. While Yawei’s competitive price and advanced features were factors, it was the excellent relationship that JC Butko has established with Applied Machinery during the pressbrake purchase that was an important consideration in the company opting for the Yawei. “We received excellent back-up and support from Applied throughout the purchase and installation process of the pressbrakes,” Paul explains. “It was this experience that provided

Members of the team at JC Butko with the new machine.

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FORMING & FABRICATION

For progressive engineers, fabricators and metal workers to manage your core business, your labour The new Yawei fibre laser allowed JC Butko Engineering to perform plate cutting operations in-house, a process that had previously been outsourced.

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The new Yawei fibre laser complements JC Butko’s existing line-up of Yawei pressbrakes.

us with a high degree of comfort and reassurance that we would be fully supported with the new Yawei fibre laser and why we ultimately chose the Yawei brand. Installed back in May, the fibre laser is an 8kW HLF model featuring a high cutting speed, extreme accuracy and a large-format cutting bed measuring 2m x 6m. The quality components fitted standard to the HLF include a Siemens 840D controller that is powerful yet user-friendly, as well as a Precitec Pro Cutter auto-focus cutting head. Another attractive feature is the machine’s ability to cut using filtered, high-pressure compressed air, which is more economical in the long term due to its lower cost compared with ‘traditional’ assist gases. “The other major benefit with the new fibre laser is that we can now turn things around very quickly, meaning we’re not reliant on other people,” Paul adds. “If something urgent develops we can stop what we’re doing and cut immediately. That’s the kind of flexibility we now have.”

Building a strong reputation The company’s list of clients is a who’s who of leading companies in a diverse range of industries. These include Thales, Skog, Fulton Hogan, John Holland, CPB Contractors, MARS, Lend Lease, GrainCorp, Visy, Nestle and Orora Paper – as well as government work such as Transport for NSW. The company was recently awarded with the Thales Australia Supplier HSE Award, in recognition for the outstanding achievements of the JC Butko Thales Team and their collaborative and proactive approach towards improving HSE culture at the Mulwala Facility. In addition, founder John Butko was named 2016 Albury Northside and Wodonga Chambers of Commerce hall of fame recipient. Paul is optimistic about the future of JC Butko and what it holds: “With significant investment in both our facilities and new, high-tech machinery, we are well set for continued growth into the future.” www.butko.com.au www.appliedmachinery.com.au

Scheduling is Updated Automatically in Real Time at Job Change

Essential Tool for Production Management to Drive Weekly Production

• Software App developed for engineers producing custom one off products or projects, 6 to 200+ workshop staff • Empower Software is simply an App. Cloud & Web based • Empower can interface to any accounting or ERP software • Pricing Low Cost Subscription eg 10 workshop staff is $108 per week • If you use manual time sheets, to record workshop staff times on their jobs 10 workshop staff for example will cost you $775 per week = $37,975 per year, in lost chargeable staff time to fill in daily and admin cost daily to rekey to produce. If you replace your manual time sheet system with Empower then you will save $667 per week saving you $32,683 per year. • Supplying Australian engineers for 13 years • Available to you on request: info pack and free trial software • Engineering Client Short Videos on youtube.com. In Youtube search: Empower MARs Transport, Empower Peppertree ... • 90% of engineers using tablets on the workshop floor and the Empower Software App achieve a 20% to 40%+ reduction in time on jobs – therefore a 20% to 40%+ reduction in labour cost on jobs. • An Engineer with 10 workshop staff is projected to increase production by 80 hours per week, therefore increase revenue by $6,000 per week and (80 hours by $75 per hour overhead cost), therefore increase revenue by $294,000 per year. This $294,000 per year is largely additional profit because overhead costs have been incured in existing production. Your 10 year investment $2.94m additional revenue, largely additional profit.

Sean O’Sullivan

B Com (Hons) Otago University

Founding Director, Empower Software sean@manufacturingandengineering.co.nz +64 27 2284211

AMT Magazine 03/11/2020

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Raising productivity, product quality with Hypertherm’s XPR300 Today’s manufacturing landscape is changing rapidly with the onset of technological advancements, leaving businesses to grapple with a variety of associated challenges. One such challenge is maintaining an edge over business rivals, requiring manufacturers to pay close attention to the way they maximise productivity while ensuring product quality is not compromised. For South Korean metal fabricator Daeyoung Sus Tech, in seeking to thrive in this competitive business environment, it was paramount to find a solution that will enable it to retain its competitive edge and improve production capabilities for the long term. Since beginning its operations in 2001, Daeyoung Sus Tech (formerly known as Cheolwon Stainless) has been focused on producing stainless steel parts and bars for semiconductor manufacturers and construction companies.

A solution to meet future needs In 2018, in a bid to consolidate its capabilities and expand operations, Daeyoung Sus Tech began the process of setting up a new factory building — one that was almost four times larger than its former plant. The management team wanted not only to update the company’s equipment, but also to find a solution to enhance its production capabilities. Previously, the company had deployed a local plasma system for its cutting needs. However, this system — which took over 12 hours to fulfil an order — was proving to be inefficient. The Daeyoung Sus Tech team embarked on a hunt for a cutting system that would reduce cutting times and equip the company to meet future production needs. After an extensive search, the team found that the Hypertherm’s XPR300 plasma cutting system met all their rigorous requirements.

Above: The XPR300 offers users full control of all functions and settings via the CNC, allowing efficient work processes on the production floor.

“We were focused on searching for a solution that would help us improve on work speed and cut quality,” says Cho Woo Je, General Manager at Daeyoung Sus Tech. “After meeting with the Hypertherm customer service team we were very impressed by both the X-Definition technology, and their service. So we made the XPR300 our top choice.”

Left: Hypertherm’s XPR300 plasma cutting system.

Reaping the benefits of the XPR300 Hypertherm’s X-Definition technology offers improved cut quality on mild steel, stainless steel, and aluminium. Through features such as HyFlow vortex or vented nozzle technology, Vented Water Injection (VWI), and vent-to-shield technology, X-Definition plasma cutting systems bring about cleaner, sharper, more consistent edge quality and colour. With this latest technology, Hypertherm’s XPR300 cutting system allows users to enjoy increased cut speed, significant improvements in productivity, and reduced operating costs. For Daeyoung Sus Tech, which works with stainless steel materials that range from 6mm to 100mm in thickness, finding a solution that could address its varied cutting needs while enjoying excellent cut quality was a dream fulfilled. New features on the XPR300 system also made things easier for operators, while ensuring optimal performance and unmatched reliability. Users possess full control of functions and settings via the CNC, which is intuitive to operate and provides automatic monitoring. All these features made it easy for the team at Daeyoung Sus Tech to get accustomed to the XPR300 system quickly and to commence their production processes. “After an initial set-up, it was very convenient for our workers to commence the cutting process automatically by simply pressing the start button,” says Shin Hui Seong, Senior Manager for Operations.

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Speaking about how the XPR300 has improved his team’s capabilities, Shin adds: “The old system used to take almost 12 hours to fulfil an order. With the new XPR300, we can now complete the same order within just 7-8 hours. Our production time has been reduced by more than 30% and we have expanded our production capacity for more orders.”

A partnership set to last After just two months, Daeyoung Sus Tech noticed the obvious benefits of the new addition to its production floor, especially the multiple improvements that the XPR300 had made over its previous system. “Our efficiency and product quality have improved significantly,” comments Cho. “I am satisfied that we’ve not had any problems since using the XPR300, which I’d highly recommend. We’re also looking at additional purchases in the future so as to move forward with our expansion plans.” www.hypertherm.com

FORMING & FABRICATION

transfluid – K series targets reliability, durability Following a recent review of its portfolio of machines to bend and process tubes, transfluid has revealed a number of changes to its K series of machines. All the machines in this series can now be controlled with a touch panel, opening up new possibilities such as displaying the comparison of target and actual values for all axes. Control of the tolerance of length and rotation reduces the need for operator involvement during tube manufacturing. The options have also been improved by the ability to load bending data for individual products from a PC via a USB port. The machines are robust and easy to operate. A selection of setups is available to process tubes of different lengths, from 1,500mm up to 6,000mm. The machines feature a range of special equipment options such as an integrated saw, a burring device, a tool for cutting ring pre-assembly, or one for flaring. The machines cover all standard diameters from 6mm to 42mm in hydraulics, and can process tubes with thin and thick walls. The DB 2076K model is capable of processing tubes with diameters of 6-76mm and all the standard wall thicknesses and materials. To obtain radii of 1.5 x D (tube diameter) of ideal quality with a bending procedure, this machine has a follower pressure die. It is operated hydraulically and supports the tubes during the bending process. This makes many applications possible, including construction of railings, tubing for installations, and the production of systems for exhaust gasses. transfluid’s K series is completed by the DB20101 machine with mandrel. Particularly suitable for the constructions of pipelines, the machine covers almost the whole range of tubes for installations. The different types of equipment available are the same as those for other types of machines. All materials can be processed, and small radii can be manufactured without any problems.

All of transfluid’s K series machines are now equipped with touch panel controls that are easy to use and compatible with several different interfaces. © transfluid

In addition to this, all machines can be equipped with a programmable controlled mandrel withdrawal, mandrel lubrication device and wiper dies. These machines are extremely reliable for tube processing, thanks to their stable construction. For this reason and because of the many options, the transfluid K series offers solutions to different sectors with the most diverse applications. This optimisation helps a lot with the reliability and the durability of the machines. www.transfluid.de

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STATE SPOTLIGHT

NEW SOUTH WALES

Leussink Engineering – 40 years experience, ever-growing capabilities Leussink Engineering is an outstanding, state-of-the-art engineering company with more than four decades of experience. The company boasts an ever-expanding range of capabilities as a result of ongoing skills training and investment in the latest technologies. Carel and Muriel Leussink founded Leussink in 1977, initially operating out of a humble home garage in Unanderra, New South Wales. Today it is a second-generation family business offering complete design, fabrication and machining services and solutions for clients over a wide spectrum of industries. It prides itself on delivering world-leading after-sales service, maintaining close client liaison to ensure expectations are met or exceeded on each job. It is equally renowned for machining bespoke components, fabrication or projects manufactured to turnkey operational level, leveraging years of skills and experience. “At Leussink we genuinely believe in local manufacturing,” says Jason Leussink, the company’s Managing Director. “Of course, in our industry, it is not always possible to buy 100% Australian made materials, but where we can, we do buy Australian and support other organisations that have the same philosophy.” The company boasts a wide range of capabilities including CNC machining, milling and turning, wire cutting, surface grinding, design, metal fabrication, welding, robotic welding, assembly, reverse engineering, power transmission and parts qualification and verification. Work is undertaken for clients in such diverse industries such as defence, manufacturing, agriculture, energy, oil & gas, mining and minerals processing, pulp and paper, heavy industry, transport, construction / civil engineering and marine. In concert with its high level of customer services, Leussink also plans and anticipates its clients’ spare parts requirements - ensuring they are available when required - thus minimising costly machine down-time. Whilst the engineering side of the business is predominately within New South Wales, the company operates nationally, manufacturing and supplying welding fabrication tables in various sizes and configurations. The ‘in-house’ Leussink fabrication department utilises these very same fabrication tables in conjunction with a 16m-long rail system, ensuring fixture flatness of 0.1mm per metre length of table. Due to a strong commitment to its clients, particularly in the defence area and international customers with propriety components, the company enforces high levels of IT protection. It has actively participated in AusIndustry’s Cyber Security Maturity Assessment program. This covered assessments in risk identification, threat detection, protection, response and recovery, ensuring that the company remains ‘low risk’ in this area. Leussink today has with more than 40 employees including apprentices. Addressing a serious shortage of apprenticeship applicants, Leussink has been proactive in working closely with local secondary schools careers advisory personnel and addressing student groups on career opportunities in engineering. This has proven to be successful and the company currently has eight apprentices under training. This socially responsible community-minded family business is also actively involved in the Illawarra and NSW South Coast community through participation in annual charity events along with other local businesses in raising money to support those in need. The company supports local schools, opening up opportunities and present a vision for young people to pursue careers in engineering.

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Jason Leussink, Managing Director at Leussink Engineering; Kenley Leussink, Property Manager; Ray Leussink, Special Projects Manager; and Carel Leussink, founder and shareholder.

A commitment to technology investment Complementing its strong engineering business, the company is firmly focused on modernising workshops and production facilities throughout Australia. Utilising a wide range of engineering solutions, it uses world-leading welding and fixturing tables and accessories to portable metrology arms that deliver the highest accuracy per part qualification. It also provides metrology solutions for industrial application nationwide with products, software and services to meet the challenges of the manufacturing environment with internationally regarded products. In the high-end technology area, Leussink has had a long association with Okuma Australia – going back some 26 years to when its first lathe was purchased. Its most recent addition is the latest Okuma LH55-N-Cx4000 CNC lathe, with an OSP-P300LA control. This machine complements an earlier similar model, providing the company with further advanced technology and greater capacity in the heavy engineering area, where it performs repair and rework, reverse engineering and specialist high-end jobs cater for clients in general manufacturing, mining, the steel industry and the energy sector. “We have found the equipment to be reliable and proven performers, and not least of all, the service and support from Okuma has been outstanding,” says Chris Walton, Sales Manager at Leussink. “The combination of these points made the company’s decision to invest in additional Okuma machinery a ‘no brainer’.” Chris adds that negotiating the purchase from Okuma was a professional and stress-free process, noting that Okuma’s communications are a particularly strong point when seeking spares or technical support. “The Okuma team and the machinery they provide is an exemplary package, making it hard to look elsewhere,” says Chris. The latest Okuma acquisition complements a number of other Okuma machines in the engineering shop, opening up new business opportunities and dramatically reducing deadlines.

NEW SOUTH WALES

STATE SPOTLIGHT

The new Okuma LH55N-Cx4000 CNC lathe in Leussink Engineering’s Unanderra workshop.

The new lathe in operation.

Leussink takes full advantage of the training support offered by Okuma where appropriate, but being familiar with the easy programming and operating systems of the Okuma machines, the skilled engineers and operators are competent in this area. “It is exciting to work with yet another progressive Australian company investing in the future and taking advantage of the current strong support for high-tech and competitive manufacturing in this country against the threat of overseas suppliers – and winning,” says Dean McCarroll, Managing Director of Okuma Australia. “A strong vibrant, competitive and reliable manufacturing base is vital to our Australian economy, supporting recovery in the current climate and in the longer term.”

For Jason Leussink, the new machine from Okuma is evidence of an optimistic outlook for his company. “The new lathe effectively doubles the turning capacity within our workshop,” says Jason. “It will complement our existing lathe and allow us to increase the size of the items we machine as well. We’re investing in our future work. Having just one large lathe in our workshop was creating a bottleneck that will now be eliminated. The old lathe will be used to rough jobs out and the new one for finish machining. “Australian manufacturing is alive and well and we will continue to invest in it. We’ve been competing with overseas companies for years, and the COVID pandemic has brought new work our way because overseas suppliers cannot always guarantee continuity of supply or the same quality that we offer.” www.okumaaustralia.com.au www.leussink.com.au

066BMS ACLR8

The capabilities also allow shorter runs, reducing inventory and enhanced competitiveness. New business opportunities for the company are being advanced in the defence sector and both the mining and the steel industries, promoting the competitive and quality advantages of Australian manufacturing.

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Sustainability woven into the fabric Australia’s largest manufacturer of geosynthetic products, Geofrabrics recently installed a low-pressure Kaeser ESD 245 rotary screw compressor at its Albury manufacturing plant in regional New South Wales. Replacing an ageing compressor, the new machine is assisting Geofabrics in continuing to meet its sustainability goals. Geofabrics Australasia is Australia’s largest manufacturer and supplier of a range of highly engineered geosynthetics for the building and infrastructure sector. Its core capabilities are across the road, rail, waste, mining, coastal, water, recreation and slopes & wall segments. Geofabrics has a presence throughout Australia, New Zealand, PNG and the Pacific. A proud Australian manufacturer, Geofabrics has two manufacturing plants, one in Albury (NSW) and other in Ormeau (Queensland) and contributes to Australia’s sovereign infrastructure construction capabilities. On every project, Geofabrics has a singular focus: to provide smarter infrastructure solutions for its clients.

Manufacturing innovative geosynthetic solutions As the Australasian leader in geotextiles and geosynthetics, Geofabrics delivers engineering support and technical leadership through a focus on innovation, research, industry education, design and independent testing services. Simply put, Geofabrics’ products are a key component in building Australia’s critical infrastructure: our roads, railways, landfills and resources (mining, oil & gas). One example of the products manufactured by Geofabrics is its bidim Green geotextile, a variant to its existing world-leading ‘Bidim’ range, which contains Australian-sourced recycled plastics (think of recycled drink bottles) and is a green innovation that came amid increasing calls for greater sustainability in the construction and infrastructure industry. Both effective and economical, bidim Green is a superior geosynthetic solution for a range of engineering problems including weak soil, rutted and cracked roads, as well as liquid and gas leaks from landfill sites. It can be used for example, in the construction of roads, railways and embankments where the ground is soft and unstable. Using a layer of geotextile to separate the soft ground from the fill material reduces the amount of fill required, increases the lifespan of the road or rail structure, and reduces long-term maintenance costs.

Sustainable practices save energy and money Geofabrics is committed to contributing to a positive impact on the environment and to manufacture and supply products that reduce reliance on non-renewable resources and reduce waste to landfill. This includes making the company’s use of resources more efficient through Lean manufacturing and a process of continuous improvement. As a result, Geofabrics has won many awards over the years including the 2019 Australian Exporter of the Year, the 20172019 Victorian Exporter of the Year (Environmental Solutions), and the 2018 AusTrade Australian Export Award for Environmental

Solutions. These awards recognise outstanding international success in environmental solutions, clean energy innovation and energy efficiency. It is no surprise then that when Geofabrics process improvement engineer Ashish Swarup began the procurement process to replace an ageing compressor at the Albury manufacturing plant, selecting an energy-efficient solution was a key criterion. Compressed air is an essential utility required to operate many functions at both of Geofabrics manufacturing plants. One crucial role is using compressed air in the filament-drawing process. Reliably delivering clean compressed air is critical in fulfilling this process. Unfortunately, the ageing compressor at the Albury manufacturing plant was becoming less reliable. It was also one of the largest energy consumers in the business, accounting for around one third of all electrical consumption. Aside from finding a more reliable solution, finding an energy-efficient compressed air solution was therefore also very important. The procurement process included evaluating a number of possible compressor options against five key criteria, including life cycle costing, reliability of asset and environmental impact, making the process very transparent. All options were then given a total rating. Thanks to a high overall rating backed up with technical advice and support, Geofabrics opted for a low-pressure Kaeser ESD 245 series rotary screw compressor to meet its requirements.

Energy efficiency as standard The ESD 245 is a specially built, dedicated low-pressure oillubricated rotary screw compressor. Unique to Kaeser, it delivers flow rates up to 30.9 cubic metres per minute at pressures of 3.5 to 5 bar.

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Geofabrics Australasia manufacturing plant in Albury, NSW.

Installed complete with a comprehensive air treatment package, this proved the ideal solution for Geofabrics. Not only would this solution reliably deliver large volumes of high-quality and clean compressed air, but as a highly efficient dedicated low-pressure compressor, the ESD 245 would also easily create energy savings in excess of 30% compared to a ‘standard’ pressure 7 bar screw compressor of a similar size. Kaeser has pushed the boundaries of compressed air efficiency and availability with its latest generation of ESD series rotary screw compressors. Intelligent design solutions have not only led to enhanced ease of operation and serviceability, but also give this series of class-defining compressors their distinctive modern appearance. Delivering improved specific power, the flow-optimised and further refined Sigma Profile rotors provide the foundation for exceptional energy efficiency. The use of high-performance IE4 drive motors maximise energy efficiency, while Kaeser’s 1:1 drive design eliminates the transmission losses associated with gear or V-belt driven systems, as the motor directly drives the airend. Kaeser is currently the only compressed air systems provider to equip its compressors with super premium efficiency IE4 class motors. Furthermore, the radial fan fulfils the efficiency requirements for fans as per EU directive 327/2011. The advanced Sigma Control 2 compressor controller achieves additional energy savings and minimises cost-intensive idling periods through the use of a variety of specially developed control options. The new Kaeser compressor is assisting Geofabrics in continuing to meet its sustainability goals

Finally, an intelligent component layout ensures even greater energy efficiency: for example, all service and maintenance points are within easy reach and are directly accessible from the front of the unit. This not only saves time and money when performing service work, but also maximises compressed air system availability.

Compressed air is particlularly important in the filament spinning process at Geofabrics.

“Selecting energy efficient equipment is a large part of our sustainability practices and our commitment to keeping our carbon footprint to a minimum,” says Ashish Swarup. “The Kaeser compressor was therefore the right choice for us. Up and running now for almost a year the compressor is reliably and efficiently meeting our compressed air requirements.” www.geofabrics.co www.kaeser.com.au

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Raymax Applications – A quarter-century of laser solutions Based in Warriewood on the northern beaches of Sydney, Raymax Applications has been bringing Australia and New Zealand the latest laser technology for more than 25 years. Light amplification of stimulated emission of radiation – or "laser" for short – technology does not sit still. Since the first demonstration of a ruby laser in 1960, humankind has sought to harness this versatile light source to create and develop new applications never before achieved.

says Grace. “These direct factory links provide a major benefit to our Australian and New Zealand customers, and are particularly helpful when new applications and installations are utilised. This is highly valuable for full system process understanding – both locally and from the manufacturer.”

Lasers have become well established in industrial processes such as welding, the cladding of fatigued or worn parts, or for cutting metal used in manufacturing sectors such as automotive, aerospace and medical instruments. Then there is the vital task of product traceability, where lasers can ablate surfaces such as glass wine bottles with a permanent Julian code or identification mark. They can even engrave a unique identification code on every medical instrument used in hospitals – readable by both humans and machines. More recently a new process has taken manufacturing by storm: that of 3D metal printing.

Meeting local needs

For more than 25 years Raymax Applications has found the latest “best in class” lasers and laser technology for companies and research facilities across Australia and New Zealand. Raymax also conducts its own research & development programs, utilising extensive process development facilities and engineering capabilities to assist customers. “We constantly seek to source the latest technology and support it with our depth of experience and a team of physicists and factorytrained engineers,” says John Grace, Managing Director of Raymax Applications. “This has seen us supply, install and service laser systems in locations such as the Reserve Bank of Australia, many wineries and breweries, Coca Cola, Carlton United Breweries, Masterfoods, Fisher and Paykel, RUAG, Telstra, Defence and many SMEs innovating their business processes.” While laser technology has proven to have a low maintenance cost and extensive life span, many of Raymax’s businesses remain demanding customers as they choose to update their facilities by taking advantage of improvements developed by the laser manufacturers. In selecting quality products, Grace explains that most of the products Raymax supplies are made by companies based in Europe, the USA and Canada. “All of these have unique partnerships with us providing support, service and factory training of our engineers and even customers,”

Australia’s geographic isolation has assisted in the growth of a service not considered until laser technology became available. Large parts used in mining and energy, and even small aircraft parts, are subject to wear and fatigue, requiring repair or replacement. Repair using a high-power diode Laserline laser can mean shorter downtimes and reduced costs against purchasing a new part and waiting for it to be shipped. Cladding repair with lasers also has the benefit of extending the life of a component, making this appealing from an economic perspective. Raymax is very strong in this sector of the marketplace. Hyperspectral imaging is a successful new field of development that has seen Raymax bring HySpex cameras to the local market. Developed by Norwegian company NEO, hyperspectral imaging cameras can be used across a number of fields for the acquisition of sophisticated data. In a laboratory setting, seeds can be scanned for different properties; in the food industry the quality of fish fillets can be checked; in field work hyperspectral imaging identifies the different layers of earth for agricultural improvements of better targeting of mining excavations. Hyperspectral imaging can also take to the skies with the HySpex Mjolnir attached to a drone. In this role data can be gathered of structures in fields for agricultural purposes or to support armies engaged in combat. This new product has seen a huge demand for local applications by companies and universities and is fully supported by Raymax. To service its diverse customer base, Raymax provides other products required for research or specialist industry applications. One field is that of spectroscopy, where it has a number of products such as spectrometers that offer non-destructive analytical solutions for close inspection of products or items being investigated in research or on production lines. Raymax also offers laser optics – with products such as VIPA, or Michelson interferometer or Etalon.

A HySpex Mjolnir hyperspectral imaging camera has taken to the skies attached to a drone.

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Raymax often exhibits at industry events, such as the Avalon Air Show.

Partnerships Partnership experience has been highly valuable in the emerging industry of 3D metal printing. With an exclusive agreement between SLM Solutions and Raymax, the expertise gained by SLM Solutions in partnerships with European and American companies has been extensively helpful for paving the way for many different manufacturing companies and universities to identify a way forward for their individual needs with 3D metal printing. “Sharing partnering information is extremely helpful, such as information about the production of a car steering knuckle through SLM’s partnership with Hirschvogel Tech Solutions, or the rocket component printed using biomimetic engineering applied by CellCore using an SLM280 to produce a never-before done monolithic thrust chamber,” says Grace. “More recently SLM Solutions has focused on developing parameters specific to moving 3D printing into series production, as that is where we see the demand heading.”

Challenges The introduction of 3D metal printers requires not only a paradigm shift in shopfloor strategies, with the emergence of disciplines such as integrating design into engineering platforms, data analytics and reassessment techniques. Each of these work towards improving outcomes in the application of 3D metal printing. To bring about successful change in this area, Raymax seeks to encourage training and learning so that laser systems operate effectively. The key skills required are computerised technology, optics and physics that enable full system utilisation, as well as additional chemical knowledge to understand metal powder performance. At the same time, mechatronics engineering supports the capability to build parameters for each stage of development of specific product types. “Our business covers a diverse customer industry base as laser technology is a stimulating and exciting field,” Grace concludes. “Very often, consumers are not aware of the influence or impact of lasers on our daily lives and the products we purchase. “Lasers have changed the world and made it easier to develop products and processes. It is as simple as that. Facilitating and bringing to production never-before-done laser applications is not just something our customer base needs, it is also our passion and keeps us challenged and focused to provide customers with the best solutions to help achieve their desired outcome.” www.raymax.com.au

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Melvelle’s rail maintenance equipment manufacturing on track with Mazak Established in 1982 and located in Newcastle, NSW, Melvelle Equipment Corp is an Australian-owned, secondgeneration family business that manufactures specialised rail maintenance equipment. Melvelle has built an enviable reputation in the rail industry, here in Australia and overseas, for the unique rail track maintenance equipment they design and manufacture locally. Recently, to satisfy the demands of the rail industry, Melvelle has developed batteryoperated equipment to replace some internal combustion-powered units.

competitors operate from. This means that their economies of scale allow them to manufacture in greater batch quantities, sometimes having dedicated machines set permanently to produce one component.

One of these products is the “Trackpack” system, which is a modular platform with multiple capabilities designed to reduce initial capital outlay and overall maintenance costs. The Trackpack is a complete hydraulic power unit with a boom arm and rail trolley, designed to allow the use of multiple hydraulic work heads without the need for numerous power supplies. A quick-change boom allows easy change over from one head to another, with adjustable counterbalance positioning so the weight on the operator handles never exceeds 3-5 kg.

AMT: Why did you choose the Mazak Integrex i-200S?

The system is powered by two lithium battery cells, and can be coupled with nine different work heads or other hydraulic hand tools. Traditionally, petrol or diesel-powered engines would drive the heads hydraulically. Now with the battery cells, the system can run a full eight-hour shift and the batteries can be recharged in two-tofour hours. Charged batteries can be swapped out to extend shifts.

To run against these competitors, we need to extend our shifts and run “unmanned” as much as practically possible. AM: When we analysed our production, sometimes we would set up at least three times to complete a component on up to three different machines. Turning and milling operations would occur on 90% of our products. We realised that if we could load a raw blank and unload a fully finished component, we would make huge competitive gains. We considered many brands, but the Mazak was the only one with a proprietary gantry loader [that’s] not an external added product. The other consideration was the programming of the machine. It is simple compared to the other brands. I found that the other brands relied too much on programming with CAM software, which takes the operator away from the machine. I like my guys to understand what the machine is doing, not just be button-pushers.

Melvelle’s machine shop has always been equipped with Mazak machine tools, and the company recently made an investment in the latest generation of Mazaks from John Hart to become more globally competitive. It added a Mazak Integrex i-200S multitasking machine, with a Mazak GL-150F gantry loader plus a Hydrafeed MSV 65 bar feeder; it has also placed an order for a Mazak HCN-8800 horizontal machining centre. Andrew Melvelle, CEO of Melvelle Equipment Corp, discussed what the additions will mean for his business.

Finally Mazak have renowned reliability built into them. I have used many Mazak machines over the years as a machinist and have always regarded the Mazak machines as my Number One pick. They have always given me years of trouble-free running.

AMT: What were the reasons behind these additions to your machine shop?

We have utilised unmanned operation for the first time in our history, with the machine gantry loaded or bar-fed, over nights and whole weekends. It is amazing how much pressure is taken from the operator when they don’t have to be at the machine to load blanks. They are able to plan new jobs and monitor the work as it comes

Andrew Melvelle: We are chasing efficiency as we need to compete in the global marketplace with our products. The Australian market, our main market, is very small compared to where our

AMT: What benefits have you achieved? AM: The Mazak Integrex i200S, due to its multi-tasking capabilities, has allowed us to save many machine hours. On one part, we reduced our component time from five hours and six set-ups to 40 minutes and only two set-ups.

Andrew Melvelle (right) with his machine shop leading hand in front of the new Mazak Integrex i-200S, with a Mazak GL-150F gantry loader plus a Hydrafeed MSV 65 bar feeder.

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NEW SOUTH WALES off the machine as the machine is performing tool checking and measuring items before they are unloaded. AMT: Why did you order the Mazak HCN-8800 horizontal machining centre?

STATE SPOTLIGHT

We have also ordered the full NC rotary table, allowing infinite positioning. There has been many jobs over the years where we have had to manually set up for a special angle or had to decline jobs that needed fourth axis work.

AM: It was time for us to upgrade our old Mazak H20 twin pallet machine, and we needed to extend our machining envelope for future product developments. The HCN will have one pallet permanently set up for machining one of our components. Currently this component has two set-ups on two pallets to allow completion, but with the new machine we will complete the component with one set-up, thanks to a suggestion from John Hart. As the machine has two pallets, we now have the option to duplicate jigs to allow higher production levels of this component or move work from our other machines.

AMT: What are your thoughts about John Hart recently opening an office nearby in Newcastle?

AMT: What benefits will this machine deliver?

Yes we can all trouble-shoot over the phone, but being able to have a representative at my door in 20 minutes is gold and adds considerable weight to all our future purchasing decisions. John Hart has provided us with world-class manufacturing technology and support.

AM: The new machine will have probing to allow measuring, as well as Mazak’s Orbiturn function. We are really looking forward to utilising this function, reducing the number of fixed boring bars and set-ups needed to produce many of the bores in our products.

AM: During the purchasing phase, having John Hart people available and local to discuss face-to-face is invaluable. They came to our facility and took the time to understand our products, and made suggestions on the machine configuration. This allowed us to select the ideal machine for our needs. The John Hart team is very responsive when it comes to helping with problems, and being local gives me confidence that we will have a technician quickly if we really need one urgently.

www.johnhart.com.au www.melvelle.com.au

Milltech selects SYSPRO to support Industry 4.0 Newcastle-headquartered engineering bar processor Milltech Martin Bright has selected enterprise resource planning (ERP) specialist SYSPRO to enable it to provide a superior customer experience and accelerate its Industry 4.0 rollout. Since 1992, Milltech has progressively grown to become Australia’s leading engineering bar processor, now employing in excess of 80 technicians, production and administrative staff located across four manufacturing plants around Australia. Producing more than 30,000 tonnes of engineering bars per annum, the company offers a comprehensive range of steel processing and engineering services using world leading processing technologies. Through ongoing investment in world-class advanced technology such as the Superquench continuous heat treatment line for bars up to 150mm, as well as state-of-the-art Marcrome continuous chrome plating lines, Milltech has achieved leading edge manufacturing status. However, the company did not have an ERP system to match its automation project. “We wanted a modern, flexible system that would capture information in real time, to support us as we move forward with Industry 4.0 to provide further efficiencies,” says Andrew Wilson, Business Manager at Milltech. “SYSPRO will assist us in not only retaining our position as the market leader, but will help us to increase the gap we have on our competitors in terms of product quality, delivery times and service levels. It will allow us to be more strategic, providing us with the capability to plan five or 10 years into the future, rather than only worrying about the upcoming quarter.” SYSPRO ERP will help Milltech achieve this through better management of production, dispatch planning and inventory management, while reducing its stockholding, improving cashflow, ensuring compliance, eliminating manual processes, and providing the capability to support strategic planning. In addition, SYSPRO ERP will enable Milltech to eliminate weekly manual business reporting, replacing it with real-time automated business reporting, so the company always has a single source of the truth at its fingertips. This will enable the company to ensure its quality products are delivered to customers on time every time, while providing proactive delivery updates to its customers, rather than reacting to a customer’s delivery enquiry. “We selected SYSPRO not only for its flexibility, but also due to its team’s deep knowledge and understanding of manufacturing and

warehousing,” says Wilson. “SYSPRO’s team of experts talked to us about the business value of the total solution and how it would integrate with our other systems. We were not just sold a standalone product as other vendors often do. Milltech’s SYSPRO 8.0 implementation is currently in the design phase and will be fully implemented by September 2021. It is replacing an ERP system that was designed for smaller manufacturers to enable the company to grow. Rob Stummer, Asia Pacific Chief Executive Officer at SYSPRO, says: “We’re thrilled to be working with the market-leading engineering bar processor in Australia and are looking forward to a rewarding partnership that will enable the company to service its customers better, whilst generating further automation and operational efficiencies and continue its digital transformation project.” www.au.syspro.com www.milltechmartinbright.com

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Ian Christensen is the Managing Director of iMOVE Australia. He spoke to William Poole. AMT: What is iMOVE Australia? How long have you been in operation and what are the organisation’s objectives?

AMT: Tell us how you got involved with iMOVE and your professional background before that.

Ian Christensen: iMOVE Australia is Australia’s national centre for R&D in transport and mobility. We run the iMOVE Cooperative Research Centre (iMOVECRC), which is funded through the Federal Government’s CRC program. It was set up in 2017 to tackle major challenges and harness opportunities in areas such as congestion, supply chain optimisation, journey planning, and a whole range of diverse transport-related tasks, all of which could benefit from the evolving tech. The CRC Program approach is an interesting way of doing this; it has a strong track record of delivery over many years by strenghthening connections between research and business and harnessing national research capability to business challenges.

IIC: After doing chemistry and maths at uni, I spent 30 years or so in the manufacturing sector, largely in the process industries, making polymers, paper, sealant, masterbatch, and ultimately pigments, in a stint overseas in Switzerland. In all those manufacturing spaces, I was always heavily involved in product and process improvement, so when I came back from Switzerland, I sought to get work in the technology development space and ended up in the first of three CRCs that I’ve been involved in.

As iMOVE operates nationally we are in the fortunate position of working with many different partners in government, industry and academia. Most of Australia’s state government transport departments are conducting some form of research through the centre, as is the Federal Department of Infrastructure. AMT: Can you give some examples of the projects you’re working on? IC: With over 60 projects in the project portfolio, we cover a very broad range of areas. I’ll give you a few illustrative examples. We conducted a study for the Department of Infrastructure looking at all the sources of freight data in the nation, and the need for freight data that exists in both the transport sector and industry more broadly. We combined the two to determine what Australia should do next to improve visibility over freight information for the transport and adjacent sectors. The Department of Infrastructure subsequently used this report to secure funding from Treasury to establish a freight data hub for the nation. In a different space, but with a common theme of how we use data to optimise transport, is our exploration of Mobility as a Service (MaaS).The big idea of MaaS is to bundle different transport or mobility options together providing a very user-friendly interface for booking and paying for transport in an integrated manner. A project we are doing in Sydney with IAG and the University of Sydney is looking at how customers would pay some sort of monthly subscription which gives them access to a range of mobility services suited to them. This research will help us understand the appetite for MaaS offerings and how we can best respond to diverse community needs. The approach to passenger transport is now becoming increasingly person-centric. Technology now presents an opportunity to determine options based on very specific criteria such as whether you want the cheapest option, or prefer to sit down, or you want wifi access for the duration of the journey because you want to work, and so on. We’re also actively involved in the connected and automated vehicle space, looking to see how Australia could generate benefits, particularly safety benefits, from early adoption of vehicle connectivity and vehicle automation. The most high-profile of these activities is the connected vehicle trial taking place in Ipswich, Queensland. This ambitious trial will determine the impact of vehicle connectivity in a range of scenarios through capturing data on vehicles from the local community that have been retrofitted with the relevant technology.

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The first one was the Molecular Plant Breeding CRC, a little bit away from manufacturing, but nonetheless an area of quite dramatic development. Then the second was the Automotive CRC, which was focused heavily on improving vehicle manufacturing and improving supply chains to manufacturers, as well as looking at alternative energy sources for vehicles. Finally, based on the automotive experience, we thought about how we could take what we had learned at AutoCRC and use it in the wider context of transport and mobility. So we set up iMOVE as a CRC to focus on further opportunities to improve the movement of people and goods. I see the common thread in all of this experience as the desire to keep pushing boundaries to make things better in our technologically advanced world. Transport of course touches all of us every day in some shape or form, so the opportunities are huge and it is an immensely satisfying area in which to work. AMT: So you were with the AutoCRC during that period when the last three car manufacturers in Australia closed down? IC: Yes. It was a sad day. The AutoCRC operated from 2005 to 2017, so that spanned the period when the support was withdrawn, when the decisions to leave were taken, and when Ford, Toyota and Holden actually wound themselves up. AMT: Looking back on that time, it was obviously a traumatic period for Australian manufacturing, but it also prompted a lot of reflection on the future opportunities both in manufacturing and in mobility and transport. IC: Yes. It was indeed traumatic, that’s absolutely the word for it. For me, I had been through a smaller version of that earlier, in late 1980s, early 1990s, when effectively the same thing happened to the chemical industry. Most process manufacturing left and went offshore at that time, and that too caused a lot of dislocation. But the wind-up of automotive had an even more dramatic impact on Australia’s manufacturing sector. And it really challenges us all to think what’s the role for manufacturing that suits the Australian context? What’s the path of the manufacturing industry and how can we configure our strengths into an economically viable industry? I think the answer to that is agility. The thing that Australian industry has developed over many years is an ability to develop new stuff, to put it into production quickly, and to cope with rapid product changes within a production process. Whether that’s changing colours or changing grades or changing models, Australian industry is adept at facilitating change processes. I think that’s ultimately the characteristic that will distinguish Australian manufacturing in the global sector. We might never be the global-scale, long-run manufacturing hub you see in Europe and North America and China, but we can compete very effectively in the innovative, shortrun agile space.

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AMT: What are the big trends taking place in transport and mobility at the moment? IC: It’s data. There’s a huge surge happening in the amount of data visibility being generated over the movement of people and the movement of goods. We now drive around in ‘computers on wheels’, and almost all of us walk around with a ‘computer’ in our pocket or bag. The huge amount of data being generated by our cars, trucks and smartphones creates enormous possibilities for improving how we get around. Coming through as well is the ability and value in actually tracking goods, whether that’s tracking containers or tracking product. The technology now exists to do that in a cost-effective way.These tracking mechanisms create another mountain of data, which ultimately will enable manufacturers to get better visibility over their supply chains. This includes their inbound supply chains of components and raw materials, and their outbound supply chains of finished product on its way to destination. Because of that visibility, there is substantial opportunity in the transport sector to apply lessons that manufacturing learnt over decades, to reduce waste of time and effort. In a way, it’s applying ‘Just in Time’ to the transport sector in the same way it has been applied in manufacturing for many years. As we improve the speed, the resilience, the predictability of supply chain behaviour, manufacturers will be able to get better efficiencies out of their operations. AMT: This all sounds a lot like the ideas around Industry 4.0 in manufacturing processes. IC: Yes, this is exactly the same, except it’s the movement of materials around the nation and the world. It’s taking Industry 4.0, but trying to run it outside the fence, rather than just inside the manufacturing system.That’s important because for Australian manufacturing to succeed, it has to engage with international supply chains. The reality is that the big markets for our products are all overseas. We have to find a way to stay closely engaged with upstream and downstream partners in other countries. And if you’ve got to turn on the furnace or clean down the production line in anticipation of the next job, you need to have confidence that the truck is going to arrive when they say it will, not the next day, because you don’t want to turn the furnace on, say, 12 hours early. A lot of things can be done to make manufacturing more efficient if we can get better prediction and reliability out of our supply chains. AMT: What about the movement of people, with public transport and private vehicles? IC: There’s a lot going on, including a general trend towards treating transport networks as one whole system, rather than a number of networks operating side-by-side. We see this integrated approach in the nature of the projects we are are doing and also in the way that our state governments are structuring themselves to develop and deliver services. Contiuned next page

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ONE-ON-ONE think the COVID has shown us that we know what we can do. It’s the question of how we might actually implement the solution that COVID has shown us exists.

Continued from previous page

Balancing use of private vehicles with good public transport and other transport services enables us to tackle a big issue: congestion. We can improve the reliability of journey times, both for people and goods, if we look at the transport system as a whole. Most people make journeys not because they want to take a journey, but because they want to get to a destination. They’re trying to get to school; they’re trying to get to work; they’re trying to get to a party. Every trip is purposeful. We want to help people execute on that purpose with less effort, less stress, less time. So, we seek to develop the ability to predict the traffic situation: in ten minutes time; in half an hour’s time; in two days’ time; at the time that you want to go. We hope to get to a situation when your diary or phone will tell you when to leave in order to get to the destination on time. It will also tell you what transport combination is the best way to get there. If you’re trying to get to a concert in the city, it may not be the best thing to drive your car – it might be better to take public transport. Can Google or your diary tell you in advance which train or bus to catch? Or if you are going to go by car, could you book a parking spot in advance? These are all anticipations; we’re trying to facilitate prediction and anticipation so people can make their journeys more easily and with less time wasted waiting for something to happen. When we travel we want to be some assurance in real time that our travel plan is working out. On my phone I can see the train coming, I can see the Uber coming, I can see the congestion building up on, say, Hoddle Street. That real-time visibility allows you to make better decisions. It also enables you to accommodate changing circumstances much more effectively. So if there is a crash on the freeway and you’re going to have to deviate, it would be helpful if your navigation system knew about the crash as soon as it happened, and immediately plotted an alternate path that would get you to your destination, rather than waiting to get into the traffic jam with no exit and then fretting about being held up for an unknown period of time while they clear the accident. AMT: Is the COVID-19 pandemic having much impact on how quickly or slowly these changes are taking shape? IC: COVID has been a dramatic experiment. It has forced people to change their behaviour at a rate and in ways that we would never have thought to be possible. And people’s movement behaviour is high amongst the behaviours that have been impacted by the COVID pandemic and the shutdowns. Some of that is really beneficial. We’ve achieved in six months what we were hoping to achieve in six years, dealing with the peak travel demand that causes congestion. Forcing people to work from home largely eliminated the morning and evening peak hour rush. So it absolutely raises the question: should we institutionalise work from home? Never mind whether people like it or they don’t like it, if some degree of working from home would actually mitigate peak congestion, maybe it’s something we, the community, should explore. The performance of the freight sector has been a strong beneficiary of COVID as well, because for three or four months they had a more or less free run of the road network. It’s demonstrated the clear value to both the transport sector and the community when transport can be freed from the constraints of congestion. Can we maintain that as we revert to ‘normal’ travel behaviour? It’s a difficult question. As people go back to work, particularly if they go back by car instead of by public transport, then the congestion issue is clearly reappear, potentially even worse than before. But I

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And of course, last-mile deliveries have gone through the roof as well. If you’re in the last-mile delivery business, you’re having a bonanza. But are we doing last-mile delivery in an efficient way? I suspect there’s an awful lot of half-full trucks rushing around the suburbs, making all the same trips in a way that, from a wholeof-system point of view, is not particularly efficient. I think out of COVID-19 there might emerge a more active marketplace for transport capacity. So if a truck is making a trip and it’s got space for a few more pallets or parcels, how does it make that capacity available to the sector? It has to be in a timely way, because the trip is going to happen at a particular time, but is there some way they can then pick up other deliveries that could be made on the same trip? If I’m heading to Dandenong and I aim to arrive there at 10.00am, and I’m starting in Werribee or Bayswater, what else can I pick up on the way, to make me a dollar and simultaneously solve somebody else’s transport problem? AMT: What opportunities exist for Australian manufacturing firms to capitalise these changes? IC: It goes back to that question of agility, or that question of quick responsiveness. I would encourage manufacturers to continue to look for additional opportunities, even if it involves a short run or a quick turnaround, and then use this emerging visibility over the transport universe to see how they can get their raw materials or their components into production in time, and similarly how they can construct the delivery process to get the goods to the customer in the timeframe that the customer wants. I would encourage them to use this growing visibility to win more short-turnaround jobs. And that could apply to overseas work as well. Though with work for overseas short-turnaround might mean two or three weeks, as opposed to something like delivering pizzas, where short-term might mean five minutes. The question of what is short-term is very much dependent on the sort of manufacturing tasks you’re dealing with. But the point about increasing visibility in the transport sector means you can pull together the plan to actually make it happen and capture additional business at the margin in a way that wouldn’t have been possible five or 10 years ago. AMT: Do you see this as an area where Australia can develop a real advantage internationally? IC: I would say that, on the one hand, Australia has already got a reputation and a capability for being relatively agile. On the other hand, I would say it’s imperative that Australia improves its agility because we absolutely suffer the tyranny of distance, and nowhere more so than in manufacturing, where there’s a big distance to your suppliers and customers, domestically and overseas. That compels us to become good at getting stuff in and out quickly. Transport agility is an essential requirement for manufacturing agility, and manufacturing agility is something that manufacturing has to execute in order to be competitive in the global markets. AMT: Finally, what’s the most satisfying aspect of your job? IC: I love finding a better way to do things. And that usually means less frustration, less wasting of time, making things more predictable, more reliable. And I love seeing the opportunities amidst the chaos. COVID is really a pain, but it has thrown a lot of balls up in the air. I think the challenge for us is to see the opportunities that that creates, or to see the learnings that that gives us, that we can apply going forward and be better as a result. www.imoveaustralia.com

Explore your unlimited possibilities additively The Additive Manufacturing Hub is a $1.85m programme that will grow and develop additive manufacturing capability and investment in Victoria. The vision of the AM Hub is to provide an industry-driven network of users, suppliers and supporters that will foster and grow the use of Additive Manufacturing technology in Australia. + Promote and market additive manufacturing sector capabilities. + Expand the knowledge base of additive manufacturing technologies. + A grant programme for Victorian businesses to encourage adoption of additive manufacturing technologies. + Support the creation of high quality additive manufacturing jobs. + Be a voice to Government on additive manufacturing sector development. Companies looking to explore the potential of additive manufacturing, or further expand their use of the technology should register interest via email at amhub@amtil.com.au

www.amhub.net.au 1407AMHUB

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SHOC: 3D printing the perfect fit for visor upgrade Sports equipment manufacturer SHOC was encountering problems with one of its key products: a visor for American football helmets. Working with AMTIL’s Additive Manufacturing Hub (AM Hub), it found a solution in 3D printing. SHOC is an Australian-owned and operated business that provides sports industry after-market polycarbonate helmet visors for American football and lacrosse. The company has been providing its products for just over five years.

The challenge SHOC’s 2.0 Lightning Visor football-helmet visor was suffering some fitting issues, which were causing premature cracking of the visor. The reason for this was that the 2.0 Lightning product was designed as a one-size-fits-all visor. While it fitted most helmets okay, on one helmet, the Riddell Speedflex, it had to be bent to fit the mask. This was a major issue because the Speedflex is the most popular helmet in the sport currently, meaning failure issues for the visor were exacerbated. SHOC pulled the 2.0 Lightning visor after several issues arose and the company did not want to risk any further problems for its end customers.

The solution SHOC engaged the team at product design and development specialists ONEPOINTSIX in late 2018 to begin the redesign of its 2.0 Lightning football-helmet visor. The Zero G project consisted of two parts. The first part: to redesign the 2.0 Lightning visor that would fit the Speedflex perfectly with zero bending of the polycarbonate. The redesigned visor would basically retain the same styling of the 2.0 Lightning visor, but to perform a shape upgrade so that it would fit the more pinched style of the Speedflex helmet’s mask. The project would employ 3D printing processes to facilitate the printing of the updated design, and test fitting. When the 3D-printed part did not fit on the mask properly, SHOC and ONEPOINTSIX made small design shape changes and reprinted the part. This enabled the team to quickly bring the part in for a perfect fit. The team also utilised the 3D printed part to present the new design to its customers and invite feedback. The importance of this part of the process became clear at one point when it emerged that SHOC had omitted to lower the top of the visor so that it did not cover the mask label. This would have been a significant issue with some of the professional teams, who must show the label on their helmets.

A render provided by ONEPOINTSIX of the final approved design.

The second part of the project was to design a new quick-fitting visor clip. The newly designed VIPER clips would be utilised not just on the new SHOC Zero G visor but on all other visors offered by SHOC, as well as other competitor visor brands. ONEPOINTSIX was contracted to perform the design work for the clips and utilise 3D printing to facilitate testing of the parts and ensure a perfect fit on the Speedflex helmet, as provided. SHOC provided the design and 3D-printed sample to its US factory, who indicated that the custom shape that had initially been chosen would prove extremely difficult to mould, and suggested instead utilising a toroid shape as the base shape of the visor. The team went back to the CAD software with this advice, with ONEPOINTSIX working directly with the factory and their mould maker to make the changes to the CAD design. The shape was quickly updated and another sample was printed; further tweaks to the shape were required and additional samples were printed. ONEPOINTSIX supplied SHOC’s factory with the CAD drawings, and 3D-printed samples were made at the factory of both the clips and the visor. Samples were received and checked by ONEPOINTSIX, and mould manufacturing began. At present SHOC has finalised the clips and they are in production. The mould for the visor initially failed optical testing but SHOC is close to resolving this. The visor part has been supplied, SHOC has test-fitted it onto the helmet and all masks, and it is a perfect fit. Finally the mould has been repolished for optical clarity and the design finalised in late February. One lesson learned in hindsight was that SHOC would have benefitted from going to end customers with design proposals and receiving feedback on various 3D-printed shapes. This would have provided direct feedback in regard to customer experience.

The outcome SHOC has completed the design and testing of its new product for the American football helmet market utilising the services of ONEPOINTSIX. It has received factory final samples of all parts and is currently awaiting final mould tweaks to begin production imminently. The use of 3D printing was instrumental in getting an exact fit of the visor to the helmet. If it was not for 3D printing, the project would inevitably have entailed large amounts of guesswork, which would have been massively time-consuming. Additive manufacturing allowed SHOC to make exact changes, and enabled quick turnarounds on testing and verification.

The 3D print as supplied by ONEPOINTSIX, with SHOC’s US distributor performing test fitting on a large variety of helmets.

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The AM Hub is an initiative delivered by AMTIL in partnership with the Victorian State Government to provide an industrydriven collaborative network of technology users, suppliers and supporters that will promote the adoption of additive manufacturing technology. For more information, please contact John Croft, AM Hub Manager, on 03 9800 3666 or email amhub@amtil.com.au. www.amhub.net.au www.shoc.com

PLASTICS

Cut To Size launches new chemicallyresistant engineering thermoplastic A hard-wearing chemically-resistant engineering thermoplastic is being introduced to Australasia by Cut To Size Plastics focused particularly on machine-building applications and production of machinery components used in food, beverage and agricultural processing and production of precision medical, electrical and electronic components. The latest Wearace copolymeric acetal offers the low coefficient of friction and good wear properties required in machinery and components being developed for production automation and Industry 4.0 applications, as well as uses in logistics, materials handling, bottle and car washing equipment, electrical and electronics production, sports equipment, textile processing and office machinery.

POM (Polyoxymethylene) offers good resistance to a wide range of chemicals – including many solvents – as well as the high mechanical strength, heat resistance and good anti-friction properties needed for higher-speed production. It also provides high strength and stiffness, coupled with easy machineability. “For parts which need to be dimensionally stable, even when exposed to humidity or wet environments, this copolymeric acetal offers better hot water, thermal and chemical resistance than homopolymeric acetal,” says Green.

Cut To Size Managing Director Laurie Copolymeric acetyl products are used globally in Green says the versatile top quality machine building and production of components, acetal is formulated by Zellamid, a global including upgrades of processing plant in preparation for automation and Industry 4.0 producer with 70 years’ experience, whose initiatives copolymeric 900 formulation is very timely The latest product in the Wearace acetyl for Australasian and Asia-Pacific manufacturers and processors range is produced according to ASTM D 6100. It is porosity-free focussed on hygienic, easily maintained and easily washed down and most formulations are approved for contact with food (BfR, machinery, components and good OH&S practices – often in FDA and EU 10/2011 compliant). Cut To Size can draw upon 40 aggressive environments. years’ experience to suggest the best formulation for particular “Tough, light and hygienic materials will become highly relevant to a post-Covid world, in which manufacturers switch production emphasis in line with demand and supply chain fluctuations,” says Green. “Easily machined and readily available parts will increasingly be part of the processing mix.” Green’s company recently invested in a high-speed, vibrationfree Italian Morbidelli Author M100F heavy-duty CNC router and machining centre, which offers unmatched finishing quality and rapid production turnaround for the company’s Australasian and Asia-Pacific markets. Green says semicrystalline thermoplastic

applications, as well as providing access to anti-static formulations where these are required for electrical and electronic applications, says Green. Cut To Size is a leading provider for some of the world’s most advanced top-quality brands of engineering plastics, including Wearace acetyl, Wearlon nylon, Wearflon PTFE, Wearex UHMWPE, Wearthane polyurethane, Wearzorb, Polysulfone (PSU), polyphenylensulfone (PPSU) polyetheretherketone (PEEK), PET, PET-GL, and chain guides, profiles and outrigger pads. www.cuttosize.com.au

Foamex wins West Gate Tunnel contract Foamex has won a $1.4m contract to supply expanded polystyrene (EPS) blocks for the massive West Gate Tunnel Project in Melbourne’s west. Justin Kelsey, General Manager at Foamex, Australia’s leading manufacturer of EPS, says the Australian construction industry is very price-driven, but notes that the COVID-19 pandemic is shining a spotlight on the importance of having a trusted supply chain that can deliver on time. Foamex is supplying S Grade Polystyrene manufactured at its customisation facility in Melbourne’s North, where it is cut into various dimensions. For the West Gate Tunnel Project, the EPS block is cut to the profile according to the specifications set out by the engineers on the project. “For this particular job, there was a requirement for the EPS to fit within bridge cages,” said Kelsey. “To do this, we needed to hot wire profile the block so that the exact profile dimensions are achieved. Our state-of-the-art equipment enabled us to create the customised profiles that also have excellent yield. This means there is very little wastage, making it cost-effective while meeting the brief and engineering specifications required.” The Foamex EPS profiles are placed inside the bridge cages, which means much less concrete is required. The EPS shapes create a void in the manufacture of the pre-tensioned concrete beams. This is taking place at a pre-cast facility in Benalla, Victoria.

“EPS is the ideal product for this as it is cost-effective, very lightweight, and dimensionally stable,” added Kelsey. “EPS has great tensile strength, which gives it the ability to resist loads without failure because of excessive stress or deformation, and this is why it is very commonly used within large construction projects. “The unique product benefits also reduce the overall weight of the concrete structures, which can be of benefit from an engineering perspective, but also means less freight weight, which means less fuel, which is beneficial for the environment. Using EPS also has environmental benefits due to the significant reduction of concrete required. A lot of people aren’t aware that the production and use of concrete is the third largest emitter of carbon dioxide in the world and its use continues to grow around the world.” The West Gate Tunnel Project is expected to be completed in late 2021. With twin tunnels, it will offer motorists an alternative to the West Gate Bridge. Foamex has been in business for 30 years and employs about 250 people manufacturing alternative building products in five states. www.foamex.com.au

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CSIRO and partners take aim at ending plastic waste CSIRO is developing a major research program to tackle plastic waste and reimagine the future of plastics. The Plastics Mission, one of 12 missions in development by CSIRO, is using science and technology to address Australia’s plastics waste issue. Each year, 90 billion tonnes of primary materials are extracted and used globally for plastics. Only 9% is recycled, with economic, social, environmental and health impacts. In Australia, we generate an estimated 67m tonnes of waste every year. CSIRO Senior Principal Research Scientist Dr Denise Hardesty said CSIRO was working with collaborators through the Plastics Mission to apply technological solutions to the entire plastics supply chain and prevent rubbish ending up in the environment. “Our research is helping to understand the extent of plastic pollution in Australia and globally, and how to reduce it,” Dr Hardesty said. “Rethinking plastic packaging is just one way of reducing waste, through better design, materials and logistics. We can also transform the way we use, manufacture and recycle plastics by creating new products and more value for plastics.” New solutions under development include plastics detection using artificial intelligence, implementing and optimising waste monitoring systems, and establishing recycling standards and best practices to reduce contamination.

Machine learning and camera sensor technologies Machine learning and camera sensor technologies are fasttracking data collection to detect and classify items of rubbish in our rivers. This project, in partnership with Microsoft, helps inform waste management strategies, highlighting where intervention is needed to stop plastic from entering waterways. Microsoft Australia chief technology officer Lee Hickin highlighted the importance of supporting the efforts to aid in the development of a national baseline to measure litter accumulation in the environment, which was key for measuring and reacting to change. “Microsoft artificial intelligence image recognition is underpinning the identification of plastic pollution,” Hickin said. “By using AI to accelerate the detection and classification of rubbish in our waterways, we can simply react more quickly and work to improve the quality of water faster than if done manually.” Camera sensor technologies are also being applied to waste traps, commonly used by councils to prevent rubbish flowing through stormwater drains into the environment. City of Hobart Lord Mayor Anna Reynolds said the City was working with CSIRO to develop an autonomous sensor network to provide real-time reporting on the amount of rubbish being captured. “Gross pollutant traps capture rubbish that ends up in stormwater drains,” Reynolds said. “But maintenance can be costly and timeconsuming. By tapping into CSIRO’s modelling capabilities, we can optimise our operations to avoid the release of pollutants, while improving safety and reducing environmental harm.”

Turning resources to riches CSIRO is also collaborating with Chemistry Australia and their Plastics Stewardship Australia initiative to inform ways to more sustainably use, re-use and recycle plastic products. Director Strategy Energy and Research for Chemistry Australia Peter Bury said new technologies and initiatives to recover and transform what are important resources into commodities supports the UN’s Sustainability Development Goals and can help drive Australia’s circular economy. “With a pending export ban for Australian waste, the time is now to address the plastic waste problem,” Bury said. “Leading science will help establish standards to ensure product security and inform decisionmaking. Leveraging the capability of industry for plastic products at their end of life will also generate new types of products and design, and help build new industries and jobs across a range of sectors.”

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CSIRO Missions Program CSIRO is working with government, universities, industry and the community on a new missions program to bolster Australia’s COVID-19 recovery and build long-term resilience. The program of large-scale, major scientific and collaborative research initiatives is aimed at solving some of Australia’s greatest challenges, focused on outcomes that lead to positive impacts, new jobs and economic growth. CSIRO’s Plastics Mission to end plastic waste is one of 12 missions in development. Early collaborators working to co-design a mission to end plastic waste include: • Chemistry Australia and Plastics Stewardship Australia. Working together on initiatives to support the sustainable use and recovery of plastics. This includes establishing best practices and standards to ensure product reliability, food security, sustainability; and partnering with Operation Clean Sweep to prevent plastic pellet loss into the environment. • Hobart City Council. Pilot project partner for cameras to measure waste flows and smart sensor and decision support technologies to reduce costs, increase safety and better manage gross pollutant trap assets. • Microsoft. Computer vision technologies from Microsoft are enabling CSIRO researchers to detect and classify the rubbish in rivers, infer litter abundance and distribution, and inform councils and decision makers in order to build more suitable policies and waste management systems. • NSW Government. CSIRO is supporting the Regional Growth NSW Development Corporation on a program of long-term engagement in the NSW Special Activation Precincts in Parkes, Wagga Wagga, Moree, Snowy Mountains and Williamtown. Its collaboration with the NSW Government as well as NSW universities and industry in these Precincts will assist to accelerate NSW economic recovery by creating future industries and highly skilled jobs. • Ocean Protect. Ocean Protect is an implementing partner for gross pollutant traps in stormwater drains to optimise performance, reduce costs and increase safety. • Standards Australia. CSIRO is working with Standards Australia to design and implement a clear set of guidelines for plastics recycling and recycled content to decrease contamination and increase the value of recycled stocks. www.csiro.au

PLASTICS

Coles cements Australianfirst soft plastics recycling technology Coles and Victorian recycling organisations RED Group and Replas plan to install a concrete slab carpark made partly out of recycled soft plastics. Under installation at Coles Horsham, the carpark is the first commercial construction project in Australia to make use of Polyrok – a sustainable alternative to aggregate minerals used in concrete, such as stone. Made from plastic bags and soft plastic packaging recovered from the REDcycle program, Polyrock has the potential to divert 105,000 tons of soft plastics from landfill each year, if used in commercial concrete projects across Australia. Fiona Lloyd, Coles State Construction Manager – Victoria, said this was the first time the product had been used in a commercial environment. “As one of Australia’s largest food retailers, we know how important it is to support initiatives that help to close the loop with soft plastics,” she said. “This project alone will help repurpose approximately 900,000 pieces of soft plastic, to be used in the carpark at the soon-to-be-competed Coles Horsham redevelopment. We’ve worked with RED Group, Replas and RMIT University throughout the whole development process and we’re excited to see how we can use this technology in more of our stores.” Replas Joint Managing Director Mark Jacobsen said: “Coles, Replas and RED Group are leading the way on recycling the soft plastics that are returned to Coles supermarkets. This new carpark will be built using Polyrok, a sustainable alternative to mineral aggregate in concrete, made from the soft plastic packaging returned to REDcycle bins at Coles. “Polyrok reduces the carbon footprint due to the reduced thermal mass it provides. This tackles the plastic problem and climate change all while being fit for purpose. If innovative products like this were adopted in all buildings and car parks, the collective reduction in greenhouse gasses would be enormous.” Trevor Evans, Assistant Minister for Waste Reduction and Environmental Management, welcomed the collaboration to find innovative and practical ways to reuse soft plastics. “There is huge potential and opportunity for infrastructure projects to help us build a more circular economy,” Assistant Minister Evans said. “This is why the Federal Government has prioritised the development of new national standards and guidelines to encourage the use of recycled content in roads and other projects.” Coles has worked with REDcycle since 2011, becoming the first major Australian supermarket to have REDcycle bins in every supermarket. Since the partnership began, Coles and its customers have diverted over 1.3bn pieces of soft plastic from landfill. www.coles.com.au www.redcycle.net.au www.replas.com.au

Fiona Lloyd, Coles State Construction Manager Victoria, at Coles Horsham with polyrock aggregate made from recycled plastic.

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Additive manfuacturing lights the way forward for Burn Brite When Ampcontrol Burn Brite set about developing a polymer moulding component for a new safety lighting product for underground coal mines, it decided to explore the potential of 3D printing, with support from AMTIL’s Additive Manufacturing Hub (AM Hub). Ampcontrol Burn Brite Pty Ltd (Burn Brite) is a member company of Ampcontrol Pty Ltd. Based in Ringwood in Melbourne’s east, Burn Brite is a designer and integrated manufacturer of lighting and power supply systems. It supplies to the underground coal, tunneling and infrastructure markets throughout Australia and South-East Asia. Employing 40 people, Burn Brite has been in operation for 63 years. Burn Brite’s operation is a classic manufacturing operation. From raw materials such as polymers, metal sheeting and electronic components, Burn Brite processes, fabricates and assembles to detailed in-house designs that require strict Group 1 and 2 certification compliance. Most of these products are safety-critical in their application. Burn Brite is essentially an independent operation, providing sales, R&D and manufacturing functions. As Burn Brite’s products have been designed in-house, the role of R&D is critical to the ongoing success of the business.

The proposed final product.

The challenge Burn Bite planned to design and develop new integrated safety lighting for underground coal mines. Its new flagship luminaire product would be called the ISLEDi. This would be an extensive change to its existing ISLED product with new leading-edge electronics embedded. These product developments are detailed and onerous, including arduous laboratory testing of properties, material compatibility and safety mechanisms. The body of the luminaire was to be made from a polymer moulding requiring detailed design, prototypes and intricate detail in injection moulding tooling. The estimated timeline for project completion was significant, and the risk of future realised injection moulding issues arising was high.

The solution In discussion with industry contacts, it was recommended that additive manufacturing (AM) could assist for fast prototype development, enable fast iterative design, and therefore lower decision risk in injection mould tooling investment. Burn Brite sought additive manfuacturing support from the Additive Manufacturing Hub (AM Hub) via the Build It Better (BIB) voucher program and was very appreciative to be accepted. Burn Brite engaged a registered service provider, Cobalt Design, to assist in CAD aspects related to additive manfuacturing and to engage with additive manfuacturing companies best suited to the form and close material property correlation requirements of Burn Brite’s prototype design.

How the Additive Manufacturing Hub helped Burn Brite knew of additive manfuacturing through media and exhibitions, but had no direct knowledge or experience of it in terms of design considerations, compatible polymers and so on. With funding assistance from the BIB program, engagement and detailed discussions with Cobalt were undertaken. This led to Burn Brite modifying certain aspects of its designs and issuing designs closely suited to additive processes. Without the opportunity of the BIB program, Burn Brite would not have pursued an additive manfuacturing path. The BIB program enabled engagement with Cobalt, design suitability for AM, fast processing of prototype parts and samples, and shortened lead times to critical decisions about product tooling.

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The outcome Cobalt’s creative design and form iterations were completed within weeks. The creation of fast prototypes then occurred within days. Burn Brite would historically take several months to iterate design between mould flow simulation to rapid prototypes and so on. The additive manfuacturing path has saved many weeks of iteration to get to a high confidence level on final body form and tooling design. All mechanical aspects of Burn Brite’s new ISLEDi are now complete. Critical decisions regarding tooling and investment were made through a series of trials and formal reviews, subsequent to the receipt of samples. The target market for this product is the underground coal longwall mining sector. Discussions regarding the flexibility and increased visual awareness and status of mine condition that this product will enable have been very positive to date. The product design and final assembly are currently undergoing certification review. Burn Brite is confident that the product design in its current form will be successful in this certification. The product is on track for a market release in July 2020. Burn Brite will now implement an additive manfuacturing step in its design process going forward. The benefits have clearly been a reduced time to investment decisions, and therefore to final product realisation. Burn Brite remains watchful of the economic improvements in additive manfuacturing and looks forward to the time when it will invest in additive manfuacturing machinery and make the transition from injection moulding. The AM Hub is an initiative delivered by AMTIL in partnership with the Victorian State Government to provide an industrydriven collaborative network of technology users, suppliers and supporters that will promote the adoption of additive manufacturing technology. For more information, please contact John Croft, AM Hub Manager, on 03 9800 3666 or email amhub@amtil.com.au. www.amhub.net.au www.burnbrite.com.au

MOTORS & DRIVES

Variable speed drives: the dark side Variable-speed drives (VSDs) are rightly hailed as effective energy savers and help industrial applications to reduce their power outputs, but their impact on power quality is less often discussed. Joshua Piccaver, Electrical Design Engineer at Cressall, explains how electrical engineers can combat VSDs’ darker side. According to power and automation company ABB, the addition of a VSD can reduce energy consumption by as much as 60%. This means that, if a 90kW motor in continuous operation is combined with a VSD, financial savings can amass to over $16,000 per year. A VSD can help achieve these savings by better catering for the needs of a specific application. Traditionally, induction motors run at fixed speeds and are suited to applications that require a constant motor output speed, such as in pumps or fans. Yet sometimes, varying motor output speeds are preferable to meet the changing requirements of the load, such as in fans, pumps and precision tools. Also known as a frequency converter or adjustable speed drive, a VSD is able to control the speed and torque of the motor to better match the process requirements of the machine it is driving. It is the slowing down, when necessary, that helps recoup energy and costs that would otherwise go to waste.

Riding the wave Of course, the bottom line of any plant manager’s ambitions is to reduce costs and improve operational efficiency, and a VSD helps to achieve just that. While a manufacturer should not be dissuaded from purchasing VSDs for use with electrical equipment, they must pay attention to an “unwanted ingredient” that the device might add to the power mix. When existing equipment has to share its power network with connected addons, harmonics can become a problem. These harmonics are voltage or current waveforms that have a different frequency to that of the network, and may cause devices to behave erratically. The undesirable aspect of a VSD is that it can create these harmonic currents due to the conversion of an incoming alternative current (AC) waveform to a direct current (DC) source, in order to create modulated pulses that control the AC motor. This back and forth, from AC to DC, results in current waveforms that are greater than the network frequency can handle. As a result of the unwanted currents, cables may overheat which damages their insulation. Other unwanted consequences include that motors can be at risk of overheating and becoming noisy; circuit breakers may trip; meters can give false readings; or equipment might fail altogether.

To prevent these unwanted effects from occurring, manufacturers can implement a number of techniques. Reduction is one obvious remedy, which involves the use of AC line reactors, known as chokes. These chokes are fitted either inside or outside the drive, to reduce the harmonics to a level where they no longer cause serious issues. However, the use of a large choke can have major size and cost drawbacks, which makes the solution unsuitable for some applications. An AC choke also has a voltage drop that impacts the system.

Filter them out Harmonics caused by VSDs can be reduced to acceptable levels by using passive filter circuits that consist of inductors, capacitators and resistors. The filter circuit allows the fundamental frequency to pass through while diverting any harmonic frequencies to the resistor bank. Here, the frequencies are dissipated as heat and are removed from the system. The introduction of a dampening resistor can also offer a number of benefits to the system. They include better filtering characteristics for higher frequencies, reduced amplification at parallel resonance frequency, as well as higher filter losses at the fundamental frequency. Cressall builds discharge resistors that meet the stringent operating conditions of customers such as Siemens, Areva, and the UK National Grid Company and its counterparts overseas. Cressall’s design

expertise in the field is well-known, as a result. Based on Cressall’s experiences within the industry, perhaps the most commonly used material in the design of harmonic filter resistors is expanded mesh. This material has a high surface area, which gives it excellent heat dissipation and makes it ideal for continuous filtering duties. The active material, insulators and mountings on expanded mesh resistor elements maximise the use of convection to avoid hot spots and local overheating. However, as the elements are thin, expanded mesh can bow when exposed to high levels of heat, and this uncontrollable bowing can cause sparks. To remedy this, Cressall has developed a technique that allows bowing to take place in the same direction. By improving the shape of expanded mesh, the company has been able to prevent this fault from occurring so that dampening resistors made from expanded mesh can filter VSD harmonics, without the risk of sparking. Given their many advantages, it wouldn’t be right to label VSDs solely as an “electrical circuit villain”. After all, the additional levels of performance flexibility that the devices give to motors are essential — as are the resulting cost savings. However, to stop VSDs from drifting to the dark side, unwanted levels of harmonics must be tackled to allow for optimal performance. www.cressall.com

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Motoring a manufacturing revival for the food & beverage industry The food & beverage sector has been widely tipped to be integral in Australia’s post-COVID revival, but it needs to find ways to operate more efficiently to truly deliver on its potential. Food & beverage is an important part of manufacturing, itself an important sector in rebuilding the Australian economy postpandemic. Food is the biggest part of the local manufacturing industry. Out of the top 100 Australian manufacturers by revenue, 35 are in food & beverage, and it makes up over a quarter of all manufacturing jobs and value-added output. The sector is a net exporter, selling to more than 200 markets and enjoying an enviable “clean and green” reputation globally for excellence. It is vital and resilient, continuing to grow even through recent conditions for manufacturers described as “reminiscent of... the Global Financial Crisis (GFC)”. Food manufacturing is also viewed by some of our leading businesspeople as a key area for accelerating the country’s economic recovery. To do the best at the important job ahead, the food & beverage sector – like every other – will need to find better ways of working. This includes investing in its people and processes, and adopting new technologies, such as flexible robotics, traceability solutions, increasingly digitalised supply chains, and new processing machinery. One area that operators wanting to run their factories more efficiently can look to are the motors behind processes like line distribution, filling, cutting and sorting. Pneumatic cylinders are a tried-andtrue solution, but they’re also noisy and energy-inefficient, and it can take hours to fine-tune air pressure. Tubular linear motors, on the other hand, can achieve very precise positional control and flexibility. Instead of being at one end or another, a linear motor can move to any single position within a stroke. Newer actuation methods, such as tubular linear motors, are a way manufacturers can drive efficiency and productivity in their factory equipment. Such linear electrical motors are quicker and more accurate, allowing higher throughput at higher qualities over the same period, and use less energy. They have fewer moving parts so require less maintenance. Moreover, their servo drives are easily calibrated, meaning less time spent between line changes. ANC Motion’s new LinX M-Series linear motor is an alternative to pneumatic, ballscrew, linear flatbed and other options. M-Series LinX motors are highly dynamic, with velocities up to 10m per second,

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acceleration over 30G, and are able to achieve a peak force of 1,200N. The direct drive nature also means there is no wear and no backlash, a clear benefit over ballscrew options. The high-speed product also allows high repeatability across cycles, with position feedback accuracy of 50μm. A typical payback period is between six and 12 months, with increased uptime and throughput and decreased maintenance quickly offsetting any cost difference versus pneumatics. The M-Series LinX’s mounting is designed so it can work as a “drop-in” for existing pneumatic cylinders. Installation is made easier by the 1mm air gap between the shaft and the forcer, which means a very relaxed tolerance requirement. The M-Series has users worldwide in machine tools, electronics, packaging and other sectors, but its high level of ingress protection (IP67, easily upgraded to IP69K) make it particularly well suited to food and pharmaceutical manufacture and the requirement of regular washdowns. Each unit has a fully potted body, with magnets fully encased in a stainless steel tube and tightly sealed using end caps and o-rings. ANCA Motion’s linear motors were originally developed for sister company ANCA CNC Machines’ FX Linear and MX

Linear machines. ANCA is a leader in CNC tool grinding technology, with a series of world-firsts since beginning in 1974 and numerous awards acknowledging it as a leader in Australian industry for both its innovation and export achievements. LinX was designed and assembled in Australia, with a team of support engineers offering a high level of locally-specific expertise. International support is also available through a network of 125 support engineers in the United States, Mexico, Germany, Brazil, the United Kingdom, Turkey, and various Asian markets. The COVID-19 pandemic has put a magnifying glass up to the importance of Australian manufacturing, both during and after the crisis. Thankfully, the scramble to tool up and provide essential medical and sanitation products is over. In the short term, Australian manufacturers proved they’re more than capable of responding to a crisis. Again, the country is looking to them, this time over the longer term, to help generate prosperity, jobs, and play a role in the return to economic growth. It’s important that the country’s manufacturing sector – including its food & beverage component – can grow sustainably, firing on all cylinders. motion.anca.com

MOTORS & DRIVES

maxon motors heading to Mars In July, NASA launched its fifth rover mission to Mars, equipped with precision brushed and brushless motors from maxon used for various mission-critical tasks. Maxon’s DC motors have been used in virtually every successful robotic mission to Mars over the last 30 years. There are now more than 100 DC motors on the Red Planet and there are likely to be more soon. NASA’s Jet Propulsion Laboratory (JPL) asked maxon to produce ten DC motor drive systems for the new Perseverance rover. Perseverance’s main mission is to take multiple soil samples, seal them in containers and deposit them on the surface of Mars so that a future mission can return them to Earth. Several maxon motors are employed to handle the samples inside the rover. For example, maxon DC motors are installed in the robotic arm, which moves the samples from station to station. maxon DC motors will also be used for sealing and depositing the sample containers.

The name to remember ...for all your linear motion needs

As with most previous Mars missions, these DC motors are modified for the highly specialised purpose and based on standard products from maxon’s catalogue. For the first time, NASA is using brushless DC motors, including: nine EC 32 flat and one EC 20 flat DC motor in combination with a GP 22 UP planetary gearbox. Working closely with JPL specialists, maxon engineers developed the drives over several years and tested them thoroughly to achieve the highest standards of quality. “We’ve learned a lot from this exciting project,” says Robin Phillips, Head of maxon’s Space Lab. “We now have very broad expertise in space applications and have established quality assurance processes that meet the expectations of the industry. Customers from other industries such as the medical sector, where requirements are often similar, can also benefit from this know-how.” Space missions place the highest demands on DC motor systems. This includes vibrations during the rocket launch, vacuum during the journey, impacts on landing and the harsh conditions on the surface of Mars where temperatures fluctuate between -125 and +20 degrees Celsius and dust penetrates everywhere. Perseverance is expected to land on Mars on 18 February 2021 – but it won’t be alone. A drone helicopter called Ingenuity will be attached to the rover’s underside. It’s solar powered, weighs 1.8kg and will perform several short flights and take aerial images. The aim is to test the concept for further drones of this kind. maxon has six brushed DCX motors with a diameter of 10mm controlling the tilt of the rotor blades and the direction of flight. The DC motors are light, dynamic and highly energy-efficient. These properties are crucial, because every gram counts on the Mars helicopter. Flying on Mars is not easy. The atmosphere is thin, comparable to conditions on Earth at an altitude of 30km. The helicopter has flown in a simulated test environment in the JPL laboratory. Whether it will lift off on Mars remains to be seen.

With over 35 years of experience, Linear Technik has gained an enviable reputation as Australia’s leading supplier of Linear Components. Our product and industry knowledge is second to none and our range covers all aspects of Linear Motion Technology.

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“We hope everything goes well and that we’ll soon see our drives in action on Mars,” says maxon CEO Eugen Elmiger. “We’re all keeping our fingers crossed.”. www.maxongroup.net.au

54-58 Arkwright Drive, Dandenong South Vic. 3175 Tel: 03 9706 7888 info@lineartechnik.com.au

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WELDING

The essential nature of welding Welding is the most ubiquitous process on the planet. It is fundamental to the construction of bridges, high-rise buildings, mining equipment, ships, and even household appliances, such as fridges and washing machines, writes Geoff Crittenden, CEO of Weld Australia. Next time you’re driving down the road, take a look around you: crash barriers, light poles, road signs, the re-bar in the concrete bridge, even the very car you’re driving. All of these elements rely on welding. Welding played an enormous role in the second industrial revolution. Without welding, we wouldn’t have the modern motor car, highspeed trains, or jet planes. We wouldn’t be able to generate power. We wouldn’t have advanced manufacturing facilities. Our world today simply wouldn’t look the same. Welders build the very world in which we live. However, it’s not just the pervasive nature of the welding process that makes it so essential – welding is also vital to the strength of Australia’s economy.

Essential to employment Australia’s welding and fabrication industry is responsible for the employment of more than 78,900 people, 91% of whom are employed on a full-time basis. While not an absolute, part-time and casual roles are more likely to be more insecure than fulltime roles, and do not always afford employees with the same types of benefits. Generally, full-time, high-quality roles reflect a stronger industry and greater competition for employees. With an overwhelming percentage of Australian welders employed on a fulltime basis, it clear the industry is strong, and an essential provider of secure employment opportunities.

Essential to innovation Australia’s welding and fabrication industry is highly diverse, with a large number of businesses that boast a total output capacity of more than 1.6m tonnes per annum. Approximately 94% of businesses operating within Australia’s welding and fabrication industry are small enterprises with less than 20 employees. Small businesses are an important source of innovation in Australia’s economy. With a proven ability, capacity and agility to respond to changes in today’s competitive global marketplace – particularly when compared to their larger competitors – the role of small businesses in boosting innovation, productivity and efficiency is vital. Through innovation and expansion, small businesses are a solid source of employment and competitive edge for Australia’s economy on the world stage.

Essential to downstream industries With its highly diverse profile, welding is critical to myriad aspects of Australia’s economy. It is a key player in various economically significant downstream and related industries. In Australia, three industries are the main consumers of steel fabricated products, comprising almost 90% of all demand. These industries are: • Construction at 50.3% • Manufacturing at 20.5% • Mining at 17.2% Combined, these three industries purchased over $11.6bn of steel fabricated products in 2013-2014. The construction, manufacturing and mining industries are all essential to the strength and prosperity of Australia’s economy and, without welding, none of them would be able to operate. Since around 2007, the construction industry value add has grown at 3.8% per annum. Based on data from the Australian Bureau of Statistics, employment in the industry has grown from around

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933,100 persons to nearly 1,098,500, making construction the single-largest employing industry in the Australia economy. The construction industry generates over $360bn in revenue, making it responsible for around 9% of Australia’s GDP. And welding is an essential input. Manufacturing directly and indirectly employs over 10% of the Australian population. With manufacturing industry output amounting to over $110bn annually, this is equivalent to approximately 6% of Australia’s GDP. And welding is an essential input. Historically, the mining industry has been important to Australia’s wealth and prosperity – a trend that continues today. Mining contributes approximately $248bn per annum and employs over 350,000 people. And, of course, welding is an essential input.

The role of compliance It is because of the all-pervasive and essential nature of welding that compliance is so vital. Welding is often mistaken as a simple process. In reality, welding requires immense skill. The engineering principles that inform the process are unbelievable. Welding requires both highly skilled craftsmen and scientists who are able to solve complex engineering problems. Welding requires strict adherence to all applicable Australian standards. It is impossible to undertake complete verification of a welded joint without destroying it. Unfortunately, inspection after completion does not guarantee weld serviceability. As such, quality must be built into the welding process, right from the very beginning. Welding must be done correctly the first time. A weld cannot be adjusted once it is complete. The only course of action is to scrap the weld entirely, and start again. As such, the welding processes set out in Australian and international standards are crucial – they must be followed exactly. If they are not, there is a significant chance that a structure will fail. The problem is, a huge proportion of welding in Australia does not comply with Australian standards. This is because welding is an extremely forgiving process. With a bit of practise, just about anyone can join two pieces of steel together. The thing is, these pieces of steel might stick together for five, 10 or even 20 years – but they might not. And when they fall apart, someone invariably gets hurt. In Australia, you’re not allow to drive a car, connect a gas pipe, or install a new light fitting without a licence. Yet you can fabricate and erect enormous steel beams, construct a bridge for thousands of cars to travel across every day, or fabricate caravans to be towed down busy highways – all without a license. It defies all health and safety requirements. It defies logic. www.weldaustralia.com.au

WELDING

Kemppi releases new X5 FastMig industrial welder Kemppi, has released its new X5 FastMig multi-process welding system for MIG, DC TIG and stick welding (MMA) as well as gouging. Designed in conjunction with professional welders specifically for steel welding, the X5 FastMig delivers a range of features to help significantly enhance arc welding productivity. Built using energyefficient inverter technology, the X5 FastMig offers faster, higherquality welds thanks to Touch Sense Ignition, effortless operation, excellent welding ergonomics and flexible equipment setup. The X5 FastMig features the latest in ignition technology – Touch Sense Ignition – as standard in all available models. When combined with WiseSteel software, which also comes as standard with every model, the X5 delivers precise ignition capability and stable arc control. It tackles the challenges of globular arc by alternating between short arc and spray transfer. In short-circuit transfer, it improves the arc stability adaptively, provding better out-of-position steel welding capabilities. In spray transfer mode, micropulsing of the current and voltage increases travel speed significantly. In doing so, the X5 helps to minimise the spatter produced by a traditional globular arc, as well as the need for post-weld cleaning, saving time and costs, while helping to deliver better quality welds. For more challenging applications, the arc control can be further optimised with optional welding programs and Wise special processes. Designed to be hassle-free, the X5 is very easy to operate. It features a large, graphical and impact-resistant TFT display panel that presents all required information clearly and without abbreviations. Welding parameters are set automatically when the user adjusts the wire feed speed. Memory channels are also available to customise and save personal settings.

Easy to use, the operating basics of the X5 can be grasped in just 10 minutes. Plus, the wire feeder’s sturdy rotate-and-push buttons can be operated with gloves on or off, helping to save time and improve productivity. The ergonomically-designed top-loading wire feeder improves occupational safety when changing the wire spool as it places less strain on the user’s back. The wire feeder can also be hung up and adjusted to multiple different angles for quick and easy access, even in a dual setup. Designed for use with the X5, the Flexlite GX guns also deliver comfort in spades and help reduce welder fatigue thanks to their ergonomic design. Each gun is lightweight and features a flexible cable set and innovative ball-jointed cable protection that reduces the load on the welder’s wrist. The pistol grip handle has been designed to feel like an extension of the welder’s hand. Providing excellent balance, it allows for a natural wrist position, which makes the work at hand easier and more effortless, particularly when doing long welds. The on-torch GXR10 remote control allows parameter adjustment at the weld joint, even while welding. The X5’s modular system allows the user to choose from a range of accessories to ensure the optimal solution for every application, including transport units, interconnection cables of various lengths and wired remote controls. Users can build their own machine with the help of the X5 FastMig Selector, an online configurator tool that lets welders easily choose the equipment best suited to make the most out of their investment. www.kemppi.com

STOP, negotiate and listen Whether it’s negotiating a new lease or an existing one, multiple or single properties, a tenant or a landlord, Rigby Cooke Lawyers will ensure your interests are protected and that any lease or agreement you enter into has the right mix of risk allocation and flexibility to match your business needs. Our top tips to get the right agreement for your business Do your research. For landlords that means investigating your tenant including company searches, credit ratings and security registers. For a tenant that could mean looking at rent for a similar space in a comparable building, rent patterns and typical lease periods. Get advice. It is important to seek financial, legal and business advice before entering into a lease to ensure you understand your rights, liabilities and obligations.

Talk to each other. As a landlord, is the property still suitable for the tenant’s business needs? As a tenant, what are your landlord’s future plans for the property? Are there mutual opportunities that benefit both parties. Understanding these motivators can assist your future lease negotiations. Treat a lease like any other commercial business contract and review it regularly to see if there are any ways it can be improved.

Always act in good faith to preserve good relationships between both parties.

Always have a plan. Both parties should consider what you are not prepared to compromise on.

Experience counts when negotiating a lease. With multiple stakeholders, unforgiving time-frames and many moving parts, you need to have the confidence that you have the right team to get the right outcome for your business. Our team can help.

www.rigbycooke.com.au

Mention your AMTIL membership to receive member discounts with us.

For more information contact Darren Marx: DMarx@rigbycooke.com.au +61 413 713 775 | +61 3 9321 7926

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A new approach to making aircract parts, without the massive infrastructure Researchers in the US have developed a method for producing aerospace-grade composites with no need for huge ovens or autoclaves, using carbon nanotube film. A modern aeroplane’s fuselage is made from multiple sheets of different composite materials, like so many layers in a phyllo-dough pastry. Once these layers are stacked and moulded into the shape of a fuselage, the structures are wheeled into warehouse-sized ovens and autoclaves, where the layers fuse together to form a resilient, aerodynamic shell. Now engineers at Massachusetts Institute of Technology (MIT) in the US have developed a method to produce aerospace-grade composites without the enormous ovens and pressure vessels. The technique may help to speed up the manufacturing of aeroplanes and other large, high-performance composite structures, such as blades for wind turbines. “If you’re making a primary structure like a fuselage or wing, you need to build a pressure vessel, or autoclave, the size of a two- or threestory building, which itself requires time and money to pressurise,” says Brian Wardle, Professor of Aeronautics and Astronautics at MIT. “These things are massive pieces of infrastructure. Now we can make primary structure materials without autoclave pressure, so we can get rid of all that infrastructure.” The researchers detail their new method in a paper published recently in the journal Advanced Materials Interfaces. Wardle’s co-authors on the paper were lead author and MIT postdoctoral researcher Jeonyoon Lee, and Seth Kessler of Metis Design Corporation, an aerospace structural health monitoring company based in Boston.

Out of the oven, into a blanket In 2015, Lee led the team, along with another member of Wardle’s lab, in creating a method to make aerospace-grade composites without requiring an oven to fuse the materials together. Instead of placing layers of material inside an oven to cure, the researchers essentially wrapped them in an ultrathin film of carbon nanotubes. When they applied an electric current to the film, the carbon nanotubes, like a nanoscale electric blanket, quickly generated heat, causing the materials within to cure and fuse together. With this “out-of-oven” (OoO) technique, the team was able to produce composites as strong as the materials made in conventional aeroplane manufacturing ovens, using only 1% of the energy. The researchers next looked for ways to make high-performance composites without the use of large, high-pressure autoclaves — building-sized vessels that generate pressures high enough to press materials together, squeezing out any voids, or air pockets, at their interface. “There’s microscopic surface roughness on each ply of a material, and when you put two plys together, air gets trapped between the rough areas, which is the primary source of voids and weakness in a composite,” Wardle says. “An autoclave can push those voids to the edges and get rid of them.” Researchers including Wardle’s group have explored “out-ofautoclave” (OoA), techniques to manufacture composites without using the huge machines. But most of these techniques have produced composites where nearly 1% of the material contains voids, which can compromise a material’s strength and lifetime. In comparison, aerospace-grade composites made in autoclaves are of such high quality that any voids they contain are neglible and not easily measured.

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MIT postdoctoral researcher Jeonyoon Lee. Image: Melanie Gonick, MIT.

“The problem with these OoA approaches is also that the materials have been specially formulated, and none are qualified for primary structures such as wings and fuselages,” Wardle says. “They’re making some inroads in secondary structures, such as flaps and doors, but they still get voids.”

Straw pressure Part of Wardle’s work focuses on developing nanoporous networks — ultrathin films made from aligned, microscopic material such as carbon nanotubes, that can be engineered with exceptional properties, including color, strength, and electrical capacity. The researchers wondered whether these nanoporous films could be used in place of giant autoclaves to squeeze out voids between two material layers, as unlikely as that may seem. A thin film of carbon nanotubes is to some extent similar to a dense forest of trees, and the spaces between the trees can function like thin nanoscale tubes, or capillaries. A capillary such as a straw can generate pressure based on its geometry and its surface energy, or the material’s ability to attract liquids or other materials. The researchers proposed that if a thin film of carbon nanotubes were sandwiched between two materials, then, as the materials were heated and softened, the capillaries between the carbon nanotubes should have a surface energy and geometry such that they would draw the materials in toward each other, rather than leaving a void between them. Lee calculated that the capillary pressure should be larger than the pressure applied by the autoclaves. The researchers tested their idea in the lab by growing films of vertically aligned carbon nanotubes using a technique they previously developed, then laying the films between layers of materials that are typically used in the autoclave-based manufacturing of primary aircraft structures. They wrapped the layers in a second film of carbon nanotubes, which they applied an electric current to to heat it up. They observed that as the materials heated and softened in response, they were pulled into the capillaries of the intermediate carbon nanotube film. The resulting composite lacked voids, similar to aerospace-grade composites that are produced in an autoclave. The researchers subjected the composites to strength tests, attempting to push the

NANOTECHNOLOGY

GET READY FOR THE MANUFACTURING MODERNISATION FUND (MMF) What is the MMF? Cross-sections of carbon fibre composites manufactured by the MIT researchers show that a nanoporous film with morphology-controlled nanoscale capillaries provides the needed pressure at the interfaces in layered polymeric architectures.

layers apart, the idea being that voids, if present, would allow the layers to separate more easily. “In these tests, we found that our out-of-autoclave composite was just as strong as the gold-standard autoclave process composite used for primary aerospace structures,” Wardle says. The team will next look for ways to scale up the pressure-generating carbon nanotube film. In their experiments, they worked with samples measuring several centimetres wide — large enough to demonstrate that nanoporous networks can pressurise materials and prevent voids from forming. To make this process viable for manufacturing entire wings and fuselages, researchers will have to find ways to manufacture CNT and other nanoporous films at a much larger scale. “There are ways to make really large blankets of this stuff, and there’s continuous production of sheets, yarns, and rolls of material that can be incorporated in the process,” Wardle says. Wardle plans also to explore different formulations of nanoporous films, engineering capillaries of varying surface energies and geometries, to be able to pressurise and bond other highperformance materials. “Now we have this new material solution that can provide ondemand pressure where you need it,” he explains. “Beyond aeroplanes, most of the composite production in the world is composite pipes, for water, gas, oil – all the things that go in and out of our lives. This could make making all those things, without the oven and autoclave infrastructure.”

The MMF supports Australian manufacturers (with less than 200 staff) with grants of $100,000 to $1 million on a 3-to-1 funding basis looking to modernise, adopt new technologies, become more productive and create more jobs. A funding round is expected to open up this calendar year, will you be ready to lodge your application?

Next steps We recommend that you prepare in advance of applying for grant funding: - a project plan - a project budget - evidence of your company's ability to fund its portion of the expenditure If this piques your interest but you’re not sure if you qualify, reach out to our friendly R&D Incentives & Grants team at William Buck for a free consultation today.

Dr Rita Choueiri Director R&D Incentives Ph: 03 8823 6840 rita.choueiri@williambuck.com

This research was supported, in part, by Airbus, ANSYS, Embraer, Lockheed Martin, Saab AB, Saertex, and Teijin Carbon America through MIT’s Nano-Engineered Composite aerospace Structures (NECST) Consortium. www.mit.edu

“The researchers proposed that if a thin film of carbon nanotubes were sandwiched between two materials, then, as the materials were heated and softened, the capillaries between the carbon nanotubes should have a surface energy and geometry such that they would draw the materials in toward each other, rather than leaving a void between them. Lee calculated that the capillary pressure should be larger than the pressure applied by the autoclaves.”

Berrin Daricili Manager R&D Incentives Ph: 03 8823 6846 berrin.daricili@williambuck.com

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Deakin’s Boron Nitride Nanotubes are industry-ready A new study has revealed that Boron Nitride Nanotubes (BNNT) produced by BNNT Technology Limited using patented technology from Deakin University has the highest purity among commercial products in the world. Conducted by another leading Australian university, the independent analysis of seven commercially available Boron Nitride Nanotubes (BNNT) samples from around the world confirms Deakin’s place at the forefront of this cutting-edge nanofibre technology. Coinventors of Deakin’s BNNT manufacturing process Professor Ian Chen, Deakin’s nanotechnology group leader; and Dr Luhua Li, Senior Research Fellow at Deakin’s Institute for Frontier Materials (IFM), welcomed the result. “The commercialisation of BNNTs is the culmination of two decades of research and it is exciting to see the rapid progress that is being made”, Chen said. “We have always been confident in the scalability and quality of our technology, but it is still pleasing to see such a stunning independent validation,” Li added. BNNTs are super flexible fibres that are 100 times stronger than steel but as light as carbon fibre, with potential applications in industries ranging from aviation to mining, medicine, and space travel. They are notoriously expensive to produce, with one kilogram valued at $900,000, and difficult to manufacture at scale. IFM has led global research in BNNTs for a number of years, becoming the first in the world to develop and patent technology that allows BNNT to be manufactured in bulk for the first time. In 2018, IFM licensed its BNNT manufacturing technology to BNNT Technology Limited, a start-up based at Deakin’s ManuFutures facility in Geelong. The company’s new $3m plant at ManuFutures began production in 2019 and is now in the advanced stages of scaling up to meet worldwide demand for BNNT product in a variety of new material applications.

Deakin’s Executive Director of Research Innovations, Ben Spincer, believes BNNT Technology could become a major new business, boosting Geelong’s reputation as the home of advanced manufacturing in Australia. “BNNT Technology has the potential to be one of the standout success stories of university commercialisation in Australia, and has already led to three further spin out businesses,” said Spincer. “As part of a broader partnership between Deakin University and the PPK Group, joint venture companies have already been established to use advanced BNNT composite materials in Li-S battery (Li-S Energy Ltd) and3D dental ceramics (3D Dental Technology Pty Ltd) with more expected to follow.” www.deakin.edu.au

‘Nano-pillared’ surface traps and kills COVID-19 Queensland University of Technology (QUT) scientists have developed a way to kill the COVID-19 virus on aluminium surfaces, proven to have both antiviral and antibacterial properties. QUT medical devices specialist Professor Prasad Yarlagadda and virologist Professor Kirsten Spann began testing the novel coronavirus SARS-cov-2, which causes COVID-19, on the nanostructured surface, after publishing their findings on its antiviral properties against common viruses earlier this year. The wetetching process was tested by applying it to commercially available aluminium alloy 6063 – commonly used for doorknobs and frames, window panels and medical equipment.

eight tests showed the virus was no longer viable.” Spann added that it was known that respiratory viruses could be transmitted via contaminated surfaces: “We presume that this is one of the ways that COVID-19 is spreading. We have tested these surfaces against rhinovirus that causes the common cold and so we do know it will work against the common cold. This means these surfaces are highly likely to work against most respiratory viruses and would work outside of a pandemic situation.”

Spann said they tested respiratory syncytial virus (RSV), which causes infant bronchiolitis and pneumonia, and rhinovirus (cause of the common cold) on the wet-etched aluminium surfaces.

Yarlagadda said wet-etching created random nanopillars using strong etchants (etching solutions) to remove the surface and leave micro-nanostructures.

“The nanotextured aluminium surfaces significantly sped up the inactivation process of these two common pathogens,” she said. “We then collaborated with Dr Alyssa Pyke, together with the Public Health virology team from Queensland Health Forensic and Scientific Services to test the nano-pillared aluminium against SARS-CoV-2 in their biological secure containment facility that is specially equipped with technology to prevent the virus from spreading.”

“The simple wet-etching technique gives surfaces a nanoscale roughness that people cannot feel, but which kills a range of bacteria and viruses,” Yarlagadda said. “We have tested the nanomechanical properties of the etched surfaces and found the nanopillars can withstand much larger forces than those applied by the hand.

Spann believes the study is the first to characterise how virus particles, including COVID-19, are influenced by nanostructured surfaces: “We tested the COVID-19 virus on the surface eight times at each different time points: after three hours, six hours, 24 hours and 48 hours. Within six hours, no viable virus could be recovered from the nanostructured aluminium, although the virus remained alive on smooth aluminium for longer than 24 hours and on plastic for longer than two days. At the three-hour mark seven out of the

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“At this stage we are working with a bus manufacturing company and one involved in manufacturing hospital beds and trolleys. However, we are also working on upscaling this technology to develop a film or spray technology.” Yarlagadda said the team had also developed another antibacterial technology for use with titanium that can be used for commercial applications to both orthopaedic implants and other surgical equipment. www.qut.edu.au

SENSORS & PROCESS CONTROL

RMIT electronic skin can react to pain like human skin Researchers have developed electronic artificial skin that reacts to pain just like real skin, opening the way to better prosthetics smarter robotics and non-invasive alternatives to skin grafts. The prototype device developed by a team at RMIT University can electronically replicate the way human skin senses pain. The device mimics the body’s near-instant feedback response and can react to painful sensations with the same lighting speed that nerve signals travel to the brain.

A concept image of electronic skin that can sense touch, pain, and heat. Credit: Ella Maru Studio

Lead researcher Professor Madhu Bhaskaran said the pain-sensing prototype was a significant advance towards nextgeneration biomedical technologies and intelligent robotics. “Skin is our body’s largest sensory organ, with complex features designed to send rapid-fire warning signals when anything hurts,” Bhaskaran said. “We’re sensing things all the time through the skin but our pain response only kicks in at a certain point, like when we touch something too hot or too sharp. “No electronic technologies have been able to realistically mimic that very human feeling of pain – until now. Our artificial skin reacts instantly when pressure, heat or cold reach a painful threshold. It’s a critical step forward in the future development of the sophisticated feedback systems that we need to deliver truly smart prosthetics and intelligent robotics.” As well as the pain-sensing prototype, the research team has also developed devices made with stretchable electronics that can sense and respond to changes in temperature and pressure. Bhaskaran, co-leader of the Functional Materials and Microsystems group at RMIT, said the three functional prototypes were designed to deliver key features of the skin’s sensing capability in electronic form. With further development, the stretchable artificial skin could also be a future option for non-invasive skin grafts, where the traditional approach is not viable or not working. “We need further development to integrate this technology into biomedical applications but the fundamentals – biocompatibility, skin-like stretchability – are already there,” Bhaskaran said. The new research, published in Advanced Intelligent Systems and filed as a provisional patent, combines three technologies previously pioneered and patented by the team: • Stretchable electronics: combining oxide materials with biocompatible silicon to deliver transparent, unbreakable and wearable electronics as thin as a sticker.

The skin-like sensing prototype device, made with stretchable electronics. Credit: RMIT University

• Temperature-reactive coatings: selfmodifying coatings 1,000 times thinner than a human hair based on a material that transforms in response to heat. • Brain-mimicking memory: electronic memory cells that imitate the way the brain uses long-term memory to recall and retain previous information. The pressure sensor prototype combines stretchable electronics and long-term memory cells, the heat sensor brings together temperature-reactive coatings and memory, while the pain sensor integrates all three technologies. PhD researcher Md Ataur Rahman said the memory cells in each prototype were responsible for triggering a response when the pressure, heat or pain reached a set threshold.

“We’ve essentially created the first electronic somatosensors – replicating the key features of the body’s complex system of neurons, neural pathways and receptors that drive our perception of sensory stimuli,” he said. “While some existing technologies have used electrical signals to mimic different levels of pain, these new devices can react to real mechanical pressure, temperature and pain, and deliver the right electronic response. “It means our artificial skin knows the difference between gently touching a pin with your finger or accidentally stabbing yourself with it – a critical distinction that has never been achieved before electronically.” The research was supported by the Australian Research Council and undertaken at RMIT’s state-of-the-art Micro Nano Research Facility for micro/ nano-fabrication and device prototyping. www.rmit.edu.au

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How to set up your business for success in export markets Philip Smith outlines five top tips to set up your manufacturing business for exporting success. Are you a manufacturing business looking to export, but unsure about where to begin? As the Government’s export credit agency, we provide financial solutions to help Australian businesses take on the world. Working across a range of industries for more than 60 years – such as manufacturing – we understand the domestic and global markets. Here are our five top tips to give your manufacturing business the best chance for export success.

1. Ensure you have enough cashflow For many manufacturers who export, there is often a long lead time from the point of delivery until the receipt of payment. This could greatly impact your cashflow. To address this, try to arrange more favourable payment terms with your long-term customers. Another solution may be arranging external finance to maintain cashflow and your operations moving. Understanding how to manage your export cashflow will be a big help.

2. Get ahead of customer demand Winning a major contract or experiencing high customer demand is a positive outcome for any business. While this may boost your profits, it may also mean you need to ramp up your operations quickly to meet a sudden spike in demand. This could involve ordering more inventory or hiring more employees and you may need additional finance. To help, Export Finance Australia offers a range of financial solutions that could support your business to take on these new opportunities.

Case study: Nature’s Dairy Australia One of our customers, Nature’s Dairy Australia, is a business which locally sources, manufactures and packages milk from across Victoria. Approximately 65% of what they produce is exported to Asia. But as a relatively new business, they needed financial support to help them meet the growing international demand. “Nature’s Dairy Australia being only a few years old, we have a huge amount of growth ahead of us,” said their Chief Executive Officer, Bevan Tippett. “But all of that comes with cashflow implications, and so we needed some assistance to fund that continued growth of the business. That’s how we came to talk to Export Finance Australia.” Our $2.6m Export Line of Credit facility is helping Nature’s Dairy Australia finance the working capital funding requirements of their business operations, particularly as sales volumes increase. This enabled them to develop new products and fund equipment specifically for exports – while meeting international demand.

3. Develop your export strategy If your business is in expansion mode, you may be looking to branch into new markets. But remember, each market has its own challenges and risks. When targeting a new export jurisdiction, it’s important to do your research. Understand the trade laws, banking systems and the reliability of their shipping and delivery schedules. This should all form part of developing your export strategy.

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4. Seize international opportunities To export successfully, your business needs to be open to international markets and seize those growth opportunities. This will require you to build strong business relationships in your overseas markets or in your supply chain. You may even need to set up physical offices or shops in key markets, or import your materials. Making sure you have access to the finance you need is crucial in expanding your business internationally.

Case study: BirdDog Australia BirdDog Australia designs and builds high-grade cameras and livestream software for homes, offices, education institutions, stadiums and houses of worship around the world. As the demand for video capability dramatically increased during COVID-19, BirdDog Australia absorbed the pressure on their supply chain and manufacturing business operations. Having identified the need to fund growth with additional cashflow, BirdDog Australia was recommended the support of Export Finance Australia. Our Victorian Business Development team worked with BirdDog Australia to understand their business and helped them secure the right financial solution. We provided a working capital facility to assist BirdDog Australia increase its manufacturing output, maintain large orders and keep up with growing demand. Our support also meant that they could win business opportunities for international growth. “Without Export Finance Australia, we would have merely grown at a moderate rate, and missed out on export opportunities across the globe, thereby stifling the business and our trajectory,” said their Chief Financial Officer and Finance Director, Barry Calnon. “We’re going to keep growing and enjoying the support that Export Finance Australia have given us.”

5. Protect against risks Working in overseas markets could expose your business to a range of risks. Researching on country profiles could help you understand the different risks of doing business around the world. Particularly with financing, it’s important to negotiate payment terms that work for you – for example, securing a deposit up front. You should also choose a robust payment method to protect yourself from any payment risks. Our range of financial solutions, including loans, bonds and guarantees, cold help your business offset such risks.

Talk to us. We’re helping manufacturing businesses take on the world, and we could help you. Talk to us about our range of financial solutions. Call our experienced team on 1800 093 724 or visit our website Philip Smith is Business Development Director, VIC & TAS, Export Finance Australia. www.exportfinance.gov.au

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Calculating ‘safety stock’: the key to minimising supply chain risk Panic-buying earlier this year and the resultant empty supermarket shelves have highlighted the importance of determining appropriate inventory levels. Levi Martins explains. The retail surge of March 2020 saw a rise of 8.5% in retail trade according to the ABS, the strongest rise since it began tracking retail trade. Whilst the panic buying saw empty shelves in supermarkets, what often goes unseen are the Australian manufacturers behind the scenes struggling to fill this unprecedented demand. Determining appropriate inventory levels is one of the most important and most challenging tasks faced by supply chain managers. If you carry too much inventory, you tie up money in working capital and risk writing off perishable goods; if you don’t carry enough inventory, you face stockouts.

What Is Safety Stock? In any supply chain planning, safety stock (sometimes known as ‘buffer stock') is extra stock to cover demand or supply variability and to avoid stockouts. Think of safety stock as serving as a type of insurance against unplanned supply chain events. For example, a supplier may deliver their product late, the warehouse may be understaffed or items may be received that are below the usual level of quality. There’s also the chance that a competitor may be sold out on a product line, which leads to increasing demand for your own product. The cycle stock portion of the inventory equation might be straightforward. But what really keeps people up at night is safety stock, and how to determine the appropriate level. Safety stock enables organisations to satisfy customer demand in the event of these variables. Panic buying during March and April of 2020 saw many manufacturers facing high levels of variables, forcing rapid changes to the planning process to meet increased demand. Some operations managers rely on gut feelings or hunches to set safety stock levels, while others base them on a portion of cycle stock levels — such as 15 or 25%. While they are easy to execute, these techniques generally result in poor performance or leave you with other stock management issues. Perishable products make the game even more challenging because they are particularly susceptible to spoilage, especially if there are improper storage conditions. Safety stock determinations are not intended to eliminate all stockouts—but they can reduce many of them. While designing for a higher service level would result in fewer stockouts, this requires significantly more safety stock. There must be a balance between inventory costs and customer service. By using different methods and equations, you can still find safety stock levels that help you achieve your desired customer service levels.

Safety days of supply Being profitable in these scenarios is reliant on the proper management of inventory, and this is where supply chain planners are the behind-the-scenes rock stars. Using a formulaic approach to safety stock helps rationalise the required levels of inventory to the business, while balancing the need to deliver on customer service and minimising costs of higher stock on hand levels. Inventory issues are one of the biggest problems impacting profitability in manufacturing. Developing production plans by simply dividing annual demand by the number of forecast periods has been the approach for many food and beverage companies,

but this doesn’t take seasonality, trends, cost of production and carrying costs into account. Other companies will base their figures on "safety days of supply” (or safety coverage). The days of supply refers to the number of days of demand that your safety stock can service. The days of supply may include the inventory held to satisfy certain and uncertain demands. To calculate how much you should produce or purchase against safety days of supply, you need to sum the projected demand for the next “safety days” number of days. Once you’ve set a safety days coverage, you should also calculate your number of days of supply. This is calculated against your current holdings, asking the question “If I didn’t receive any other supply, how many days would I have before running out of stock?” Sadly, Excel (which is the number one tool used by supply chain planners) doesn’t have the simplest formulas to calculate Safety Days or Days’ Supply. This means planners tend to use static approximate safety stock calculations, since this is what they can produce in a spreadsheet. Supply chain planners need an easy-to-use system that can perform the calculations quickly and generate credible results.

Improving the supply chain planning process One way to simplify the process around safety stock and general stock planning is to use the right tools. That way, you can not only stay on top of planning, but take advantage of other features to fine-tune your forecasting. The biggest benefit of having a tool for supply chain planning, among other features, is being able to clearly see the stock levels and quickly calculating safety days in one application, such as the customisable TilliT Planner designed to address production planning challenges. SAGE Group company Nukon specialises in delivering digital transformation for companies and has a number of clients who already use their advanced planning solution - TilliT Planner to address production planning challenges. When developing this part of software suite, the team at Nukon made sure safety days of supply was one of the features. TilliT Planner can draw on the real-time existing stock levels and customer demand to calculate the correct stock you will need to be covered. All calculations are made for you, instead of having to refer to multiple spreadsheets and formulas. Levi Martins is a Senior Consultant at Nukon. www.nukon.com

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FORUM LAW

Return to work – Managing COVID-19 risks What COVID-safe practices should a business implement if their workers cannot work from home? Rob Jackson explains. As COVID-19 infection rates drop dramatically, Victorians welcome back normality. Or something close to it. Since 11.59pm, 8 November, metropolitan Melbourne entered the third stage of reopening, in line with regional Victoria. Manufacturers, like all employers, must be vigilant in managing COVID risks before re-opening the doors. Manufacturing workers cannot work from home, and the layout of a factory may make physical distancing difficult to achieve. So, what should a business do?

Get a COVIDSafe plan Every Victorian workplace must have a COVIDSafe Plan based on six key principles: 1. Physical distancing, where work is performed 1.5m apart, and the 4sqm rule is applied. Continue to work from home, if possible. 2. Wear face masks with the provision of face masks and other personal protective equipment (PPE). An employee must wear face masks. 3. Good hygiene practices by supplying effective sanitiser, ensuring frequent surface cleaning. 4. Keep records of all people (workers, visitors, customers, suppliers) who enter the workplace. 5. Avoid interaction in enclosed spaces, and where possible enhance air flow. 6. Create workforce bubbles to minimise cross-infection between the workforce, staggering work start and finish times, and lunch breaks. A manufacturer within metropolitan Melbourne must also keep cleaning logs, provide PPE training, ensure daily cleaning for all areas accessed by workers and clean between shifts. A worker must declare they are free of COVID symptoms before starting work. Further, manufacturing is one of seven designated ‘high risk’ industry sectors. The other five are closely related to manufacturing: warehousing, supermarket and chilled distribution, postal, and wholesale. The remaining sector is the care industry. All sectors, apart from manufacturing, must have a High Risk COVIDSafe Plan, unless involved in meat and seafood processing. Construction, pharmaceutical and medical suppliers are no longer considered high risk industries. A new initiative is the COVID Marshal to ensure somebody has specific responsibility for complying with a COVIDSafe Plan. Marshals must be appointed to all Victorian abattoirs and meat processing facilities, and to all Melbourne-based supermarket and chilled distribution centres. Also, public gyms, casino and gaming facilities must have COVID Marshals. For all other sectors, such as manufacturing, a COVID Marshal is recommended. A COVID Marshal must do what any safety-conscious business should already be doing - proactively managing workplace safety. To support manufacturers in their return to work preparation, in addition to information on numerous websites and telephone support lines, free accredited infection control training has been made available to employers in a high risk industry. (1)

Day one A business should induct returning workers as if they are new starters and this includes all employees: casuals, part-timers, volunteers,

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labour hire employees, and also contractors. The return presents a valuable opportunity to consult and discuss safety. Keep attendance records; ensure individual responsibilities are clearly allocated in writing concerning for example hygiene practices and face masks, distancing in the lunchroom, visitor protocol, keeping a register. Workers will be distressed by lengthy absences from workplace due to social isolation, family responsibilities, childcare, elderly parents, family discord and many other factors. An employer must anticipate these risks, and have counselling services available. Psychological risks are as important as the physical risks, and form an important part of a business’ risk management strategy. Poor management practices will increase legal risks such as bullying or WorkCover claims. It is important supervisors and managers are supported to look after their own health, before they try and deal with an employee’s distress displayed in the workplace. Working from home has benefits: no commuting, no interruptions, no risk of infection. Or, carer or family responsibilities may dictate staying at home, prompting a request for flexible working arrangements under the National Employment Standards. Or a business may restructure its business model to rely on home-based working. This may give rise to an obligation to consult under an award or enterprise agreement. Checking and updating the employment contract is also wise. A sick employee, however minor the symptoms, must stay away from workplace, and obtain medical advice. An employer may provide financial support, or seek government assistance. An employer has an obligation under section 22 Occupational Health and Safety Act to monitor the health of employees and workplace conditions, and provide information in appropriate languages. An employer must not turn a blind eye. And if there is a positive case, an employer since 28 July 2020 must notify WorkSafe of a ‘confirmed COVID-19 diagnosis’ by calling WorkSafe immediately on 13 23 60, and submitting a written notification within two days. Fines can be imposed for a failure to notify.

Future trends There is no going back to the pre-COVID normal workplace! Employers and workers have learnt what can be achieved away from the workplace, leading to a questioning of what the postCOVID workplace will look like. The Australian Council of Trade Unions is calling for a right to Work From Home, relying on a recently published survey of 10,000 employees. Enterprise bargaining is likely to see such clauses negotiated. A manufacturer will need to stay a step or two ahead on safety, and not just perform the minimum required by law. What will your business do? Think now, and consider not only the risk of infection in its own right, but also of the human effect, on workers holistically as part of a risk management system. Rob Jackson is a Partner in Rigby Cooke’s Workplace Relations, International Business and Manufacturing groups. Rob has extensive experience in employment and industrial relations, occupational health & safety, workplace investigations and employment related migration. Ph: + 61 3 9321 7808; E: RJackson@rigbycooke.com.au www.rigbycooke.com.au (1)

See generally www.coronavirus.vic.gov.au

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How COVID-19 lockdowns are affecting communities mentally Brendan Torazzi takes a closer look at the mental impact of COVID-19 lockdowns, the signs to look out for, and the advice and resources available. The first case of coronavirus in Australia was reported on January 25, 2020. By the end of October, the country had over 27,000 confirmed cases, many in Victoria. As the biggest city in Victoria, Melbourne was hit by the coronavirus particularly hard. Officials even imposed a curfew between 8 pm and 5 am to help contain the virus. The lockdowns may have helped slow the virus, but they also took a toll on people’s mental health.

The signs to look out for while adapting to the “new normal” Coronavirus restrictions were first nationwide in March and April. Victoria introduced additional lockdown conditions at the beginning of July as the daily case count rose. Metropolitan Melbourne endured a long period in stage four. Fortunately, the government has now eased some restrictions, but many remain in place. When Melbourne entered stage four of the lockdown in September, the government also had a curfew in place and heavy restrictions on travel. These restrictions are designed to slow the spread of the coronavirus. Unfortunately, dealing with these restrictions can lead to a wide range of physical and mental health issues.

What can you do to help protect against mental health problems? If someone is experiencing suicidal thoughts, do not hesitate to contact medical professionals or a suicide hotline. However, some situations are less urgent, such as helping someone through their depression or anxiety. To help yourself or others cope with the negative aspects of social isolation and coronavirus restrictions, find distractions. Taking up a new hobby which interests you can help keep the mind busy, which is one of the challenges of isolation. Maintaining a routine is also helpful for dealing with lockdowns. Following a routine provides structure and gives you more control over your daily life. This leads to a greater sense of self-reliance, which may ease anxiety. Exercise is also a top recommendation for protecting against mental health. Getting your blood pumping provides oxygen to the brain and promotes better cognitive function. With a healthy body, you are more likely to have a healthy mind.

Do the benefits of lockdowns outweigh the costs?

Understanding the psychological impact of lockdowns

The lockdowns have led to a spike in depression, anxiety, and other mental health issues. However, the alternative to the lockdown is allowing the virus to spread uncontrollably.

Social isolation and the anxieties related to the coronavirus have taken their toll on people from all walks of life. Staying indoors and isolating from others is known to create a wide range of negative effects, such as an increased risk of:

The coronavirus has already cost the lives of over 900 Australian citizens. Without social distancing, masks, and the closing of nonessential services, there would likely be far more deaths and hospitalisations from the virus.

• Depression

• Anxiety

• Stress

• Cognitive decline

Mental illness is a serious issue, but the loss of life is also significant. There are resources available to help those who are suffering from depression and anxiety due to social isolation and the fear of the virus. However, there are no resources for bringing people back from the dead.

One study found that about 35% of people experienced some form of mental distress at the start of the pandemic. The pandemic enhances people’s anxieties. However, lockdowns may add to the problem. When people are forced to stay home, the limited socialisation they receive may not be adequate. People are more likely to become withdrawn and despondent, which leads to depression. Limited social contact and confined spaces are also known to increase the risk of cognitive decline.

How to detect mental health issues in yourself and others People are generally good at hiding their feelings, which can make it difficult to detect mental health issues. You may even lie to yourself about your own mental health. Here are some of the signs that you should look out for in yourself and others: • Loss of appetite

• Restlessness

• Lack of interest

• Muscle tension

• Fatigue

• Anger

• Reckless behaviour

• Lack of concentration

Some signs may be subtle while others are more obvious. The main thing to watch for is changes to a person’s overall demeanour. When people suddenly change their attitude or behaviour, there is likely an underlying cause, which may be related to a mental health issue brought about by the lockdowns.

What can we learn from this whole situation? The coronavirus was a wake-up call for many, as it showed the strengths and weaknesses of the way that governments responded to a pandemic. If anything, the situation has taught the public that limiting the spread of a virus requires sacrifices. For the greater good of the country, people may need to deal with continued restrictions on travel, work, and socialisation. However, there should also be help available for those who are suffering from mental health issues brought about by the restrictions. If the country continues to stay locked down, continue to pay attention to the signs of mental health in yourself and others. Do not hesitate to receive help when necessary, even for symptoms that may appear minor, such as depression. Suggested websites of companies specialising in mental health are listed below. Brendan Torazzi is the CEO of AlertForce - a registered training organisation specialising in short Health and Safety courses to meet compliance. Brendan also runs the Australian Health and Safety Business Podcast and is the owner of OHS.com.au, an online marketplace for safety courses. Ph: 1800 900 222 www.alertorce.com.au www.OHS.com.au www.beyondblue.org.au www. lifeline.org.au www.vichealth.vic.gov.au/search/coronavirus-information www.vichealth.vic.gov.au/media-and-resources/coronavirus

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AMTIL INSIDE

Taking stock of the year In writing my CEO report for our recent Annual General Meeting, I needed to concentrate on the specific period the report addressed, being July 2019 through to June 2020. It is obvious that the COVID pandemic had an impact on the latter half of the financial year, but a lot took place prior to this global crisis hitting us in March 2020. I thought I would share some of my report with our readers. Being a non-Austech year we concentrated efforts on running many events around the country, celebrating our 20th year of operation. We had some fantastic events starting with our Victorian member function at the SEA LIFE Melbourne Aquarium in August 2019. We ran around 30 events including business breakfasts, CEO dinners, member focus sessions, networking functions and social activities. We will continue to change the range and type of events to engage with the membership and provide the networking and opportunities they are looking for. In particular, more effort on running virtual events and webinars will improve our knowledge dissemination to members. The advertising support we receive from our members for AMT magazine is sensational. We are very proud of the regular feedback we receive, which reiterates that AMT is very well regarded and respected in the industry and I would like to thank our members who have supported our magazine over the past year. We have been much more active on social media, with almost daily news and information being shared through Twitter, LinkedIn, Facebook and Instagram. This move has allowed us to have even more focus on great Australian stories and positive news. We also continue to keep our members up to date with our regular Hotspot communication. This is our way of passing on anything that comes across our desks that we feel is of interest to members, whether it be opportunities for work, networking functions, information on running a business, funding prospects from Government or specific industry information. Our work with the Federal Government continued, though our involvement as a Partner Organisation for the Entrepreneursâ&#x20AC;&#x2122; Programme finished up in June. We will continue to support this initiative and hopefully be involved again in the future. We continued our administration and management of the Additive Manufacturing Hub, supported by the Victorian Government. This is a one-stop shop for the sector, which has delivered industry capability, a grant program to encourage design and business case analysis, and overall communication mechanisms that will boost investment and take-up of this technology over the next few years. We were also funded by the Commonwealth to undertake some work in the truck, tram and train sector with a view to developing export markets, but we unfortunately had to withdraw from that work due to a lack of financial support at state level. This was a disappointing outcome as the opportunities for growth in these areas are substantial. We continue to work with the Advanced Manufacturing Growth Centre on initiatives and we are looking forward to having a closer involvement with them as they have been extended for a few more years. The work we have been doing in this area has brought us closer to other industry groups and government departments and this is certainly an advantage to us as we seek to address the industry issues facing our membership. This will be a core focus for us over the coming years. I would like to take the opportunity to thank all our members, our Board of Directors and all the staff at AMTIL for their support and commitment over the past 12 months. Have a great Christmas and New Year and I look forward to seeing or speaking to you in 2021.

Shane Infanti, CEO AMTIL

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AMTIL HEADING INSIDE

Board changes, life members announced at AMTIL’s virtual AGM AMTIL held its annual general meeting (AGM) on 27 October, with the event taking place online for the first time. The AGM saw the appointment of a new member to the AMTIL Board, as well as the confirmation of two new life members. The decision to hold the AGM online had been in response to the COVID-19 pandemic, but it also allowed the participation of members from much further afield, with around 90 AMTIL members logging in from across Australia. While conducting the AGM through video conferencing marked a big change from previous years, proceedings went smoothly, with voting on AMTIL matters taking place through onscreen polls rather than the usual show of hands. Proceedings kicked off with a keynote address from guest speaker Mike Rolls. In September 2001, Mike contracted meningococcal septicaemia, one of the deadliest diseases on the planet. He lived to tell the tale, but the infection left him with horrific internal and external injuries, including the amputation of both his legs. However, Mike refused to be set back by the illness, and has used his experience as a springboard to personal and professional success. In telling his inspirational story, Mike drew incisive parallels between his experience and the challenges we’ve all faced during 2020 as a result of the COVID-19 crisis. “We all have our individual battles, and there is absolutely no good comparing our own situation to someone else’s” said Mike. “What I do know is that we are all far more resilient than we give ourselves credit for. And what I do know is that in the face of an impossible challenge, when we choose to ask ‘What’s next?’, remarkable things can happen.” Following Mike’s talk, the AGM itself took place. AMTIL President Brigitte Stavar gave the opening address, while board member Adam Nichol provided a summary of AMTIL’s 2019/20 financial report. In addition to the usual AGM business, AMTIL welcomed a new member to its Board, with Pat Green of Automated Solutions

Australia confirmed to replace Paul Fowler of Dimac Tooling. Paul is stepping down after 12 years on the Board, including a term as President from 2012 to 2019. Paul was also confirmed as a life member of AMTIL, along with Pat Boland of ANCA, who preceded Paul as President. “On behalf of the Board, to all the staff led by (AMTIL CEO) Shane Infanti, your resilience and hard work has been remarkable, managing working remotely through this crisis supporting members and keeping the finger on the pulse,” said Stavar. “I would like to take this opportunity to thank all the Directors on the Board of AMTIL, for their invaluable commitment to the organisation, navigating and responding to the impact of COVID-19 on our industry during this stressful period.” Finally AMTIL CEO Shane Infanti provided an update on the Association’s activities over the previous year. He also detailed AMTIL’s plans for the future – most notably its new exhibition, Australian Manufacturing Week, which is scheduled to take place alongside Austech in March 2022. “I would like to take the opportunity to thank all our members that have been involved in our activities over the past 12 months,” said Shane. “Your input is valued highly. I would also like to thank the Board and Directors of AMTIL, who have given such good guidance and support to the Institute over a long period of time. To all the staff at AMTIL, your commitment and dedication to the members is valued highly by myself and the Board. I thank you sincerely and look forward to the coming year or two with great anticipation.” www.amtil.com.au

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AMTIL gratefully acknowledges the support of its Corporate Partners. AMTIL’s corporate partners offer a selection of products and services that will benefit our members in their business. For any enquiries about our Corporate Partnerships, and how they can benefit you, contact Anne Samuelsson on 03 9800 3666 or email asamuelsson@amtil.com.au

Our Partners. Our Members. Your Benefits.

www.amtil.com.au

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AM Hub, TBGA team up on training AMTIL’s Additive Manufacturing Hub (AM Hub) has signed a Memorandum of Understanding (MoU) with The Barnes Global Advisors (TBGA) engineering consultancy to deliver training solutions for Australia’s additive manufacturing community. Based in Pittsburgh, Pennsylvania, TBGA is the world’s largest independent additive manufacturing engineering consultancy. It helps companies work through the adoption of additive manufacturing processes, covering strategy, design, leadership, training, materials and economics. TBGA’s CEO and founder John Barnes previously worked with CSIRO, where he helped establish the Lab22 Innovation Centre, one of Australia’s leading centres for metallic additive manufacturing. TBGA’s team of specialists collectively boasts well over 130 years of experience in additive manufacturing. The company already has a well-established presence in the UK and Europe as well as across the US. With its new partnership with the AMHub, TBGA’s additive manufacturing training is now available on five continents. Initially TBGA will be offering the Additive Manufacturing Certificate for Engineers, Managers and Executives, delivered in collaboration with Purdue University’s Online College of Engineering. The Additive Manufacturing Certificate Program is ideal for professionals with a manufacturing background and is designed to bring you from novice to broad awareness. As an online course, training can be undertaken at your pace and in line with your schedule. “TBGA has an unrivalled reputation when it comes to helping manufacturers bring additive processes into their operations,” said John Croft, Manager of the AM Hub. “The Additive Manufacturing Certificate Program is a recognised course delivered by Purdue University, a highly regarded US university with outstanding credentials in the additive manufacturing space.”

Further down the line, TBGA will also be delivering a range of additional training options, including shorter and more specialised courses, that will also be available via the AM Hub. “This will be the first of a series of courses that will be developed around additive manufacturing which will be offered as we move forward,” Croft added. “Our plan is to engage with the Australian manufacturing industry by bringing a range of short courses brought to you by experienced industry leaders to start the building skillsets around additive manufacturing!” Led by AMTIL and supported by the Victorian Government, the Additive Manufacturing Hub has been established to grow and develop additive manufacturing capability. To find out more, contact John Croft, AM Hub Manager, on 03 9800 3666, or email jcroft@amtil.com.au. www.amhub.net.au www.barnesglobaladvisors.com

Get a helping hand with HotSpots Have you ever had a piece of work that needed doing, and you just didn’t have the time or resources to get it done yourself? That’s where AMTIL HotSpots can help you out. Maybe your company is involved in a big project, but your workshop or workforce just aren’t big enough to handle the volume required. Perhaps you need a specific component made, but you lack the capabilities in-house. Or maybe your business is diversifying into a new area and needs some outside expertise. Often finding an organisation who can help is the hardest part of the problem. AMTIL’s HotSpots service can simplify the process. Available specifically to AMTIL members, HotSpots is an incredibly powerful way to reach large numbers of key decision-makers from across the manufacturing sector. Details of a range of current opportunities go out in a regular AMTIL HotSpots email, which also includes information about significant issues affecting our industry, details of AMTIL services, upcoming industry events, and advice on ways to help you improve your business. HotSpots provides a range of useful information and resources of relevance to Australian manufacturing. HotSpots is designed to help businesses connect, informing them of the sorts of opportunities that could help their businesses to grow. So next time you have a piece of work that needs doing, don’t waste time – get in touch and get HotSpots working for you.

website. You’ll need your AMTIL membership to log in and find out more details about each individual listing.

The connections that HotSpots makes work both ways. If you’re looking for opportunities for work, HotSpots is designed to help you find them. So keep an eye on Hotspots by visiting the AMTIL

For more information, please contact AMTIL’s Membership Manager David Mohorovicic on 03 9800 3666, or dmohorovicic@amtil.com.au. www.amtil.com.au

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If you are interested in gaining access to HotSpots or you have something you feel will meet our criteria for listing, please forward them on to AMTIL for assessment by e-mailing info@amtil.com.au with the subject line HOTSPOT.

AMTIL INSIDE

William Buck: The advantages of outsourcing parts of your business Outsourcing has become a fact of life for all businesses, but it has its downsides as well as its advantages. Scott Harrington of AMTIL corporate partner William Buck offers advice on how to reap the benefits while avoiding the pitfalls. The global outsourcing industry has grown exponentially over the years but continues to have a variable reputation. In 2020, these concerns were heightened by COVID-19 with businesses shocked at how quickly their operations can be disrupted and vulnerable. Media coverage has typically spotlighted the negative impacts of outsourcing and focused on job losses to offshore competitors and damage to the Australian economy. Now we’re seeing more businesses, even start-ups, taking advantage of outsourcing to qualified professionals and using it as a tool for growth and expansion. What was once thought of as a simple way to access cheap overseas labour is now changing as more businesses look to outsource domestically – a practice known as ‘onshore outsourcing’. While onshore outsourcing is nothing new, the variety of functions that are outsourced has grown in recent years. Information technology, public relations, human resources, virtual assistance, engineering, distribution and logistics, and finance and accounting are just a handful of the services on offer.

Onshore outsource vs offshore outsource Australian companies who previously relied on offshore service providers to manage critical activities are having to review whether this still makes sense commercially and economically. COVID-19 lockdowns and the closure of borders has forced many businesses to operate with limited offshore support, if any. The pandemic has shown how quickly the benefits of offshoring can fall away. With businesses facing greater pressure, many are reassessing their business continuity risks and establishing onshore models that use local services. For many business owners and management teams, onshore outsourcing provides assurance above offshore outsourcing: • There is no language barrier or time zone challenges. • Local service providers understand the market, regulations and legislation. • Customers feel more confident dealing with domestic service providers. • More control and access to local talent pools, skills and expertise. • Minimised risk and reputational exposure not relying on global providers and governments.

Accessing world-class skills and expertise An increasing number of businesses are approaching outsourcing as a way to access the expertise, skills and technology they lack in-house. Outsourcing certain functions, such as marketing or accounting, gives a small-to-medium business access to a whole team of experts they could not employ on their own. The best service providers will invest in education, research and the latest technologies, and have experience working with other clients that have faced similar challenges.

Creating scalability and flexibility Outsourcing non-core functions of the business can provide greater flexibility, particularly for businesses going through a difficult transitionary period.

For example, a business experiencing rapid growth is likely to require additional layers of management and new business processes but may not yet be profitable enough to establish these functions. Outsourcing can lower overheads until such a time when the business can appoint additional managers or establish new processes. This can be particularly beneficial for businesses uncertain about how long their growth will last. Similarly, businesses that are sensitive to seasonal or economic changes may benefit from the additional control over the costs that outsourcing affords.

Saving time and money For many small to medium businesses, the owners or management team must wear many hats. Juggling the accounts, supervising the latest direct mail campaign, handling customer queries and IT back-up can leave little time for ‘real work.’ Outsourcing can allow the business owner or management team time to focus more productively on the business’s core capabilities while having an external expert look after the operational functions. Similarly, by eliminating tasks and outsourcing them to experts, you can create more development opportunities and ‘high-skills’ jobs for your employees. Scott Harrington is a Director in William Buck’s Business Advisory division. www.williambuck.com

Tips for outsourcing Whether outsourcing domestically or overseas, the following tips will help you to do so effectively. 1. Analyse your own business first. Look carefully at your core capabilities, only outsource those functions that are not core to the business. 2. Ask the right questions. Don’t be afraid to put your service providers to the test. Ask for evidence of past experience, testimonials or a portfolio and make sure of the quality of their work. 3. Set clear objectives and deadlines. Be specific about the deliverables you expect and be realistic about schedules. 4. Read the small print. Ensure the scope of the project is laid out in a contract and agreed to in writing. Where a specific piece of work is involved, be aware of who will ultimately own the intellectual property. 5. Monitor performance. Set milestones from the outset and stick to them. Ensure that the service provider is aware of the criteria by which they will be evaluated. 6. Manage the relationship. An outsourcing relationship works best when the business and provider work together collaboratively and in partnership.

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AMTIL INSIDE

AMTIL Events – Getting back underway in 2021 AMTIL is gearing up for a busy start to 2021 as it prepares to restart its program of social and networking events after a long year of social distancing. With 2020 dominated by COVID-19 lockdowns, AMTIL’s events calendar has been confined to online gatherings, with our Virtual Meeting webinar series proving a great success. However, as Australia begins to open up with the virus largely contained, it has now become possible to resume holding social events such as the AMTIL Golf Day and networking sessions. “Like everyone, we had to adapt quickly when the pandemic hit, and we got really nice feedback for things like the webinars we ran,” said Kim Banks, Events Manager at AMTIL. “But face-to-face social gatherings are very important to AMTIL, so we’re thrilled to be able to start running these events again. And we’re looking forward to catching up with our members too.” With the pandemic still highly active overseas, appropriate measures will be in place at all upcoming AMTIL events to ensure they are are conducted safely. Moreover, with the ongoing possibility of further outbreaks in Australia for the foreseeable future, AMTIL may be forced to make changes to scheduled events at short notice. Anyone planning to attend should always register in advance and be on the lookout for updates from AMTIL. “We want to make sure people attending our events can relax in the knowledge they’re in a safe environment,” added Banks. “Obviously there will be some things that will be different for the time being, and

that’s just the way things are these days. But it’s still good to be able to get back to something resembling normal – even if that is COVID-normal.”

exceeds availability. Any individuals who book will be placed in teams by the organisers. AMTIL would like to thank William Buck Chartered Accountants & Advisers for their generous support as the major sponsor of this event.

Networking nationwide

Tee up for Golf Day AMTIL’s annual Corporate Golf Day and Lunch will take place on 5 February at Riversdale Golf Club in Melbourne. The Golf Day will be a four-ball ambrose event with participants invited to nominate teams of four. The event includes a light breakfast, lunch and drinks, plus trophies, prizes and giveaways. Golf will commence at 7.30am, with lunch served as the golf finishes at around 1.00pm. • Date and Time: 5 February 2021. 7.00am – 2.30pm • Location: Riversdale Golf Club Cnr Huntingdale Rd & High Street Rd Mount Waverley, Victoria 3149 Places are limited, and preference will be given to AMTIL members if demand

Along with the Golf Day, AMTIL will be organising a series of Maximise Your Membership networking events around the country during February. An opportunity to learn about AMTIL’s latest initiatives as well as mingle with contacts from across the industry, these events are free to AMTIL members and include finger food and drinks. • Brisbane, QLD Tues 16 Feb, 6.00pm – 8.30pm • Sydney, NSW Wed 17 Feb, 6.00pm – 8.30pm • Melbourne, VIC Thurs 18 Feb, 6.00pm – 8.30pm • Adelaide, SA Tues 23 Feb, 6.00pm – 8.30pm • Perth, WA Wed 24 Feb, 6.00pm – 8.30pm To book your place at any of AMTIL’s upcoming events, please visit the Events page on the AMTIL website. For more information, please call 03 9800 3666, or email Events Manager Kim Banks on kbanks@amtil.com.au. www.amtil.com.au/Events

New members AMTIL would like to welcome the following companies who have signed up as new members of our association.

3DCS 9 Parker Street Mount Martha VIC 3934 T: 0418 501 707

GEETHA ENGINEERING PTY LTD 53 Willandra Drive Epping VIC 3076 www.geetha.com.au

SECURITY ONE PTY LTD PO Box 4203 Balwyn VIC 3103 www.amcogroup.com.au

AGCOM PTY LTD 94 Bald Hill Road Pakenham VIC 3810 T: 0402 399 880

RADETEC PTY LTD 710 Collins Street Melbourne VIC 3000 www.radetecdiagnostics.com

SYNAPSE DESIGN PTY LTD Brunswick VIC 3056 T: 0425 820 844 T: 0425 820 844

AMT DEC/JAN 2021

Hotspots is proudly owned and managed by AMTIL

Look further from a higher vantage point. •

You need a specific component made, but don’t have the capabilities in house.

•

Your company has landed a major project, but your workshop or your workforce just aren’t big enough to handle the volume required.

•

Your business is diversifying into an area where the expertise available within the company is not sufficient.

HotSpots is a service designed to connect AMTIL members with opportunities to help their businesses grow. That piece of work that you need done might be just the sort of opportunity they’re looking for. And by featuring that opportunity as a HotSpot, you gain access to a wealth of Australian manufacturing capability and expertise.

Our regular AMTIL HotSpots email goes out to over 1,000 people every month, making HotSpots an incredibly powerful way to reach large numbers of key decision-makers from across the manufacturing sector. Provided your opportunity meets our criteria for listing, inclusion in AMTIL HotSpots is free. If you have something you feel will meet our criteria, please forward it to AMTIL for assessment by emailing info@amtil.com.au with the subject line HOTSPOT. www.amtil.com.au/Membership/Hotspots

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INDUSTRY CALENDAR Due to the ongoing coronavirus pandemic, many industry events world-wide have been postponed, rescheduled or cancelled, while both domestic and international travel has been severely disrupted, with many countries’ borders still closed at time of going to print. Readers are advised to check direct with all event organisers for the latest information. For up-to-date advice on coronavirus, visit: www.australia. gov.au/health-advice . For more events, please visit www.amtil.com.au INTERNATIONAL ALL ABOUT AUTOMATION HAMBURG Germany, Hamburg 20-21 January 2021

CIMT China, Beijing 12-17 April 2021

STEELFAB Arab Emirates, Sharjah 7-10 June 2021

www.automation-hamburg.com/de

www.cimtshow.com

www.steelfabme.com

SMART FACTORY EXPO Japan, Tokyo 20-22 January 2021

HANNOVER Germany, Hannover 12-18 April 2021

ROSMOULD Russia, Moscow 15–17 June 2021

www.sma-fac.jp/en

www.hannovermesse.de/en

www.rosmould.com

AMTEX India, New Delhi 20-23 January 2021

EXPO MANUFACTURA Mexico, Monterrey 13-15 April 2021

IMTEX/TOOLTECH India, Bengaluru 17-23 June 2021

www.amtex-expo.com

www.expomanufactura.com.mx

www.imtex.in

ADVANCED MANUFACTURING/SUBCON UK, Birmingham 26-28 January 2021

MHL New Zealand, Auckland 13-15 April 2021 Materials Handling & Logistics expo

INTERPLAS UK, Birmingham 29 June-1 July 2021

www.advancedmanufacturingshow.co.uk

THAILAND INDUSTRIAL FAIR Thailand, Bangkok 27-30 January 2021 www.thailandindustrialfair.com

AUTOMATION & TESTING Italy, Turin 10-12 February 2021 www.aetevent.com

MACHAUTO India, Ludhiana 19-21 February 2021 Iwww.machautoexpo.in

HOUSTEC USA, Texas 23- 25 February 2021 https://easteconline.com

EUROBLECH 2020 Germany, Hanover 9-12 March 2021 www.euroblech.com

INDUSTRIE PARIS France, Paris 16-19 March 2021 www.industrie-expo.com/en

MADE IN STEEL Italy, Milan 17-19 March 2021 www.madeinsteel.it/en

ADVANCED ENGINEERING Sweden 24-25 March 2021 www.advancedengineering.se

MACHINEERING Belgium, Brussels 24-26 March 2021 www.machineering.eu/nl

AI EXPO Japan, Tokyo 7-9 April 2021 www.ai-expo.jp/en-gb.html

AMT DEC/JAN 2021

www.mhlexpo.co.nz

TORNITURA Italy, Bergamo 22-24 April 2021 Turning & lathe exhibition. www.tornitura.show

BLECH INDIA India, Bombay 22-24 April 2021 www.blechindia.com/2021

INNOTRANS 2020 Germany, Berlin 27-30 April 2021 Transport technology exhibition. www.innotrans.com

FABTECH MEXICO Mexico, Monterrey 4-6 May 2021 https://mexico.fabtechexpo.com

STAINLESS Czech Republic 5-6 May 2021 www.bvv.cz/stainless

ADVANCED DESIGN & MANUFACTURING EXPO Canada, Toronto 11-13 May 2021 www.admtoronto.com

EASTEC USA, Springfield 11-13 May 2021 www.easteconline.com

METALLOOBRABOTKA Russia, Moscow 24-28 May 2021

www.interplasuk.com

ATX WEST USA, California 10-12 August 2021 www.atxwest.com/en/home.html

VIETNAM MANUFACTURING EXPO Vietnam, Hanoi 11-13 August 2021 www.vietnammanufacturingexpo.com

FABTECH CHICAGO USA, Chicag 13-16 September 2021 www.fabtech-chicago-exhibition.com

EUROSURFAS Spain, Barcelona 14-17 September 2021 www.eurosurfas.com

WESTEC USA, California 21-23 September 2021 https://easteconline.com

EMO 2021 Italy, Milan 4-9 October 2021 www.emo-milano.com

TOOL TECH Korea, Goyang 19-22 October 2021 www.tooltechkorea.com

PLASTEC USA, Minneapolis 3-4 November 2021 Plastics Industry exhibition http://plastecminn.plasticstoday.com

www.metobr-expo.ru/en

2022

BUTECH South Korea, Busan 26-29 May 2021

MACH UK, Birmingham 4-8 April 2022

www.butech.or.kr

www.machexhibition.com

INDUSTRY CALENDAR HEADING LOCAL

Advertiser Index

COSPAR SCIENTIFIC ASSEMBLY OF THE COMMITTEE ON SPACE RESEARCH SYDNEY 28 JANUARY-4 FEBRUARY 2021 Combines the latest in space research findings with activities to enrich the global space research community to inspire the next generation of scientists and engineers. www.cospar2020.org

SYDNEY BUILD EXPO SYDNEY, ICC 3-4 FEBRUARY 2021 Australia's leading construction, architecture and infrastructure expo. www.sydneybuildexpo.com

SAFETY IN ACTION (VIRTUAL) 22-26 MARCH 2021 www.safetyinaction.net.au

AUSPACK SYDNEY SHOWGROUND 25-28 MAY 2021 Food, beverage and pharmaceutical processing and packaging sector. www.auspack.com.au

QLD TRANSPORT INFRASTRUCTURE CONFERENCE BRISBANE CONVENTION & EXHIBITION CENTRE 25- 26 MAY 2021 www.expotradeglobal.com/events/ qldtransport

LAND FORCES 2021 BRISBANE CONVENTION & EXHIBITION CENTRE 1-3 JUNE 2021 Key decision-makers, defence officials, government representatives, procurement managers and senior army officers to network with defence manufacturers, equipment suppliers and service providers. www.landforces.com.au

VICTORIAN TRANSPORT INFRASTRUCTURE CONFERENCE 2021 MELBOURNE, MCEC 16-17 JUNE 2021 Victoria’s largest transport infrastructure conference. Features presentations that discuss the prioritisation, planning and delivery of critical transport infrastructure across the state. Topics covered: Transport, Ports, Roads, Railways & Airports.

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FOODPRO SYDNEY SHOWGROUND 25-28 JULY 2021 Includes the technology and innovations to shape the future of food processing and packaging and solutions for a more sustainable world. Six zones: Ingredients, Food Science & Technology, Processing Equipment, Plant Equipment, Packaging and the new Supply Chain Integrity Zone.

Empower Software

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DESIGNBUILD MELBOURNE, MCEC 11-13 OCTOBER 2021 Trends and strategies shaping the architecture, building, construction and design sector. www.designbuildexpo.com.au

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Applied Machinery

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Hare & Forbes

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INTERNATIONAL MINING & RESOURCES CONFERENCE MELBOURNE, MECC 26-28 OCTOBER 2021 Includes global mining leaders, policy makers, investors, commodity buyers, technical experts, innovators and educators from over 100 countries in Australia’s largest mining event.

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Sheetmetal Machinery

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ViscoTec

SmartBadge 9 Sterna 85 Sutton Tools

Taiwan Intl. Machine Tool Show

Thyssenkrupp 19 51

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HISTORY

Big wheels & little wheels – the story of UK-born Australian Sir Laurence John Hartnett (1898 – 1986) Australia’s “Father of the Holden” and much more

PART 40

MISSION X (Part 2)

World War 2: January 1942. Penang fell to the Japanese a month earlier and Kuala Lumpur is now occupied. It is obvious Singapore could not be held. There is very little time for Sir Laurence to execute his dangerous plan to tow a cache of precious machine tools from Singapore to Australia ahead of the encroaching Japanese who would employ the tools as weapons

outlined my plan to the War Cabinet to load the machine-tools on to the Royal Navy floating dock and tow the lot home to Australia. "There's no time to lose. I could go right now”. "What do you want from us?" they asked. "I want an aircraft, and one or two fellows to go with me. There's a fellow called Jackson here in Melbourne. Used to be managing director of the Borneo Company when I was in Singapore. And then there's Captain John Williams the salvage expert - dependable and resourceful, with a good knowledge of ships.'' "All right," they said. Frank Forde (Deputy PM) turned to me and said: "You'll need a lot of money for this, Mr. Hartnett. I'll fix that up immediately." "Yes," said one voice at the table. "Make sure he's got plenty of gold.” As one man, they rose and wished me good luck. I left the room, and sped back to my office to get ready for a sudden departure. Meanwhile, cables had gone to all the Chiefs of Services in Singapore notifying them of the mission, called Mission X. Twenty-four hours later Jackson, Williams and I were climbing into a flying-boat at Rose Bay in Sydney, for the start of our flight to Singapore. Jackson and Williams hadn't hesitated. I couldn't tell them many details, because Cabinet had impressed on me that secrecy was essential. But then, there weren't many details to tell. It was all a half-formed plan in my own mind. Get to Singapore, order, cajole, bribe, buy, but get the machine-tools out of Singapore! The flying-boat flew north all that hot summer day. On past Brisbane, over the Barrier Reef, beyond the pretty coral atolls. At dusk we reached Townsville. The town was completely blacked out, except for the Queen's Hotel, which had lights in every window, blazing out across the Coral Sea like a lighthouse. This annoyed me intensely, and I dashed off another of my impetuous memos to someone in authority down south, complaining about it. Next morning we flew on, and landed at an R.A.A.F. base at Groote Island. A signal from Darwin was waiting for me. It told us that a pilot had just landed from Singapore and was about to return. Did we want him to wait for us, and take us, or should he return immediately? I said our captain was confident we could make the flight, but would like the officer to go with us. But the pilot preferred to push on immediately. That pilot got as far as Timor when the Japanese spotted him and shot down his flying-boat. Cabinet had heard of the loss of the flying-boat and had assumed it was our aircraft. Frank Forde went to my home and personally broke the news to my wife, Gladys, that I had been shot down. For a few hours we were considered dead. But fortunately, the true situation was made known to my wife before the day was over.

The Battle of Darwin, 19 February 1942, was the largest single attack ever mounted by a foreign power on Australia. Approx. 240 Japanese aircraft attacked the town, ships in the harbour and two airfields. Darwin was totally unprepared. More than 240 civilians and Australian and US service personnel were killed, including the post master of the Darwin post office, his family and six young women telegraphists. The 64th, and last, air raid on Darwin occurred on 12 November 1943. In total there were more than 90 air attacks on northern Australia.

The-news from Singapore grew worse by the hour. The Japanese were racing toward Singapore. There was not much time left. We were refuelling for the long hop to Singapore when a cable came from Melbourne: "Cabinet desires Mr. Hartnett and party not to proceed. Malayan situation far too serious. Now considered impossible to carry out mission." I showed this to the captain of our aircraft. “What do you think?" He thought he could make it. The prize·was too important. I decided to ignore the cable and carry on. But before our pilot could leave Darwin he had to get a pass-out. His superiors refused to give it to him. So we were stumped by red tape. Our high adventure, upon which so much had depended, had ended in a dismal anti-climax. And what happened to the machine-tools? The Japanese got them, of course, but I believe someone had the foresight to sabotage most of the really important pieces before the enemy marched in. The trip was not entirely wasted. Cabinet asked me to look Darwin over very closely and give them a report on the situation there, from a strictly unbiased observer's viewpoint. I was appalled by the incredible state of unpreparedness and the complacency. The anti-aircraft defences were meagre and disorganized. The few guns were positioned away beyond reach of their ammunition supplies. At the R.A.A.F. base they still had a huge concrete arch at the entrance gates, a perfect landmark for raiding enemy planes. "Can't you blow this thing over, or remove it? It's as good as a neon sign to any Japanese pilot who comes over!" I told some Air Force officers. They just shrugged. "Oh, don't worry, she'll be right;'' they replied. The couldn't-care-less attitude staggered me. Those people didn't seem to realize they were at war. They realized it a few days later, though, when the Japanese came over in force and pasted the town and the harbour at their leisure. Before leaving Darwin I visited a squadron of American P40 fighters that had just flown in from Brisbane. There were fourteen in all. The American pilots were very young, very tense. They had never been in action. Ten of those fourteen boys were shot down when they went up to meet the Japanese bomber squadrons as they began their Darwin bombing raid.

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT DEC/JAN 2021

To be continued…

MACHINERY FORUM (NSW) Pty Ltd 33 Brodie Street, Rydalmere NSW 2116 Ref. Mr. Heino Windhorst T. +61 (02) 96389600 E. heino@mafosyd.com.au

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AMT DEC/JAN 2021

Articles inside

A new approach to making aircraft parts

AMTIL FORUMS

MANUFACTURING HISTORY – A look back in time

WELDING

SENSORS & PROCESS CONTROL

maxon motors heading to Mars

Motoring a revival for the food & beverage industry

CSIRO and partners take aim at ending plastic waste

Variable speed drives: the dark side

Additive manfuacturing lights the way for Burn Brite

ONE ON ONE

Melvelle’s rail maintenance on track with Mazak

SHOC: 3D printing the perfect fit for visor upgrade

Raymax Applications – 25 years of laser solutions

Mazak unveils next-gen compact five-axis VMC

Sustainability woven into the fabric

New fibre laser gives JC Butko total quality control

Leussink Engineering – ever-growing capabilities

COMPANY FOCUS

Hypertherm’s XPR300 - Raising productivity, quality

Bremont luxury watchmaker doubles capacity

New MultiSwiss helps SPM progress medical turning

Deep hole drilling with high pressure MQL

Overcoming process uncertainty to reduce scrap/rework

Iscar – Stainless competence

3D printing electric vehicles: The future of automotive?

Jayco Australia – Safe working with Smart Badge

ViscoTec revolutionises dispensing applications in e-mobility

HSP 4x4 Accessories: Australian-made, competing globally

Bentley Group invests in versatility from MaxiTRANS

VOICEBOX Opinions from across the manufacturing industry

Set to charge – Australia and the EV revolution

INDUSTRY NEWS Current news from the Industry

From the Ministry

From The Union

From the Industry

From the CEO