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CONTENTS

Volume 22 Number 03 JUNE 2022 ISSN 1832-6080

FEATURES AUSTRALIAN MANUFACTURING WEEK 2022 PREVIEW AMW 2022 – Where technology meets innovation MEDICAL Preventing medical devices’ cybersecurity risks and threats RMIT research commercialisation trailblazer Precision 3D printed implants in the scan to surgery Regrowing bones with sound waves IMCRC collaboration developing laser Ellume’s COVID-19 rapid diagnostic tests MATERIAL REMOVAL Grinding robots market size to grow Suck it up EcoClean at atomic range ELECTRONICS 3D electronics enables greater integration Wearable power generators whip up watts while walking LAPP Group smoke free cabling Monash University opens world-class robot research facilty Charging ahead making vehicle components Energy Renaissance pass local government goal ADDITIVE MANUFACTURING Knaus Tabbert AG on the post processing solution KAW Engineering to 3D print metal in the Pilbara Automated post processing of 3D printed metal and plastic 3D printed cemented carbide PLASTICS Tolerance attainment in micro molding Cutting plastic Shot peen technology Using plastic dent restoration tools BUSINESS MANAGEMENT Cynthia Dearin’s five top tips in international business WELDING Collaborative robots to automate welding?

The special spot welding solution from Queanbeyan Telwater welding gear bringing results after upgrade Torch-integrated high-vacuum extraction system CUTTING TOOLS Future trends in aerospace parts Getting the most out of your flap disc FORMING & FABRICATION The evolution of HMPS VALO onshore expansion Customised machine configuration Charging around Australia Customised protective visors in 4D printing Working Iron Man welding helmet

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Australian Manufacturing Week 2022 – Preview

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Sydney will be the stage for a showcase of the latest manufacturing technology and cutting-edge innovation in June, as the inaugural Australian Manufacturing Week exhibition takes place at Darling Harbour.

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Preventing medical devices’ cybersecurity risks and threats The MTAA Cybersecurity Working Group, Anatomics and Avicena speak to AMT about good cybersecurity practices.

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REGULARS From the Editor 8 From the CEO 10 From the Industry 12 From the Union 14 INDUSTRY NEWS: Current news from the Industry 16 GOVERNMENT NEWS 25 VOICEBOX: Opinions from across the manufacturing industry 26 TECH NEWS: New and interesting technology 34 ONE ON ONE 80 COMPANY FOCUS 98 STATE SPOTLIGHT – WA & NT 100 AMTIL FORUMS 112 AMTIL INSIDE: The latest news from AMTIL 116 M INDUSTRY CALENDAR 120 ANUFACTURING HISTORY: A look back in time 122

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One on One: Mr Ludovic Labat (PhD) Ludovic Labat (PhD) is the CEO of Neo-Bionica.

He spoke to AMT about the advances in the bioelectric and neurotechnology fields.

98 Company Focus: Eilbeck Heavy Machines Charlie Eilbeck tell a great story of the family company of Toms, taking the right steps, and lifting above its weight.

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FROM THE EDITOR PAUL HELLARD

The time to move on plans is now If ever there was a time to be up close to the manufacturing industry here in Australia, it is right now.

At the time of writing, we are still approaching the Australian Federal Election. The country could indeed turn in any direction. And you have the benefit of hindsight. This election is now in the past for you, and I hope now you are looking for new challenges. There will be plenty of them out front, and great opportunities. This will be my first issue as Editor of Australian Manufacturing Technology magazine, and I’d like to wish William Poole all the best after his ten years as Editor here. Challenges and Opportunities.

There is genuine excitement for the AMW trade show after the postponement of so many events during the worst of the COVID19 global pandemic. This is the opportunity to invest, collaborate and start moving on stalled plans. A lot of the constraints are supply-side.

Anyone spending during the last two years of the pandemic could tell inflation hikes were coming, and the interest rates hikes were one the cards. More productivity might be the answer to the problem in the long term, and that will put more money in people’s pockets.

But that will be inflationary to an economy like Australia’s.

This whole election campaign has been a contradiction. Anything that people would ask of government in an election campaign, like better wages, will make the inflation and interest rate hikes even worse. The only way to bring the economy around is to begin to transition to renewables as soon as industrially possible. Part of the answer was in the 2022 Federal Budget within the vision to grow the country’s manufacturing base, with the caveat of achieving the goal of net zero emissions by 2050. Part of me is hopeful, but they’ve wasted a lot of time being dragged, kicking and screaming to this point. If you don’t understand the economics, there’s plenty of explanation out there in the market. I’ll also be compiling stories in future issues from the many manufacturers who have made the switch and are winning back healthy returns on their own terms.

As mentioned, COVID has had a debilitating effect on economies of the world over the last two or so years. This has affected workforces, logistics and shipping of stock, well, everywhere. While we are now lifting restrictions in parts of the nation, the threat of an Omicron 2022 winter variant is still quite real. It’s not over yet. The Russian invasion of Ukraine is terrifying, shaking Europe and the surrounding populations. It has its very real human repercussions as well as logistical effects regarding energy supplies. And then there’s the effect yet to come, of Australia’s largest trading partner moving swiftly and snugly into a South Pacific position everyone except Canberra saw coming.

Whoever is in the Lodge by the time AMW begins, will have a swiftly changing world to navigate. But the Australian manufacturing industry has its orders already. There is a great opportunity to invest, collaborate and start moving on plans. There will be challenges ahead as well, but they must bring home their supply lines where possible, gear up and learn fast with their industry partners.

See you all at Australian Manufacturing Week.

Editor Paul Hellard phellard@amtil.com.au Contributors Carole Goldsmith Brent Balinski Amanda Carlson Sales Manager Nicholas Raftopoulos nraftopoulos@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 FSC™ Programme for the Endorsement of Forestry Certification Chain of Custody certified from sustainable forests Contact Details AMT Magazine AMTIL Suite 10, 5 Corporate Boulevard Bayswater VIC 3153 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 $185.00 (ex GST) per annum.

Contact AMTIL on 03 9800 3666 for further information.

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AMT JUN 2022

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FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

Where Technology Meets Innovation – Australian Manufacturing Week 2022 Australian Manufacturing Week is set to welcome the world to Sydney this month, with the show being held at Darling Harbour for the first time since 2008.

Australian Manufacturing Week replaces Austech and National Manufacturing Week as the premier Manufacturing Technology and Machine Tool show in the country. Being held from 7-10 June in Sydney at Darling Harbour, the event showcases six Technology Zones, including Machine Tools & Ancillary Equipment, Welding and Air Technology, Additive Manufacturing, Robotics & Automation, Manufacturing Solutions and the Australian Manufacturers Pavilion. The last time the show was held, in Melbourne in 2019, we had visitors from 45 countries around the world – highlighting the international recognition the show has built up over the last 20 years.

We are very pleased to return to the International Convention Centre at Darling Harbour for the first time since the Centre was rebuilt in 2016. During the rebuild, Austech and National Manufacturing Week relocated to Homebush for the 2010 and 2012 shows. Whilst these years were still successful events for us, a move back to the city venue was always considered the obvious choice.

AMW 2022 takes place during a period of resurgence for Australian manufacturing. The COVID-19 crisis highlighted Australia’s vulnerability to disruptions in global supply chains, and reinforced the belief among the general public that a strong manufacturing sector is essential to our country’s future prosperity. The industry was quick to regroup and rebound from the initial shock of the pandemic, and despite subsequent outbreaks and lockdowns, has

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SYDNEY: 7-10 June, 2022 INTERNATIONAL CONVENTION CENTRE SYDNEY WWW.AUSTRALIANMANUFACTURINGWEEK.COM.AU maintained a steady upwards trajectory ever since. This mood of optimism has been evident in the preparations for AMW 2022 with the early interest both from exhibitors and from people planning to visit the show, suggesting there is strong positive sentiment across the industry and a willingness to invest for the future.

With 170 exhibitors across the six Technology Zones, the event will have something for everybody to see. I hope our readers take the time to visit the show and that it is a worthwhile experience for you.

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FROM THE INDUSTRY MEGAN LILLY – Executive Director, Ai Group Centre for Education & Training

The future of skills and training Funding and support is continually needed to update skills and training opportunities. Greater investment in, and improved approaches to skills development, education and training are fundamental to our further economic and social development.

Our approach to this challenge needs to be informed by current demands both of individuals and employers and by flexible, forwardlooking planning. The work of the National Skills Commission (NSC) on the state of Australia’s skills landscape in examining current, emerging and future workforce needs has been an important development and should be appropriately resourced to continue its work program.

Areas of particular importance highlighted by the NSC’s analysis include STEM (science, technology, engineering and mathematics) skills, skills related to data analysis, and a wide range of digital skills as well as the overarching importance of employability skills.

Alongside a strong and evolving knowledge of current and emerging skills needs, Australia also needs a coherent framework of micro and macro credentials, adaptable by industry and individuals and underpinned by a modern qualifications framework, which better connects our tertiary education sectors.

The newly released Industry Clusters model to improve industry engagement with the VET system presents a much-needed leadership role through which deep and meaningful engagement across providers and users of the VET system will occur. Importantly the engagement incorporates collaboration with the National Skills Commission, National Careers Institute and the Australian Skills Quality Authority (ASQA). A broad range of functions, including workforce planning and labour market analysis, will ensure better and more responsive implementation of changes.

The effectiveness of this new model will be crucial for Australia in meeting its future skill needs. The new system must embed skills alignment, quality, speed to market, responsiveness and innovation.

The National Skills Commission is a critical component in the revised architecture for VET. It must continue to provide data-led advice on workforce skill needs, the state of labour markets and the performance of the VET system.

Qualifications need to be able to be designed differently, combined differently and be accessible across contexts in many more varied and timely ways. This questions funding models; the role of our institutions; and the relationship between learning and credentialing.

Continued commitment to addressing long-term declines in VET funding by all levels of government is also necessary. This requires real investment in VET along with the revised funding model for national consistency and efficient pricing.

A good starting point would be implementing the recommendations of the 2019 Australian Qualifications Framework (AQF) Review, which provide an architecture for future qualifications. The reimagined AQF was designed and developed in a way that organises knowledge and skills that enable individuals to gain, retain or build upon meaningful work.

VET, university and industry partnerships

A key part of a modern qualifications framework is the need for a broad range of shorter-form ‘micro-credentials’ that align with growing and regular re-skilling needs of individuals and industries.

Central to this is the need for access to information on credential offerings for industry and the public; for coherence in offerings; and for information on where credentials sit/how they stack up in relation to specific qualifications. Ai Group supports the Review of University-Industry Collaboration in Teaching and Learning in its call for ‘responsive, industry-focused micro-credentials that offer rapid skilling into defined workplace roles’.

Improved access to micro-credentials, particularly when they are developed in conjunction with industry requires a greater commitment by government to systemwide support for microcredentials frameworks.

Coupled with this, the Australian Skills Classification has the potential to provide refreshed sets of skill descriptors that help identify transferrable skills between jobs, workforce skills gaps, and training package update requirements. Barriers to the provision of micro-credentials by education and training providers should be uncovered and removed to ensure that education and training offerings are relevant.

VET skills reform Australia’s performances against the indicators for vocational education and training remain mediocre. This reflects a number of system-wide VET issues identified in major reviews commissioned over the past few years. Major skills reforms driven by the Heads of Agreement for Skills Reform have promised to address the issues by strengthening VET qualifications and the quality of training.

The decreasing shelf life of skills means new paradigms must be created for partnerships between industry and higher education providers. Embedding collaborative cultures for skills development will assist Australia’s future success. In this regard the release of the Review of University-Industry Collaboration in Teaching and Learning is timely.

There are several examples of mainly larger companies forming strategic alliances with universities to develop and deliver new programs that align with their future business requirements. As a leader, BAE Systems Australia has recently circulated a Request for Information to other companies to collaborate on innovative education and training initiatives to nurture talent for their industry.

The company is similarly working with universities and TAFEs to achieve these ends.

Such collaborative activity now needs to be widespread, including with support provided to smaller-sized companies to recognise the benefit of, and establish relationships with, larger employers and providers. These alliances would guide the learning at universities, explore new skilling models, and help to build learning into the everyday business of companies.

With regional skill pressures exacerbated during COVID-19, regional universities will strongly benefit from support to establish greater cultures of collaboration with local industries and other education and training sectors that co-create skill ecosystems. Australia would benefit from a system of collaborative metropolitan and regional hubs, learning from the Centres of Vocational Excellence model in Europe by developing strategies to meet local skill needs and assist large and small employers in creating innovative solutions to skill challenges.

While initiatives already exist in Australia, more are needed. Funding and support for these initiatives can range from financial incentives, education vouchers, training grants and scholarships and general tax deductions. aigroup.com.au

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

At the time of writing this column, a Federal Election campaign is underway.

The data is telling us we will most likely have a Labor government. There is opportunity in this change.

The Australian Labor Party has committed to a range of important policies for our industry. A $15.2bn National Reconstruction Fund, a national rail strategy and stronger procurement protections all mean that as an industry we need to have a big conversation.

If Labor is elected, and legislation of those promises become certainties, I want to see our industry ready to step up and make the most of it.

Manufacturing has been a low priority for decades, and we’re out of practice at asking for what we need to make our enterprises thrive.

If we’re to revive our industry as one of the core components of the national economy, we need to have urgent conversations about what that looks like and where we need to start.

We need a strong, clear and attractive position on what the future of our industry looks like. We need it to be heard clearly at every roundtable, photo op and forum during and beyond this election.

As a union leader, I worry that the old industrial ideology of more power and profit for bosses, will be the short-term small vision of the business lobby in Australia.

The political spotlight is on our industry, and I want to make sure we don’t fumble it. I know union members would support a tripartite approach – of business, government and unions - to problem solve our future, provided we are able to have a mature discussion at the table.

As a union leader, I have ideas on where that money is best spent in ways that deliver significant job creation and social good for our communities.

AMWU members expect that any investment in our industry results in decent, secure jobs and products that are socially good and useful.

Also, that we work together to create safer workplaces, invest in skills and training and where the profits created are fairly shared.

The truth is though, the committed spend is so significant that national consensus is a must.

If we have a change of government, we also need a change in our national conversation.

We have all seen the real-world impacts of the decisions that have led to the decline of manufacturing in Australia. I would hate to see this opportunity squandered because of industry disunity, while we have the audience and support of the nation.

I look forward to hearing other views about how we best invest in the future of our industries and workforce.

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INDUSTRY NEWS

RUAG Australia to secure F-35 wheels and brakes RUAG Australia is the first Australian company to be granted Authority To Proceed from the US Government F-35 Joint Program Office to establish F-35 Wheels and Brakes sustainment capability in the Asia-Pacific region.

RUAG Australia has secured inaugural F-35 wheels and brakes sustainment capability in Asia-Pacific region. With Phase 1 and 2 now successfully completed, RUAG Australia received JPO ATP and will now proceed into Phase 3 and 4 to become an official Depot Source of Repair (DSOR).

The wheels and brakes sustainment capability will be exclusive to RUAG in the APAC region and support ongoing maintenance and sustainment of the fifth generation F-35 fleet. RUAG Australia will transition its highly skilled and experienced defence and aerospace technical staff from current legacy programs into the F-35 Global Support Systems (GSS).

The ATP achievement is a critical step for developing Australia’s industrial sovereign capability and delivering our commitment as one of the joint partner nations in the F-35 Program.

“RUAG Australia is the first Australian industry Component Assigned Product Service Provider (A-PSP) to complete the F-35 JPO Depot Maintenance Development Plan (DMDP) process through Phases 1 and 2, and I congratulate you and your team in achieving this important milestone” said Kirrilee McNeill, Director Industry Aerospace Combat Systems Branch, Aerospace Systems Division. Terry Miles, General Manager of RUAG Australia, notes “We have seized the opportunity to deliver

reliable wheels and brakes solutions for the F-35 Program, by leveraging our expertise and long-standing success of providing MRO sustainment for complex aircraft components, and the fifth generation of military aircraft sustainment.”

“The Australian team has embraced continuous improvement and capability development at a local level to improve global competitiveness. Long-standing relationships with customers and business affiliates will strengthen RUAG Australia’s sovereign capability in the APAC region,” said Felix Amman, Executive Vice President, RUAG MRO International.

RUAG Australia is an independent supplier and life cycle support provider of systems and components on behalf of the Royal Australian Air Force and other international air forces, as well as civil aviation, worldwide. The company combines engineering expertise with landing gear hydraulic actuator manufacture, maintenance, repair and overhaul (MRO), and metal treatment and finishing in their role as a widely approved organization.

RUAG Australia ranks as Top SME on behalf of the Australian Defence Force, features as a supplier in the Australian Defence Export Office’s Australian Military Sales Catalogue and has been inducted into the Victorian Manufacturing Hall of Fame. ruag.com.au

Cape-class patrol boats to be built in Henderson Austal Australia to supply two additional Evolved Cape-class patrol boats for the Royal Australian Navy.

Austal Limited has announced the Department of Defence will order an additional two Evolved Capeclass Patrol Boats (ECCPB’s) for the Royal Australian Navy, for $124m.

The two new vessels are in addition to the six Evolved Cape-class Patrol Boats that are currently being delivered by Austal Australia for the Royal Australian Navy.

Austal Limited Chief Executive Officer Paddy Gregg said, “We are incredibly proud to be supporting the Royal Australian Navy by providing and enhancing fleet capability; working in collaboration with the Department of Defence and Industry partners.

“This announcement for additional Evolved Cape-class Patrol Boats further strengthens and supports Australian sovereign shipbuilding capability and provides Austal, and our outstanding supply chain partners, with a level of continuity that will provide stability and security for the National Naval Shipbuilding Enterprise. Austal will also continue to invest and develop our facilities in Henderson to ensure we have the capability and capacity for the fu-ture programme of work,” Gregg said.

Austal delivered the first of the Evolved Cape-class Patrol Boats, the ADV Cape Otway last month. Eight Evolved Cape Patrol Boats to be delivered through to 2024. The Evolved Cape-class Patrol Boat is an evolution of Austal’s proven Cape-class Patrol Boat platform, first developed for the Australian Customs and Border Protection Service (now Australian Border Force) in 2013.

With eight Capes delivered to the ABF over 2013-2015 and an additional two Capes delivered to the Royal Australian Navy in 2017,

AMT JUN 2022

there are now ten Capeclass Patrol Boats operating around Australia.

In 2021, Austal Australia delivered a further two Cape-class Patrol Boats to the Trinidad and Tobago Coast Guard – the first exports of a vessel class which has become a benchmark for offshore patrol capability around the world.

Based on the original 58m aluminium monohull design, the Evolved Cape-class Patrol Boats include several enhancements that further extend the capability of the vessel and the fleet. Crew capacity has been increased by 10 people, to now total 32 and quality-of-life provisions have been enhanced, ensuring those who operate the new vessels have connectivity to the outside world, regardless of the operating environment.

The Evolved Cape-class Patrol Boats will be utilised for a wide variety of constabulary and naval missions and play a critical role in Australia’s national security, as a high-performing, reliable and effective maritime asset for the Royal Australian Navy.

In addition to the Evolved Cape-class Patrol Boat Project (SEA14451), Austal Australia is also currently delivering 21 Guardian-class Patrol Boats for the Australian Department of Defence under the Pacific Patrol Boat Replacement Project (SEA3036-1), with 14 patrol boats delivered since 2018.

Austal provides in-service support to both the Cape and Guardianclass Patrol Boat fleets through dedicated service centres located in Henderson, Western Australia; Cairns, Queensland; and Darwin, Northern Territory.

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INDUSTRY NEWS

Space mission funding boost a game-changer In the recent Federal Budget, Government announced $1.16bn to design, build, and operate four new Earth Observation satellites — the Satellite Cross-Calibration Radiometer (SCR) mission.

This funding is significant because it will enable Australia to develop an end-to-end sovereign skill base in the design, manufacture and operation of satellites for Earth Observation services. These are critical to Australia’s security and prosperity.

It will also make Australia more self-sufficient when it comes to critical Earth Observation data for the immediate action against bushfires, and flood monitoring.

“The funding will create hundreds of jobs in the first few years of developing and building these satellites,” said RMIT Space Industry Hub Director Distinguished Professor Brian Falzon. “Moreover, having an established skill base in satellite development, deployment and operation, will give Australia the confidence to pursue additional space missions, growing the sector and becoming a significant global player.

“Not only will we see job growth in the upstream sector but the data gathered, which will be of particular relevance to Australia, will also facilitate growth in the downstream sector as we develop new ways of analysing and using this data. The SCR mission will

give Australia the ability to compare and combine data from the many different foreign systems; and more importantly, reduce our dependence on any single foreign satellite system.”

By having a sovereign capability in earth observation, the current heavy reliance on foreign-owned satellites to provide data will be reduced. Australian observers will be able to determine the type of data required, which is of particular relevance and urgency at the moment. For example, this may include data from natural disasters (e.g. bushfires or floods), which is then used to rapidly develop and deploy damage mitigation strategies.

“An established skill base of critical size and capability also provides a solid foundation on which to raise the ambition and undertake more complex space missions.”

“Within the RMIT Space Industry Hub we have one of the world’s leading research groups in Earth Observation and this announcement will provide additional opportunity for the Hub to contribute its expertise in delivering this ambitious programme,” added Professor Falzon. rmit.edu.au

The budget was a missed opportunity: Rewiring Australia Subsidising pilot programs to decarbonise Australia’s homes and road fleet will minimise bills and boost local manufacturing.

The Commonwealth Budget fails to take the crucial first step on the path to decarbonising and slashing household energy bills, because it prioritises subsidies for fossil fuels over renewable-powered electrification of our homes, according to Rewiring Australia.

The 2022 Budget contained more than $10.5bn in fossil fuel subsidies, according to an Australia Institute analysis released this week, the vast bulk of which $8bn goes to the Fuel Tax Credits Scheme. “This budget was the perfect opportunity to start that process with a pilot program to electrify a sub-urb and a street.

It’s disappointing to see taxpayer dollars directed to subsidising fossil fuels rather than investing for a cheaper, cleaner future,” said Rewiring Australia chief scientist, Dr Saul Griffith.

The Budget should instead have directed money towards electrifying Australia’s homes and vehicles, replacing fossil-fuelled devices with solar panels, batteries, heat pumps, induction stoves, electric vehicles and household and community batteries.

“This budget could have been underwriting electric vehicles that run on Australian sunshine and de-velop the zero-emission vehicle market, but instead is investing in dated technology and the chief source of our domestic emissions.”

Last year, Rewiring Australia modelled the cost benefit of total household electrification for Australia's 10m homes, demonstrating how Australians could take advantage of the falling costs of electric ve-hicles, batteries, solar, and wind, to help every Australian household save money. It found a $12bn investment would retrofit 10m Australian households for full electrification by 2030 leading to national savings of more than $40bn.

And previous modelling, predicated on a petrol price of $1.46, would deliver household savings of close $5,000 per year. However, with petrol now at $2.20 a litre, the annual saving to households is closer to $7,000 every year.

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“There are profound environmental and cost of living benefits to making the big switch to renewa-ble-powered electrification,” Dr Griffith said. “When you put this in context, if we redirected one year worth of fossil fuel subsidies to an eight-year program of electrification we could smash domestic emissions by a third and obliterate energy bills and completely decarbonize all 10m households in Australia.

“Beyond the household economics this is a critical national security question. Energy independence weakens the power of oligarchs and petro-states. It is unquestionably in Australia’s national interest to decarbonize, especially our vehicles.

"Renewable backed electrification is a big step toward improving the three great problems of our time, climate heating, cost of living and national security. It is a great shame the Government’s budget missed this opportunity again,” Dr Griffith added. rewiringaustralia.org

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INDUSTRY NEWS

Volgren delivers first electric vehicles to Kinetic The first Volgren bodies are rolling off the production line in Dandenong and being delivered to Kinetic Australia’s largest bus body builder, Volgren, has delivered the first of two battery electric buses (BEBs) to Victoria’s Department of Transport and new Melbourne Bus Franchise operator, Kinetic.

The BEBs are the first of 36 electric buses that will roll off the production line in Dandenong over the next three years to join Kinetic’s Melbourne fleet, an average of one per month.

Thiago Deiro, CEO of Volgren, said the Department of Transport’s decision to prioritise green transport is already creating new jobs and demonstrates the trust that government has in locally manufactured buses. "Since the Melbourne Bus Franchise was announced last year we’ve created 30 new jobs. We hope to employ another 20 staff this year alone as production on BEBs picks up," Deiro said. "As has been the case for many years now, most of the content we use for these buses will come from the local supply chain. Australian manufacturing now offers the highest quality levels I’ve ever seen during my time in the industry. That comes from Volgren expertise, combined with the exceptional quality of materials and components

produced by suppliers throughout Victoria and Australia," Deiro said.

Deiro said the state’s transition to electric vehicles under the current Melbourne Bus Franchise agreement enables Volgren to plan, invest and make sure the vehicles are delivered on time and on budget.

"Of the 30 new employees, 11 have been enrolled in apprentice programs, including Automotive Electrical Technology, Automotive Manufacturing Technical Operations and Supply Chain. These new jobs and skills are future-proofing our business and delivering huge benefits to our community," Deiro said.

Yuri Tessari, Volgren’s chief commercial officer, said the two vehicles took around six weeks to complete. He put the “extremely smooth” build process down to detailed preparation and planning, as well as clear direction from Kinetic.

Ben Carroll and Gabrielle Williams met with some of Volgren's young apprentices who are being upskilled as a part of the rollout.

“As we’ve stated before, when project planning is properly done, the outcomes are usually excellent and that’s been the

Thiago Deiro (Volgren), Adam Begg (Kinetic), Minister Ben Carroll and Gabrielle Williams (Member for Dandenong) with the Volgren bus delivered to Kinetic.

case as we’ve worked with Kinectic,” Tessari said.

“With every BEB built, Volgren has improved its processes and we can comfortably say now that building an electric bus is second nature for our company. All three of our factories are fully prepared and can produce electric vehicles with the same speed as we produce buses using other technologies,” he said.

Volgren is on schedule to deliver a further 12 BEBs to Kinetic by the end of this year. volgren.com.au

Deakin University hosts the Advanced Manufacturing Showcase Advanced Manufacturing Showcase highlights the future of manufacturing in Australia The future of advanced manufacturing was on display on March 30th in the successful 2022 Advanced Manufacturing Showcase at the Deakin University campus in Waurn Ponds, Geelong. Jointly presented by Deakin University, MEMKO and Dassault Systèmes, the event saw over 120 experts, manufacturers, engineers and key industry players gather at Deakin University.

The event's key theme was supporting businesses by accelerating their ideas into innovative manufacturing solutions, while creating future manufacturing jobs through a sustainable, value-added economy focus that is commercially successful and positively impacts communities in regional Victoria.

A key highlight of the event was the technology ‘playground’, featuring hightech manufacturing displays from seven different companies and displaying industry leading solutions for the workforce of the future. Mark Curnow, Deakin's ManuFutures Director, launched two new 2022 initiatives. ManuFutures Ignite, an advanced manufacturing program

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to support entrepreneurs and startups to grow concepts into production, and ManuFutures Engage, a program that includes cutting-edge gap analysis using the highly-regarded futuremap tool to deliver a roadmap for emerging technologies and new business models.

Both programs offer a doorway to Deakin’s advanced capabilities and equipment as

well as multidisciplinary experts and the multimillion-dollar ManuFutures facility.

Miro Miletic and Brenton Dodd from MEMKO shared on the role of digital platforms in advanced manufacturing, and Nirajit Syamal, Dassault Systems, illustrated a day in the life of advanced virtual manufacturers. deakin.edu.au/research/researchpartnerships/manufutures

INDUSTRY NEWS

OKUMA expands service and support for Queensland customers Okuma expands its service and technical support for Queensland’s new and existing clients.

Okuma Australia has been expanding its service and technical support for its current and ever-growing list of Queensland customers in line with the Okuma business Monozukuri philosophy – ‘the art of making things better’.

With modern new Queensland premises in Hamilton and a growing team of four engineers and technical support personnel, each with a passion for Australian manufacturing, Okuma Australia is well placed and committed to advance its strong market position in Queensland.

Northern Regional Manager for NSW & Queensland, Sydney based Steve Norbis, has more than 30 years in the industry.

Steve leads a team of eleven in New South Wales and Queensland and his passion for the industry filters down through the entire team.

“We currently have a broad range of advanced technology machine orders in hand and a growing level of enquiries in the pipeline,” said Steve Norbis. “The new team appointments and expanding branch structure will ensure that Okuma’s solid presence in the Queensland market is maintained and supported thus enabling our Queensland team to maintain the level of service our customers currently enjoy and have come to expect from Okuma,” he said.

With the dedication, strength and experience of our personnel we are now well positioned to further support strong current market conditions with firm orders and enquiries coming in from both long standing and new customers,” said Branch ManagerQueensland, John Baker. “At Okuma we are known for going the extra mile with regards to training and service in particular and this will continue to be our primary focus.

Our team provides customers access to decades of industry experience and a network of local and global machine tool experts. It’s their passion, integrity, loyalty, experience and knowledge that ensure that we deliver leading edge solutions coupled with enduring partnerships,” he said.

Okuma Queensland Branch Manager John Baker training engineering clients.

As a recognised market leader, Okuma Australia is a 100% wholly owned subsidiary of Okuma Corporation, Japan and the Australian operation has the added benefit of a resident fully trained liaison engineer from the factory. With such support, the company and its clients have the distinct market advantage of not only direct factory technical support throughout Australia but extensive global support for the brand.

The Queensland branch is also backed by full mechanical service workshops in both Sydney and Melbourne to ensure streamlining repairs, refurbishment, service and replacement parts. Recent installations and commissioning of machines have been completed within major customers such as Sharpe Engineering, Gilmore Space, Upton Engineering, Gessner Industries and far north Queensland company, Perrott Engineering with more in the pipeline.

“At Okuma Australia we are committed to expanding our presence in response to our customers’ growth and needs” said Dean McCarroll, Managing Director Okuma Australia & New Zealand, “In support of corner stone industries such as Mining, General Engineering, Defence, Agriculture and Aerospace, we continue to invest in this key region with people and resources.

This is clearly evident with our continued investment in Northern Australia with the expansion of our Queensland technical and service operation.”

“I am personally excited about the future of Australian Manufacturing as I witness every day how inventive, pro-active and resilient our customers are in taking on international competition and winning, thus providing real benefits for Australia,” he said. okumaaustralia.com.au

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INDUSTRY NEWS

Premier’s Sustainability Awards – celebrating 20 years of leadership The search is on for Victorians who are leading the way to a sustainable future with entries now open for the Premier’s Sustainability Awards.

2022 marks the 20th anniversary of the prestigious awards program – one that continues to grow and reflect the action happening across industry, business and community from regional to metropolitan Victoria. This year’s Premier's Sustainability Awards will be delivered collaboratively by Sustainability Victoria on behalf of the Victorian Government, along with the Banksia Foundation and Keep Australia Beautiful Victoria.

It features six categories aligned to the United Nations Sustainable Development Goals (UN SDGs) – a globally accepted, robust and comprehensive sustainability framework.

Sustainability Victoria’s Interim CEO Matt Genever said, “We’re excited to be delivering these awards in partnership with the Banksia Foundation and Keep Australia Beautiful Victoria. By combining our experience, passion and resources, we will deliver an inspirational awards program celebrating those working towards a more sustainable future.

“We know there are tremendous strides being taken to reduce waste and litter, conserve energy, care for the environment and operate more sustainably, and we encourage you to showcase your efforts through this awards program. By recognising the innovative work being done in sustainability we aim to inspire others so that together we can progress faster towards our goal of a circular economy with net zero emissions.

“It’s so positive and uplifting to see how this awards program has gone from strength-to-strength over the past 20 years. Entries have

increased six-fold which demonstrates how sustainability is being embraced across the state,” Mr Genever added.

Two awards within each of the six categories will be presented: the Community Champion Award - for individuals and small organisations, and the Industry Leader Award - for medium and large organisations. In addition, the Premier will select two overall winners to be presented at the award ceremony: The Premier's Recognition Award, a stand-out submission from the twelve award winners and The Premier's Regional Recognition Award, a standout regional organisation/project from all qualifying finalists. These two awards cannot be entered.

“Through our new partnership, program winners will be able to connect with a larger alumni network meaning more organisations, communities and individuals can learn from other sustainability changemakers. It will be very exciting to see,” Mr Genever said.

The Premier’s Sustainability Awards Community Champion winners will have a pathway to the national Keep Australia Beautiful awards program and all winners will be eligible for the National Banksia Sustainability Awards.

The judging panel will include a broad range of independent environmental experts selected for their sustainability and industry expertise. Entries for the Premier’s Sustainability Awards closed on 1 May 2022.

Entries for the Premier’s Sustainability Awards closed on 1 May 2022. sustainabilityawards.vic.gov.au

Inaugural tech event Generate22 builds bridges for the next generation Industry experts, educators and enthusiasts convene at the inaugural Generate22 robotics and AI conference in Lilydale, Victoria.

As a major sponsor, ANCA continues its commitment to the growth and development of young people entering the robotics industry in Australia, to empower the next generation to strike up an interest in advanced technology.

The two-day conference staged in late March in Lilydale Victoria, showcased cutting-edge developments in robotics and AI and featured a host of industry expert speakers to inspire the next generation of tech gurus.

Victoria’s Lead Scientist Dr Amanda Caples delivered a keynote speech for the landmark event, while ANCA’s Head of Engineering Matt Mannix spoke on an expert panel, discussing the challenges students face transitioning from education settings to the workplace.

Mr Mannix said ANCA’s involvement aimed to open the eyes of young participants to the world of Science, Technology, Engineering and Maths (STEM). He explained the biggest barrier to pursuing careers in the field was often due to a lack of exposure, particularly for girls and women.

“The great thing about engaging students at a younger age where social constructs are not as ingrained is that both girls and boys are openly exposed to all the possibilities and equally encouraged to participate,” Mr Mannix said.

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“It gives them an opportunity to really take a look at STEM industries, and it also allows us to generate excitement for young girls and nurture pathways to greater equality and diversity,” he said.

The maiden convention encourages enthusiasts aged 12 and over to get hands on with technological design and development in the Robotics and Automation Competition. Competing as an individual or as part of the team, contenders can choose their brief, build and code a robot from scratch or add to an existing robotic system, or create a machine that makes a simple task complicated and fun.

“It’s important for people within the industry to grow our networks at events like this so we can ultimately inspire young people to embrace studies and careers in advanced technology,” Mr Mannix said.

Event organiser Exaptec Robotics CEO Nicci Rossouw said there was a huge appetite from automation, robotics and AI experts to develop a platform to inspire a new generation.

“Generate22 is a fantastic opportunity for all these stakeholders to have open and constructive discussions about Australia's growing tech industry,” said Rossouw, “and how we are going to support it in future years for generations to come.” generateconference.com.au

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INDUSTRY NEWS

PhosEnergy to develop nuclear batteries Funding PhosEnergy’s long-life, reliable, maintenance and fuel-free nuclear battery technology for space.

The University of Adelaide’s industry partner PhosEnergy has received a grant under the Federal Government’s Cooperative Research Centres Projects (CRC-P) Grants scheme to work with the University on development of next-generation nuclear batteries. The University's Deputy ViceChancellor (Research), Professor Anton Middelberg said: “This latest funding will help University of Adelaide experts to work with our industry partner PhosEnergy on research that will directly improve the capability of the defence and space sectors. “This funding will help our defence forces have access to cutting-edge technology that will help to ensure the safety of our nation and that of our trusted allies.

“A long-life, reliable, maintenance and fuel-free power system for low-Earth orbit, lunar and deep-space applications is critical for enabling the next phases of space exploration.”

“The burgeoning space industry and increasingly sophisticated remote defence sites where power-hungry technology is located are creating enormous demand for long-life, fuel-free power sources,” said Bryn Jones the Managing Director of PhosEnergy.

A grant of $2,427,689 will be used to further develop PhosEnergy’s long-life, reliable, maintenance and fuel-free nuclear battery technology for space and defence industries and to improve the availability of people skilled in this area. “We will progress to the development, commissioning, and validation of a capable pilot manufacturing process that can produce battery prototypes for enduser evaluation,” said Scott Edwards, General Manager - Generation Technologies at PhosEnergy Limited. The GenX technology was invented by PhosEnergy’s Managing Director Bryn Jones and Chief Scientist Dr Julian Kelly. “The burgeoning space industry and increasingly sophisticated remote defence sites where powerhungry technology is located are creating enormous demand for

long-life, fuel-free power sources,” said Jones. “The global market for power generation in space is already estimated to be worth US $2.8bn a year and is forecast to continue double-digit growth for the foreseeable future, with the focus on extended missions and long-term habitation and sustainable resource recovery on the Moon.”

The University’s Professor Nigel A. Spooner and Associate Professor Tony Hooker from the School of Physical Sciences in the Faculty of Science, Engineering and Technology, will lead the University’s role in the project. “The space and defence industries currently need more effective technology for remote power generation as it currently limits their capability,” said Professor Spooner.

“What sets this new generation of nuclear batteries apart is that they use beta particles unlike current batteries which use plutonium.

By selecting the beta isotope used we can customise battery life according to different applications.”

Secured integrated communications and sensor developments are driving the requirement for a portable and autonomous long-term power source. Professor Spooner and Associate Professor Hooker work in the University’s Prescott Envi-ronmental Luminescence Laboratory (PELL) and the Centre for Radiation Research, Education and Innovation (CRREI). Professor Spooner’s research commitment is divided equally between the University and the Defence Science and Technology Group.

In addition to Adelaide company PhosEnergy Limited and the University working together on the project, the partnership includes DEWC Systems Pty Ltd, Duromer Products Pty Ltd, the University of South Australia and the University of Western Australia.

Cooperative Research Centres Projects (CRC-P) Grants provide funding for short-term re-search collaborations. adelaide.edu.au

Ivanti Wavelink to turn data into actionable insights Ivanti Velocity empowers customers to further improve operations through automation and actionable insights leveraging Ivanti Neurons for IIoT platform.

Ivanti Wavelink, the supply chain business unit of Ivanti, has announced a new offering that delivers operational insights for new and current Ivanti Velocity customers. These insights enable KPI user cases, helping customers to make the right decisions and further improve sup-ply chain operations.

The complexity of warehouse operations has increased over the past decade, thanks to rapid technological changes and the rising demand for better products and services. At the same time, many operational leaders have struggled with limited visibility and ineffective data, making it difficult to make informed decisions and manage intricate supply chain processes.

With the new operational insights offering, Ivanti Velocity customers can leverage real-time data gathered from their rugged devices and day-to-day processes and take immediate action to improve workflows.

The out-of-the-box offering provides actionable insights into warehouse operations. For exam-ple, it can track how long it takes to complete an order or how long it takes for an employee to travel from one location to the next. It can also identify issues

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with bad bar codes, damaged goods, incorrect location details, cargo snaps, and more. Operations managers can then use that data to improve operations and build workflow automation around certain processes to trans-form the supply chain.

“I’m excited for our customers to leverage our Ivanti Neurons for IIoT platform and integrate Ivanti Velocity to further improve efficiencies and enhance workflows through automation,” said James Reilly, Senior Territory Manager ANZ, Ivanti Wavelink.

“Currently, if there is a damaged barcode scanner that doesn’t get reported, it slows down productivity or impacts accuracy in picking. This new solution easily solves those common challenges. It enables customers to get operational predictability while tracking warehouse KPIs on a consistent basis and increase productivity, efficiency, and customer satisfaction.”

With these operational insights, customers with Ivanti Velocity can immediately connect to Ivanti Neurons for IIoT to achieve enhanced visibility into order management, inventory management, resource planning, and transportation management. ivanti.com/wavelink

GOVERNMENT NEWS

The AUKUS defence alliance to cooperate on Hypersonic weapons and electronic warfare applications.

US, UK and Australia will cooperate closely to develop hypersonic weapons and electronic warfare capabilities.

Australia, the United Kingdom and the United States in a grouping known as AUKUS, have agreed to cooperate on hypersonic weapons and electronic warfare capabilities, the leaders of the three countries have said.

The development follows the creation of the AUKUS defence alliance between the three nations in September last year, which prompted Australia to cancel a contract for a conventional French submarine in favour of a nuclear submarine programme supported by the US and UK, damaging relations with French President Emmanuel Macron.

In a joint statement in early April, the AUKUS leaders – UK Prime Minister Boris Johnson, US President Joe Biden and Australian PM Scott Morrison – said they were pleased with the progress of the programme for conventionally armed, nuclear-powered submarines for Australia, and the allies would co-operate in other areas too.

The Australian Department of Defence had reviewed 19 potential sites and estimated a $10 billion cost for the base at one of the preferred east coast sites to add to an existing base near Perth.

Steps had already been taken to ensure Australia had the workforce to the necessary training and qualifications to manufacture, operate and service the nuclear submarines, according to source from each of the three countries. The federal government is also taking initial steps to secure additional land to build a construction yard

for the nuclear submarines, including land adjacent to the existing Osborne North Shipyard in Adelaide. The leaders said they were “committed to commence new trilateral cooperation on hypersonics and counter-hypersonics, and electronic warfare capabilities, as well as to expand information sharing and to deepen cooperation on defence innovation,” they said.

“These initiatives will add to our existing efforts to deepen cooperation on cyber capabilities, artificial intelligence, quantum technologies, and additional undersea capabilities. As our work progresses on these and other critical defense and security capabilities, we will seek opportunities to engage allies and close partners.”

While the US and Australia already have strategic agreements with a hypersonic weapons program call SCIFiRE, the UK isn’t involved in that program at this point. Hypersonic missiles travel at five times the speed of sound, flying on a trajectory low in the atmosphere, as opposed to a ballistic missile which flies in a high arc into space on its way to the target, making it easier to track and defend against.

The three countries are continuing to work together on R&D in this area to increase their options. The US, UK and Australia launched their landmark security pact last September. The pact was proclaimed at the time as allowing the three allies to share advanced technologies. Source: News Agencies

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Making way for observability Why Aussie manufacturers need to embrace end-to-end visibility across modern technologies. The Vice President & General Manager, Asia Pacific & Japan at LogicMonitor, Richard Gerdis, brings it all into clear view.

The manufacturing sector has been experiencing a shift to the digital world for a long time. Over two decades, the industry has been able to uproot its traditional methods and transform them to maximise performance, output, and productivity.

Advanced technology has been the catalyst for this evolution, with innovations constantly pushing boundaries and exceeding what we once knew possible.

In this new age, it is imperative manufacturers are armed with tools that allow for smoother processes, ultimately working towards scaling up and cementing themselves as leading competitors. The 2022-23 Federal Budget announced its injection of over $1bn into Australian Manufacturing, adding to the Modern Manufacturing Strategy, aiming to accelerate growth and create jobs. It is paramount these investments prioritise emerging technology to support a prosperous manufacturing industry.

Advancements in technology such as artificial intelligence (AI) and the growth of cloud capabilities have helped many industries tackle some of the world's biggest problems. Technology has been able to grant businesses greater visibility across their operations, allowing leaders to identify roadblocks that may hinder workflows. In such a dynamic and fastpaced industry, visibility is precious, but Australian manufacturing still has its challenges to overcome. Some of these include: 1. Data siloes impact downtime When managing information technology (IT) and operational technology (OT) independently, there is no consideration for how they inform one another.

Resolving complications without a holistic view of a digital infrastructure can be time-intensive resulting in disrupted production. Ensuring IT and OT are synced makes for a streamlined process that provides consolidated insight into a tech ecosystem.

2. Gaps of visibility across your IT stack Greater coverage of technology systems is needed to ensure processes continue to work effectively and efficiently. While manufacturers can be agile in adopting new tech, gaps are often left when older IT systems are still in play, revealing weak points.

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3. Monitoring advanced technology The internet of things (IoT) presence in manufacturing continues to see massive investment and is a driving force enabling operational productivity.

Understanding new bespoke technology is challenging, especially as it becomes more prominent with the addition of AI. Management of this data is essential to generate meaningful conclusions and support decision-making.

4. Being protected in the cloud In a time when most manufacturing hardware connects to the internet, how do we ensure these systems are reliable, functional and most of all, protected? Manufacturers experience a real threat of coming under attack

by hackers to breach data, disrupt operations and pinch secrets.

Manufacturers must be secure to minimise possible entry points from malicious hackers.

Observability as a value-add to manufacturing In an ever-growing, complex and competitive industry, one thing is sure; manufacturers need to seize new technologies to remain strategic and deliberate in their operations.

Say you have a dozen digital systems in place that are core to your business operations; ensuring they work together to reach their best potential will save you time and money. Chances are, your employees are spending more time than needed managing the complex intricacies of each system.

027 Monitoring most likely is already taking place within your organisation; we're referring to capturing of data to analyse performance, alert to issues, and pinpoint what's happening within your business. To take this one step further, observability is a window into understanding the internal environments of your systems so you can identify the root causes of issues and create a holistic platform accessible by all.

Observability is not a form of monitoring but rather provides real-time status updates on the health of your overall system so you can answer questions about why issues are occurring and what the knock-on impact is.

This insight into your entire infrastructure is game-changing and allows your operation to run an integrated and seamless ship.

The manufacturing sector needs to be empowered to adopt observability to gain greater control and visibility of its systems.

Observability is about better using data to understand supply-demand and help inform innovation in response. Through its implementation, Australian manufacturers can expect to see benefits including: 1. Reducing costs The foundation of a successful manufacturing model is keeping costs low. As the well-known saying goes,

time is money, and by understanding the health of your systems, you are lowering investment in your ITops and DevOps. By automating monitoring, manufacturers can exert fewer employer hours to observe and manage numerous digital systems. As the monitoring process optimises, it continuously works to resolve complications, ensure they don't happen again, keeping your systems running faster and at peak performance.

2. Prioritising user-experience With the added time back into employees' day, manufacturers can invest in matters that will propel their business forward. These valuable hours are better spent improving product performance and delivering a high-quality customer experience.

3. Improving uptime The implications of downtime can quickly cause financial loss, meaning trouble-shooting needs to be instantaneous. Observability platforms alert their users of issues at the first implication of problems meaning IT teams can resolve them before it escalates and has a flow-on effect.

4. Seeing what's to come Having visibility of your system at a deep level allows manufacturers to understand the current state of their operations. Observability is valuable in mapping out future events and responding accordingly to ensure final outputs are unaffected. Manufacturing sees fluctuations in outputs during peak periods,and having the insight to react to foreseeable problems can put your organisation ahead of its peers.

In anticipating demand, manufacturers can invest in product improvements or innovations.

Regardless of scale, Australian manufacturers can unite their technology systems on a single unified observability platform. In a fast-paced environment, manufacturers will benefit significantly by adopting observability to smooth out pain points, anticipate challenges, and create responses in real-time. To further build Australia’s reputation globally as a competitive player, manufacturers need to look within their operations, safeguarding themselves against loss of productivity and the risk of downtime.

Richard Gerdis is the Vice President & General Manager, Asia Pacific and Japan at LogicMonitor, logicmonitor.com

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

The key trends to happiness in hybrid work of the future Flexibility makes us happier, with three clear trends emerging in post-pandemic hybrid work The first national study of working arrangements in Australia since government work-from-home directions were lifted shows post-pandemic office life is going to be dramatically different to what existed before.

Our survey of 1,421 knowledge workers – essentially anyone doing computer-based work able to be done remotely at least some of the time – was conducted in the week of 21-25 March 2022. It shows fewer than a quarter of workers (about 23%) returning to commuting five days a week, with about the same percentage working remotely full-time.

About 44% were doing “hybrid work”, splitting their week between days in the office and working remotely. These workers were split evenly between three emerging models of hybrid work. Our survey asked participants a total of 46 questions, covering their current work arrangements, ideal work arrangements, health and wellbeing, workplace culture, skills changes and communication technologies, along with demographic information (age, sex, income etc).

The survey sample was nationally representative of state and age populations, though slightly skewed towards male participants (58% male vs 42% female).

The following chart shows working arrangements at the time of the survey.

The “other” category includes hybrid variations such as a mixing fixed and flexible days (for example, having one fixed day in the office and two days of the worker’s choice) as well as unspecified arrangements. Including this category, our results show a majority (54%) following a hybrid work model, with 23% still working remotely full-time and 22.9% back in the office full-time.

By comparison, just 28% of Australian knowledge workers had the chance to work remotely for any part of the week prior to the pandemic.

Three main types of home and office arrangements Our main motivation for this study was to better understand how new work arrangements are being designed and implemented in what the Productivity Commission has described as the second wave of work experimentation – following the first wave of working from home enforced by COVID-19. Our survey shows no clear “winner” between the three broad

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approaches to hybrid work: Days in office fixed, with workers expected to attend the office for a specific number of set days (e.g.

Tuesdays, Wednesdays and Thursdays).

This applied to 29% of hybrid workers (and 15.6% of all respondents).

Fixed office frequency, but workers have the flexibility to choose which days (i.e. any three days a week). This applied to 24.3% of hybrid workers (and 13.1% of all respondents).

Flexibility to choose where they work and when. This was the case for 28.5% of hybrid workers (and 15.4% of all survey respondents).

Happier with autonomy From the individual perspective, our survey strongly indicates those with the greatest flexibility were happiest.

We asked participants to indicate how happy they are with their current work arrangements on a five-point scale from “very unhappy” to “very happy”. About 94% of those with the greatest flexibility said they were happy or very happy with this arrangement. This compares with 88.5% of those working remotely full-time, and 70.6% for those going into the office full-time.

When asked to choose their ideal work arrangements, the most popular choices were having control over the location where they work and when (23.0%), followed by working remotely full-time (22.8%).

Better health and well-being In good news for employee health, one third (30.2%) of workers said they now have a better work-life balance than they did two years ago, compared with less than one in ten (8.7%) who think it has worsened.

Over a quarter (27.4%) said the key benefit from having a better work-life balance was having more time to invest in their health and wellness.

As the Productivity Commission has noted, while the first wave of forced experiment broke down resistance towards flexible work practices, this wave of voluntary experimentation involves “negotiating, trialling and adjusting” to see what best works for individuals and organisations.

It is still very early days in the evolution of hybrid work, and organisations will no doubt have to experiment and test out several different arrangements before they find the ones that produce the best longterm results for them and their employees.

Anne Bardoel is a Professor at Swinburne University of Technology, and John L Hopkins is an Associate professor at Swinburne University of Technology. swinburne.edu.au This article was originally published by The Conversation. www.theconversation.com

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

The Philosophy of Technology: Substitutive or Additive?

With the advancement in 3D printing technologies and the considerable progress in 3D printing materials, additive manufacturing has become a complete hi-tech method for producing various parts. Jason Allen explains.

The introduction of 3D printing in prototype production has substantially improved product development. As a result, 3D printing has become a viable alternative to CNC machining, a key pillar of manufacturing today. Moreover, additive technologies are already being viewed as an obvious replacement for CNC machining.

How valid is this assertion? Can 3D printing oust machining from the smart factory of tomorrow?

Despite the glamour and prospect of 3D printing, it cannot completely replace CNC machining as the dominant technology for fabricating metal parts. However, there is no doubt that additive manufacturing (AM) will have a significant impact on an entire range of production methods. Broadly speaking, both technologies, CNC machining and 3D printing produce the shape of a part by forming material layer by layer. Which of the two methods is more effective, and how will the combination of both solutions affect production?

To find the answers, let's compare the main features of CNC machining and 3D printing being modern day counterparts.

Workpiece materials - Metals are the main materials for CNC machining. In 3D printing, despite the significant increased share of metals, non-metallic materials are still dominant. At the same time, the progress in powder metallurgy has enabled printing parts from difficult-to-cut materials, such as nickel-based superalloys, which completely opens new prospects for additive manufacturing.

Physical properties - Metals are isotropic – their properties are the same yet in different ways. In contrast, 3D printed products feature distinct anisotropy. For example, the strength in a horizontal direction is higher than in a vertical direction.

Engineering science, which has plenty of theoretical tools and experience for accurately calculating structural behaviour, rigidity, and reliability of parts made from isotropic metals, faces difficulties when dealing with 3D printed products. Thus, introducing AM in the production of metal key elements is advancing slowly for understandable reasons; CNC machining is the dominant method for producing critical heavy components.

Generated shapes - CNC machining has various limitations that are mainly caused by the limited access of a cutting tool to the machined surface (especially

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the setup, the required workplace, flexibility, etc., however, our analysis is enough to conclude that 3D metal printing will not fully replace CNC machining in the foreseeable future.

inner parts). 3D printing, which is free from most constraints, substantially expands the boundaries when producing complex shapes.

Dimensions - Metal removal by CNC cutting facilitates machining parts in a wide dimensional range. 3D printing capabilities are much more modest. In principle, a largesize part may be produced by AM methods, consequently this part should be divided into several smaller links to be assembled after the 3D printing process is complete.

However, this process significantly increases production time and raises a question about the required strength and rigidity of the assembled product.

Accuracy, repeatability, and surface finish - Today, 3D printers can provide dimensional accuracy of 0.25 mm (.01"), which is far less compared to the precision of CNC machining that maintains tolerances of at least two-three times less. CNC machining also ensures better parameters in contrast to AM methods for repeatability and surface finish.

Economical aspects and sustainability - Despite the large variety of CNC machines and 3D printers which may vary in price according to the characteristics, the price of a 3D printer is considerably lower compared to a typical CNC machine.

The process of cutting material results in chips – intended for recyclable refuse.

Sustainable, low waste 3D printing utilises material more effectively and therefore saves energy.

For limited production runs, particularly prototypes, AM has an obvious economical advantage. But in large-scale volume manufacturing, CNC machining is much faster and more cost-effective. We can continue to analyse other features such as possible structural defects, thermal integrity,

In metalworking, AM can be an effective and a fast method for fabricating precise workpieces that are very close to the desired final part shape, especially when related to complex shaped workpieces. The fabrication of intricate workpieces demand CNC machining with minimal stock removal to answer to advanced machining methods where accuracy and surface finish are the essence. 3D printing enables quick and accurate prototyping results and reduces valuable production time for achieving the optimal solution.

3D printing methods are not a substitute for CNC machining yet complement the machining processes. In addition, metal removal and additive processes are integrated in modern day machines which combine precise multi-axis cutting with 3D printing. Therefore, the one word that best describes the relationship between 3D printing and CNC machining is “together” and not "instead of".

The rise of 3D printing intended for manufacturing workpieces will affect the world of cutting tools. Specifically, milling cutters that shape complex parts will be affected as they answer to the growing demands for high efficiency, high accuracy, and high reliability. Ensuring these "triple high" characteristics seems to be a common prerequisite, however, advanced metal cutting solutions demand techniques that answer to less stock removal.

When machining allowances are small, maintaining high metal removal rates requires increased feed and speeds, which can be reached by utilising high speed machining (HSM) strategies. Milling tools that spin with high angular velocity must be balanced to sustain stable, durable cutting under increased centrifugal forces while minimising the number of passes.

The ideal result is to obtain the surface finish parameters in a single pass that demands highly accurate cutting tools. We can ascertain that solid carbide endmills, assembled tools with exchangeable cutting heads, and precise one-insert profile mills are the first choice for precise and productive machining of complex shapes with minimal stock.

Cutting tool manufacturers account for

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synergy between 3D printing and CNC machining in the production of complicated configurations for special indexable cutters.

Despite the limitations, the anisotropic properties of printed products show an advantage. Moreover, 3D printing enables a quantum leap in tool design, optimising a cutter body configuration, especially for designing and producing inner surfaces and coolant channels for pinpointed coolant.

additive components of metalworking when forming their product portfolio and planning strategically for advanced cost saving solutions. That said, ISCAR has expanded the range of multi-flute solid carbide endmills designed for HSM. ISCAR's latest NEOLOGIQ campaign places special emphasis on "arc segment" or "parabolic" endmills that feature barreland lens-shaped cutting edges. These endmills are intended for 5-axis high-speed machining complex profiles providing a

perfect solution for productive finishing procedures. Additionally, cutting "barrels" and "lenses" have found themselves in a one-insert indexable tool design that covers greater mill nominal diameters.

Evidently, the arc-segment cutting edge was adopted in ISCAR's MULTI-MASTER tool line, the family of assembled tools with exchangeable heads, which combines the advantages of solid and indexable tool concepts. In tool customising, there is a good example showing the

ISCAR R&D engineers consider AM as a powerful tool in finding the best solution for both special and newly developed products to assure maximum sustainability. The major leap forward relates to 3D printing of carbide inserts. The production of insert prototypes by use of AM methods does not require die sets and enables examining various design versions of the inserts. This method significantly decreases development time, cuts production costs, and minimises waste.

To conclude, 3D printing today and tomorrow is not meant to replace CNC machining, but the symbiosis of these two technologies will be a typical feature of metalworking technologies soon to come.

Jason Allen is Managing Director at ISCAR, iscar.com.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

The cyberwar shift: a new target in operational technology Cyber security threats pose one of the biggest risks to companies, particularly those with significant infrastructure and in essential sectors, such as food manufacturing. Chief Technology Officer at Sapien Cyber, Michael Counsel says the concept of an air-gapped OT environment as rapidly diminishing.

Cyber incidents ranked number one as the biggest concern for companies around the world in 2022.

With information technology (IT) data breaches like NASA, Microsoft and the more scandalous example of Cambridge Analytica making headlines and taking over news cycles almost daily, it’s easy to assume that IT should be at the forefront of concern when planning to protect your company from cybercrime. However, in the last decade an even bigger concern has arisen – the threat to operational technology (OT).

Where IT attacks can result in data breaches and the nonconsensual sharing of personal information, OT targets the actual hardware and software that controls the equipment. Disrupting the infrastructure controls can trigger facility shutdowns, equipment malfunctions and even result in explosions. The potentially lifethreatening impact of OT attacks places great significance on the importance of understanding how to best protect your company’s product, equipment and most importantly, its people.

How it works: A food manufacturing example As the food manufacturing industry takes more steps towards digitalisation, the threat to OT increases, and with examples around the globe of attempts to disrupt operations like temperature monitoring and quality assurance, it’s now a more important time than ever to understand OT. The vulnerability begins with the controls, buttons and switches used to automate the essential processes within your industry.

This automation is made possible using Supervisory Control and Data Acquisitions, otherwise known as SCADA, a computer-based system for gathering and analysing real time data to monitor and control equipment.

As SCADA remains mostly wire-based and offline, the environment was once considered primarily ‘air-gapped,’ meaning, almost impossible to touch or hack into. However, with personal devices, USBs and other factors coming into play, it can no longer be considered completely safe.

Many of these systems were locked away, designed in a time when the air-gapping was thought to be enough. However along came modern technology that is everywhere and now linked with human frailty that makes mistakes. Attackers and viruses love that.

processes unless a ransom was paid in cryptocurrency. JBS Foods, which accounts for around 24 per cent of all food and beverage shipments in the US, found itself causing a major disruption to global supply chains – with operations being forces to temporarily shut down in Australia, Canada and the US. To recover its processes safely, the company paid the equivalent of US$11 million in bitcoin to the hackers.

“It’s not uncommon for these hackers to be seeking revenge on a company or industry with their actions, but the risks to a global supply chain far outweigh any other potential outcomes – particularly when you’re dealing with something like food manufacturing.”

What you can do The real challenge in the example above is that the cybercrime was detected much too late. The key is knowing how to identify the threats and intrusions and bringing them to the attention of the right people to act at the right time. There is information coming from everywhere and security information isn’t noise, it’s vital data which requires action.

By connecting the OT security events as data and visualisation, we can transform that data into security operations and business visibility. Much like when your body signals when a virus has entered your system, it sends out the warning signs. While prevention is always better than cure, we need to respond and deal with it when it happens.”

Knowing the risks is only the first step; knowing how to protect your software and hardware from the damage that can be caused can not only save thousands of dollars in equipment replacement costs, but at the end of the day, save lives.

Some tips to get you started: •

Understanding your organisation’s systems and connected networks is critical to early detection and will allow you to develop an effective and well-structured security plan in case anything goes wrong.

•

Once the hacker is in the system, the opportunities to disrupt SCADA begins. This means, critical processes and monitoring programs can be interrupted and altered – causing major concerns for companies.

An example of a cyberattack that caused major disruption to the manufacturing industry is the targeting of JBS Foods in June of 2021.

The hackers made way into the U.S. meat company’s computer network and threatened to cause major disruption to the operational

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Always monitor While you’re building your plan, you’re vulnerable. Monitoring these systems while they’re in the process of being made stronger is crucial in the process of preparing for an attack.

The ability to break into an OT network can often be through a completely innocent action as simple as an employee plugging in their phone or other device that carries malware, or from a roving support engineer moving between sites. Attackers will often deliberately target known workers to piggyback their way in.

The physical attack begins

Know what you’re protecting

While monitoring tools in the OT space are a little harder to come by than IT, there are options out there, and it pays to do your research. Look for tools which are highly sensitive to external disruption and have safety responses implemented as soon as they detect an attack.

•

Talk to the experts The OT environment is still new to many, and while it can be considered extremely complex, the outcomes can lead to catastrophic consequences. OT specific cybersecurity companies can help you identify the risks and vulnerabilities of your industry and develop and install monitoring programs to combat potential threats.

sapiencyber.com.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Securing manufacturers expanding threat landscape Operational Technologies security requires every part of the supply chain to work together. Christina Hoefer, VP of Global Industrial Enterprise at Forescout Technologies, takes us through the future of manufacturing security.

In February 2021, Toyota was forced to halt production in all 14 of its Japanese plants following a cyberattack on one of its significant parts suppliers. As a result, Toyota saw production drop 5%, with approximately 400,000 vehicles not being manufactured, causing major headaches across the globe.

•

Due to the interconnected nature of organisations’ infrastructures today, cyberattacks are increasingly impacting the wider supply chain. In shutting down one partner’s parts supply system, hackers were able to shut down Toyota’s entire production system.

Top of any CISO’s to-do list should be a risk assessment of all onsite OT systems with the help of OT asset owners, including those assets you have been assured don’t interact with the network. The results are likely to surprise everyone: it is no longer possible to keep OT systems disconnected.

Historically, Operational Technology (OT) and Information Technology (IT) have been siloed, but the increased use of rapidly advancing connected systems has now intertwined them beyond traditional organisational borders, creating a much wider threat surface for bad actors to exploit.

Where OT meets IT Modern manufacturing is powered by thousands of connected devices, massive computing power and artificial intelligence. While on one hand they improve efficiency, reduce errors, and cut costs, they also create significantly greater cyber risk. Digital transformation is underpinned by the convergence of OT and IT systems, wherein information is shared to allow them to interoperate.

For manufacturers, the challenge is to securely connect IT and OT systems which need to communicate while eliminating those that don’t. Sometimes organisations don’t even realise the link exists until it is exploited by a threat actor.

OT and IT’s Unique Security Challenges The convergence of IT and OT introduces a variety of unique cybersecurity challenges: •

Security as an afterthought: Historically, OT assets have never connected to networks and so were not built with security or even integrity in mind. While some manufacturers are now implementing “secure by design” principles, this practice is still the exception.

•

Long refresh cycles: While IT organisations refresh their technology every few years with new hardware, operating systems and applications, OT systems are built for reliability and remain relatively static. Some OT assets are only replaced every thirty years.

•

Zero downtime requirements: Many OT systems are designed for continuous production and are designed to never go offline. Even an hour of downtime can result in staggering revenue and productivity losses. As a result, stopping production to attempt a security patch is a luxury many manufacturers can’t afford.

•

•

Exponential growth of IoT: The use of IoT devices in manufacturing is also exploding, reducing costs and delivering more value to customers. IoT devices are used in a variety of processes to communicate between IT devices and the field.

But, despite their pivotal role, IoT device communication is often not tracked or monitored.

Geography and scale: Manufacturing sites can be huge, and can be geographically dispersed across multiple regions and countries. Each environment can rely on thousands of systems and devices, developed by different vendors on different architectures.

OT cybersecurity skills shortage: OT systems are generally operated by OT engineers rather than IT security staff, which can result in tension based on competing priorities. Balancing operational and cybersecurity risk can be a challenge especially when it requires shutting down operations.

Cybersecurity in Manufacturing Best Practices There are multiple resources and frameworks available to organisations including: The Essential Eight and the NIST Cybersecurity Framework. The following recommendations build on these frameworks, based on over a decade of industrial threat research and experience protecting global manufacturers and critical infrastructure.

1. Discover – Complete security starts with knowing what your assets are, where they are, and how they communicate.

Unfortunately, the same discovery approaches that work for IT and IoT might not work for sensitive OT devices given safety rules, vendor interoperability issues, industrial process requirements and other considerations.

2. Assess – OT engineers must understand both the cybersecurity and operational risks of each asset. As a rule, assume that no system is vulnerability free. With the increase in supply chain vulnerabilities, they are only going to become more difficult to track.

3. Detect – To prevent downtime, threats to operational continuity must be detected and investigated as quickly as possible. Asset discovery and risk assessment produces a flood of information about potential threats and vulnerabilities, but it’s not all actionable.

4. Respond – Any risks and vulnerabilities identified above must be mitigated and, ideally, remediated. In manufacturing environments response actions range from automated remediation activities, to more drastic measures including access control and segmentation.

5. Recover – Security policies, from assessment and alerts to mitigation actions, should naturally involve communication between IT and OT teams. For example, how can the SOC security analyst inform the right OT engineer on site?

Policies often come into effect after breaches. Suppose malware on the contractor’s laptop infected the network. How did you recover from the incident and restore operations, and what could have been done to prevent it?

Working Together for Success OT security requires every part of the supply chain to take responsibility and work together. The efforts made to secure these systems can avoid costly shutdowns, stolen data, and other adverse outcomes.

While the security of OT systems has long been overlooked, the increasing connectedness of our world only increases opportunities for threat actors.

By Christina Hoefer, VP, Global Industrial Enterprise, Forescout Technologies

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TECH NEWS

Germany: Smart screws keep infrastructure safe Screw connections on critical infrastructures are exposed to major stresses and must be checked regularly. Researchers have developed a technology - The Smart Screw Connection - that allows the stability of the screw connections to be checked at any time by remote monitoring. It is a fully integrated, self-powered IoT device for determining the preload force. The data is transmitted wirelessly and is designed as a flexible, retrofittable system for DIN screws of various sizes. It comes with a screw fitted with a washer that is equipped with a piezoresistive DiaForce® thin film. When the screw is tightened, the pressure-sensitive sensors register the preload force at three points. Any change in the preload force changes the electrical resistance. When a screw comes loose, the resulting change in resistance is reported to a radio module located on the screw head. The radio module, in turn, sends the data to a base station. It can be adapted for a wide variety of applications.

Fraunhofer

– envisioning a future where a robot or stretchy electronic devices could be 3D printed via the press of a button.

The researchers first designed a series of computer simulations that probed the physics of printing different kinds of materials next to each other. One of the big problems was how to keep droplets of solid materials from mixing into the liquid materials.

The team established a set of rules to help them A network of capillaries 3D-printed do that. The surface using a newly developed technique. tension of a liquid can be used to support solid material, but it is helpful to pick a liquid material that is more dense than the solid material. Next, the researchers experimented with a real 3D printer in the lab. They loaded the printer with a curable polymer, or plastic (the solid), and with a standard cleaning solution (the liquid). Their creations were impressive: The group was able to 3D-print twisting loops of liquid and a complex network of channels.

University of Colorado at Boulder

USA: Waterless dust removal for solar panels

The Smart Screw Connection is a fully integrated, self-powered IoT device for determining the preload force.

UK: Rail sensor goes ultrasonic to grease the wheels Engineers are working on an ultrasonic sensor for the rail industry that can detect sections of track where vital lubrication has been worn away. The sensors will be embedded in the wheels of trains and will allow track conditions to be almost continuously monitored.

In curved track, a special type of grease is applied between the wheel and rail to reduce wear but also the risk of derailment, whereby in some circumstances the wheel can climb up and over the railhead. This new measurement technology will provide an automated vehicle-mounted system that will communicate the presence of lubrication, and critically, locations where it is absent, thereby reducing maintenance costs and improving railway safety. Embedding ultrasonic sensors into the wheel provides the opportunity for continuous monitoring of lubrication effectiveness and allows preventative measures to be applied before problems arise.

The Engineer

US: How to print a robot from scratch: Combining liquids, solids A team has established a strategy for using currently available printers to create materials that meld solid and liquid components

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The accumulation of dust on solar panels or mirrors is a significant issue — it can reduce the output of photovoltaic panels by as much as 30% in one month. But cleaning solar panels is estimated to use about 10 billion gallons of water pa. Attempts at waterless cleaning are labour-intensive and tend to cause irreversible scratching of the surfaces. Now, a team has devised a way of automatically cleaning solar mirrors in a waterless, no-contact system that could significantly reduce the dust problem. The new system uses electrostatic repulsion to cause dust particles to detach and virtually leap off the panel’s surface, without the need for water or brushes.

To activate the system, a simple electrode passes just above the solar panel’s surface, imparting an electrical charge to the dust particles, which are then repelled by a charge applied to the panel itself. The system can be operated automatically using a simple electric motor and guide rails along the side of the panel.

MIT

USA: Heat engine with no moving parts as efficient as a steam turbine Engineers have designed a heat engine with no moving parts. Their new demonstrations show that it converts heat to electricity with over 40% efficiency — a performance better than that of traditional steam turbines. The heat engine is a thermophotovoltaic (TPV) cell, that passively captures high-energy photons from a white-hot heat source and converts them into electricity. The researchers plan to incorporate the TPV cell into a grid-scale thermal battery. The system would absorb excess energy from renewable sources such as the sun and store that energy in heavily insulated banks of hot graphite. When the energy is needed, TPV cells would convert the heat into electricity, and dispatch the energy to a power grid MIT

TECH HEADING NEWS

USA: Tumours partially destroyed with sound don’t return Noninvasive sound technology called histotripsy has broken down liver cancer tumours in rats with millimeter precision, spurring the immune system to prevent further spread. By destroying only 50% to 75% of liver tumour volume, the rats’ immune systems were able to clear away the rest, with no evidence of recurrence in more than 80% of animals. Where a typical ultrasound uses sound waves to produce images, engineers have pioneered the use of those waves without the harmful side effects of radiation and chemotherapy. The transducer delivers high amplitude microsecond-length ultrasound pulses — acoustic cavitation — to focus on the tumour specifically to break it up. Traditional ultrasound devices use lower amplitude pulses. The microsecond long pulses generate microbubbles within the targeted tissues — bubbles that rapidly expand and collapse.

These violent but extremely localised mechanical stresses kill cancer cells and break up the tumour’s structure.

University of Michigan

ago — computed axial lithography (CAL) — to print much finer features and to print in glass. They dubbed this new system “micro-CAL. The CAL process is fundamentally different than today’s industrial 3D-printing processes. CAL 3D-prints the entire object simultaneously. Researchers use a laser to project patterns of light into a rotating volume of light-sensitive material, building up a 3D light dose that then solidifies in the desired shape. The layer-less nature of the CAL process enables smooth surfaces and complex geometries. This study pushes the boundaries of CAL to demonstrate its ability to print microscale features in glass structures - printing objects in polymers with features down to about 20 millionths of a meter (1/4 of a human hair’s breadth). For the first time, this method can print not only into polymers but also into glass, with features down to about 50 millionths of a meter.

UC Berkeley

Australia: Breakthrough opens door to low-cost green hydrogen

The 700kHz, 260-element histotripsy ultrasound array transducer

Australia: Insect wings inspire new antibacterial packaging Inspired by the bacteria-killing wings of insects, scientists have developed a natural antibacterial texture for use on food packaging.

The lab-made nanotexture from an Australian-Japanese team kills up to 70% of bacteria and retains its effectiveness when transferred to plastic. Dragonfly and cicada wings are covered by a vast array of nanopillars. When bacteria settle on a wing, the pattern of nanopillars pulls the cells apart, rupturing their membranes and killing them. The team developed their nanotexture by replicating this and developing nanopatterns of their own. To assess the pattern’s antibacterial ability, bacteria cells were monitored at RMIT’s worldclass Microscopy and Microanalysis Facility. Until recently, it was difficult to find suitable technology to reproduce this nanotexturing on a scale suitable for manufacturing. But now technology exists to scale up and apply antibacterial properties to packaging, among other potential applications, like PPE. RMIT

USA/Germany: 3D-printing glass microstructures Researchers have developed a new way to 3D-print glass microstructures that is faster and produces objects with higher optical quality, design flexibility and strength - expanding the capabilities of a 3D-printing process they developed three years

In a clean energy breakthrough, researchers from the UOW and ACES have developed new electrolyser technology that brings cost-competitive renewable, or green, hydrogen closer to reality via the “Capillary-fed electrolysis cell” which enables production of green hydrogen from water at 98% cell energy efficiency. This productivity is superior to other existing technologies, and is well above the IRENA 2050 target, enabling an affordable hydrogen production cost that can match the production costs of fossil fuels. A UOW spin-out company, Hysata, was formed last year to commercialise the breakthrough. Electrolysers have existed for 200 years, however the large amounts of renewable electricity required to produce green hydrogen and the overall cost of electrolysers has prevented large-scale uptake of green hydrogen. Hysata’s overall electrolyser system has been designed for ease of manufacturing, scaling and installation, delivering 95% overall system efficiency, equivalent to 41.5 kWh/kg, compared to 75% or less for existing electrolyser technologies. This will significantly reduce both the capital and operational costs to produce green hydrogen -enabling hydrogen production of below US$1.50/kg per kg by the mid2020s, meeting Australian and global cost targets much earlier than generally expected.

University of Wollongong

“3D printing a liver or heart could take hundreds or thousands of years” – Mark Skylar-Scott, Ass. Prof. of Bioengineering, Stanford University. Even if 1000 cells per second are printed, organs contain many billions of cells. The team is working to speed up the printing process by laying down dense clumps of cells called “organoids.” Genetically modified stem cells are put in a centrifuge, generating a paste-like substance. A large number of cells are printed simultaneously into a gelatinous 3D structure. Each line of stem cells are genetically engineered to respond to a specific drug, allowing them to differentiate into specific cell types. But scaling-up will be a big challenge.

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PRODUCT NEWS

Battisti & Co. and Kaiser Compressors come along for the ride Maintaining its position as one of the best luxury vehicle repairers in Australia has meant a long-term commitment at Charlie Battisti & Co. to continuously investing in the latest and most efficient technology. Kaeser Compressors has been on hand for over two decades now, ensuring their team of highly trained refinishing, repair and painting experts have access to a reliable and efficient supply of quality compressed air on demand.

When it comes to repairing prestige vehicles, Charlie Battisti & Co. has over 30 years of experience under its belt.

Melbourne’s finest smash repairers, Charlie Battisti is one of only a handful of body shops Australia wide, that is a Porsche Certified Collision Centre, an Accredited BMW Body Shop and Mercedes Benz dealer recommended.

Accident repairs, detailing and windscreen replacement are just a few of the services Charlie Battisti offers to its customers.

However, regardless of the job at hand the focus is always the same - to ensure that the customer is 100% satisfied with all repairs undertaken and to maintain the vehicle's original build quality, strength and integrity.

To meet these goals Charlie Battisti invested some years ago in a state-ofthe-art and purpose-built vehicle repair facility. Built with vehicle manufacturers specifications in mind, this modern facility in Nunawading houses all the latest approved repair, chassis alignment and measuring systems to ensure that all repairs meet the most exacting industry standards. To maintain its position as one of the best luxury vehicle repairers in Australia, the company continuously invests in the latest technology - not least the compressed air system.

Compressed air is an essential utility at the facility that is used extensively.

From powering the air tools - such as the sanders and polishers - to providing air to the dedicated paint refinish facility, the highly trained refinishing, repair and painting experts at Charlie Battisti require a dependable supply of high-quality compressed air.

To meet these requirements back when Charlie Battisti first moved into the new facility, they opted for a Kaeser AS 31 series rotary screw compressor. Renowned for quality, reliability and efficiency, Kaeser was the ideal choice. After 15 years of reliable service, it was time to once again upgrade the compressed air system and invest in the latest and most efficient compressed air technology available. To reliably and efficiently meet the compressed air requirements of the facility, Kaeser recommended and subsequently installed an ASK 28 rotary screw compressor

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complete with air treatment. True class leaders when it comes to performance, the ASK series of rotary screw compressors deliver more compressed air for less energy.

At the heart of every ASK system lies a premium quality screw compressor block featuring the energy saving Sigma Profile rotors. Kaeser airends are equipped with flow-optimised rotors, which contribute significantly to the overall system’s classleading specific package input power.

Efficiency is further enhanced with the inclusion of a Premium Efficiency IE3 drive motor, which complies with and exceeds prevailing Australian GEMS regulations for three phase electric motors. Furthermore, the internal Sigma Control 2 controller always ensures efficient compressor control and monitoring.

The ASK series also combine ease of use and maintenance-friendliness with exceptional versatility and environmentally responsible design. In addition, the soundproofed housing keeps operational noise to a minimum. Normal conversation can take place right next to the compressor,

making the ASK series ideal at point of use.

Seven years on and the ASK 28 continues to reliably and efficiently meet Charlie Battisti’s compressed air requirements, with the AS 31 remaining onsite as the back-up, when for example the ASK 28 is being serviced.

“As a prestige vehicle repairer it’s always been important for us to invest in high quality equipment and Kaeser certainly ticks that box,” said Shane Perry, Paint Shop Manager of Charlie Battisti says.

“We’ve been more than happy with the performance of the Kaeser compressors over the years. Moreover, the after sales and service support we’ve received from Kaeser over two decades now has been great.”

The standard ASK series of rotary screw compressors from Kaeser Compressors are available with drive powers of 15 to 22 kW and produce flow rates from 1.93 to 4.45 m3/min, pressure 6 to 13 bar. au.kaeser.com

PRODUCT NEWS

University sets up Industry 4.0 Technology Hub with Demmeler cobot system In September 2020 during the COVID pandemic, the University of Wollongong (UOW) opened a new industry hub at its Shoalhaven campus in Nowra featuring Industry 4.0 technology.

This new Industry 4.0 hub includes a working demonstration unit of the Demmeler 3D table system supplied by Leussink Engineering with a cobot (collaborative robot).

Evan Brown demonstrating the Demmeler table and cobot at UOW.

The Hub has several goals: Support local and regional industry (for example SMEs in manufacturing, agribusiness, defence industry) with the awareness and adoption of Industry 4.0 technologies Engage with schools and community to educate around Industry 4.0 and generally promote interest in STEM (Science, Technology, Engineering and Mathematics) Strengthen connections between UOW researchers and local industry.

The innovative Hub showcases numerous Industry 4.0 Technologies, including cobots, virtual and augmented reality (VR & AR), as well as additive manufacturing (3D printing).

“The equipment is used to demonstrate and showcase resources to industry partners looking to adopt new technologies.

Equipment can also be accessed and used by students and the community through ‘makerspace’ activities,” said Evan Brown, Research Engineer, UOW Industry 4.0 hub.

“Once the COVID lockdown period ended last year we had pent-up demand for people wanting to visit the Hub which is great.

“HMAS Albatross, the largest operational Naval establishment and the Navy’s only Air Station is based in Nowra with many supporting businesses, so there are plenty of locals who want to see the Industry 4.0 technologies in action. It allows people to see how new technology could improve their business, and how they can adopt the latest equipment,” added Brown.

Evan and his team worked closely with Leussink to set up two Demmeler tables to mount the collaborative robot welding system.

Cobots are designed to operate close to humans as they perform their tasks, and unlike fully-fledged robots, they are an affordable solution to automate processes to support employees.

In the UOW Industry 4.0 Hub, the cobot is set up on a Demmeler table system to undertake welding tasks. The Demmeler system plays a dual role. It holds the cobot firmly and accurately in place, and it also holds the workpiece securely and precisely while the welding is taking place.

“The two systems demonstrate great synergies and visitors can see how this system will work in their business,” said Brown.

Unlike traditional industrial robots, cobots are responsive to human touch and the environment around them, and therefore do not need to work behind large safety screens because they pose little risk of accidents occurring. Humans provide the direction to the cobot, and the cobot provides the precision steering and control.

“One of the key advantages which we can demonstrate is how quickly it can be setup and programmed for just a few welds, before moving on to the next. Operators do not have to be experts in computer programming or welding to be able to operate the Demmeler cobot system,” said Brown.

The Demmeler welding and fabrication system, distributed exclusively in Australia

by Leussink Engineering, is the ideal partner product for a cobot. The main reason Demmeler tables and cobot systems were chosen for the Hub was to meet the objective to support local and regional industry (manufacturing, agribusiness,

defence industry) with the awareness and adoption of Industry 4.0 technologies.

As a consequence, the Business Development Manager and acting lead of the Industry 4.0 Hub works closely with groups like the Shoalhaven Business Chamber and local industry as well as attends industry events to spread the word with local businesses and those further afield.

The Demmeler 3D workbench and welding table is a versatile jig and fixturing system for all types of welding and fabrication work.

A cobot can be anchored and fixed to a Demmeler table system to ensure accuracy and versatility. The cobot can return to the same position every single time.

Working in partnership with robotic experts, Leussink develops cobot-based systems for clients in a range of industries, enabling them to meet many different requirements.

Leussink has extensive experience in the design and production of a wide range of bespoke equipment and solves engineering problems for companies across a wide range of industries. leussink.com.au

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PRODUCT NEWS

Lightweight Australian ingenuity solves heavy rooftop challenges Industry pioneer and leader Con-form Group broke the mould for roof-mounting mechanical equipment in 2014 and has not looked back since.

Not that you would have noticed, because as Con-form Group Managing Director Nigel Cro says, “People will drive along on a highway overpass and there are a lot of things on roofs that you see; now if you don’t see those things, that’s because we’ve done a good job – that’s our goal.”

Industrial HVAC systems are heavy and often noisy. Con-form Group provide an engineered solution for the structure to cater for the weight on rooftop installations and additionally deliver acoustic solutions to minimise environmental noise. Con-form Group’s lightweight aluminium plant platforms and screens are now found on industrial, commercial and public infrastructure roofs right around Australia.

The Bathurst-based business was established more than 20 years ago and employs approximately 35 staff. In 2014, the Conform Group team developed an industry leading lightweight roofmounting platform system for mechanical equipment.

“It was painful to see large structural steel sections getting craned onto roofs laboriously day after day, piece by piece and the danger and the logistics involved,” says Cro. “I remember just looking at that and saying, ‘There just has to be a better way.’ Why can´t we go to a lightweight structural system that removes a lot of this pain?”

Cro explains that from his perspective, roofs and aluminium are something that go together very well. Aluminium is lightweight but can be engineered as part of a structural solution. Aluminium is an inherently non-corrosive material, well suited to Australian roofs subjected to harsh environmental conditions.

The Con-form Group team pride themselves on being able to innovate and rapidly develop bespoke solutions for their clients. Employing a skilled team of engineers, draftspersons, fabricators and installers and encouraging a culture of excellence and innovation.

“Your employees are your biggest asset – that is true. That will never change, it doesn't matter what sort of building you operate from, or what sort of machinery have. Your biggest asset, your most valuable asset will always be your team. So we´ve gone through very, very

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carefully and picked our team. Those individual people absolutely have to share the same culture and the same values that we as business owners do,” Cro says.

Nigel Cro describes the agility of his team as being unprecedented.

“I can go to our structural engineer who can do up a preliminary design sketch, send that through to the CAD team to draw it. It goes down to the machinery, which is fully automated, and I can have a sample on my desk within an hour. It´s as quick as that and that is very, very rarely seen.”

Equally important to Con-form’s business and success are strong industry partnerships with key suppliers. Nigel emphasises the importance of cultural fit and the significance this plays in selecting suppliers Con-form Group will partner with.

“We're very proud to be an Australian manufacturer. In years gone past we, like a lot of companies, purchased a lot of things from offshore. But as we realised what the importance to our customer is in timing as well as value of getting things local, we´ve brought a lot of things in house,” says Nigel.

Capral Aluminium is a key supplier to Con-form Group providing regular supply of standard and exclusive aluminium sections along with aluminium sheet and mesh products. Custom extrusions are a key element in the solutions Con-form create, and Capral works hand in glove with the Con-form team to assist in the development of exclusive extruded sections and ensure the business receives consistent and regular supply to its regionally located manufacturing site.

For Nigel Cro, the value of a strong partner like Capral is not limited to reliable material supply, “We get more value than a pallet of aluminium from Capral. That´s really where we’re at, and that comes back to the culture again. What can we exchange as industry colleagues between each other, rather than simply being a supplier that a truck comes in and it drops off something and you pay for it.

That´s not what we´re about. We need to exchange data between ourselves so that we can grow together as industry partners.”

PRODUCT NEWS

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There have been significant changes within the Australian aluminium industry over the past 24 months as many Australian manufacturers grapple with material import issues and supply shortages not to mention turbulent aluminium pricing and LME fluctuations. These changes are significant for manufacturers like Con-form who rely heavily on their ability to procure aluminium to manufacture and satisfy customer needs in a timely fashion.

Capral’s NSW Industrial Market Manager Mark Murray works closely with the Con-form team to ensure their needs are being consistently met and they are abreast of changing industry dynamics.

“Mark came out to visit us today, and that´s always great because things are changing so fast in the industry, extremely fast. Quicker than we can almost keep up with. Mark, he´s just a wealth of knowledge so I really took that time to try and draw out a lot of things out of him that I really didn´t know, and that really helped us as a company,” says Nigel, emphasising the value of this supplier partnership for his business.

Visit us during Australian Manufacturing Week on Stand MT83 to find out more and be in with a chance of winning a (lego) Ford F-150 Raptor.

Or visit ecisolutions.com/au How business gets done

Con-form Group stands out in the market for its solution focus and as a regional Australian manufacturer using Australian materials, ingenuity and labour. But more importantly, what they nail every minute of every day is their focus on what the customer is trying to achieve rather than simply responding to an order. ʺAny roof, any pitch, any weight, anywhere,” Nigel says, “that’s our promise, we will create the solution our clients need, and we are glad to have partners like Capral to support us.” capral.com.au

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At-Home Toolholder assembly program Building toolholders at home is a new direction in Innovation.

Lockdown has been tough for everyone, but the people at Integra Systems recognise they have been luckier than many due to the continuity of their work. For those in the local community who haven’t been so lucky and may have lost their income and/or sense of purpose, Integra found a way to help them through these difficult times: an at-home program for assembling toolholder kits.

The program idea came from their Director of Innovation, Russell Hughes, who adapted it from a traditional German cottage industry model used by the cuckoo clock trade.

In the Black Forest region of Germany, the villagers would get snowed in during the winter, so, to combat this issue, families focused on specific parts of cuckoo clock production, such as woodcarving, so they could generate an income during their isolation across the colder months.

The Integra at-home program works in a similar way to these cuckoo clock creators in Germany. “We create kits at our facility in Melbourne’s North and then send these kits out to members of the community,” explains Hughes. “These are families, students without work, single people, anyone who puts up their hand for it – who then assemble these kits into toolholders from their lounge rooms, garages or kitchen tables.”

Georgia Hughes and Nick Hardy, part of the team at Integra System, have been in charge of running this at-home program, packing their cars to the brim daily to deliver kits directly to the doors of workers as early in the morning as possible. Each kit comes as a set of components – screws, grub screws, final bags, final boxes, tools and parts ready to be assembled – that equate to 200 tool-holders per kit. Workers are paid per toolholder so, the more kits they can get through, the more money they make.

The completed toolholders then go to Integra’s client where they are distributed to major retail centres for tool merchandising displays.

“Providing kits to homeworkers in exchange for earning money is not a new initiative at Integra Systems,” explains Hughes. “The programs have had varying levels of success in the past but, with COVID and more people than ever working from home, or stood down from work, this initiative has worked extremely well.”

“The idea is to provide workers with a continuous supply of toolholder kits and incentivise the workers to make the toolholders by paying them for their hard work,” Hughes continues. “To run

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effectively, the program must involve simple processes that require few specialty tools. When the toolholders are picked up and kits are dropped off regularly, we’ve found that the home workers feel highly valued; that they are doing something productive and contributing to the supply chain.”

The Integra at-home toolholder kit program has been running since August, with a total of 18 families currently assembling toolholders on a regular basis. By the end of 2021, the home workers had assembled 25,000 tool-holders.

“We’ve got a family of workers – the Cleeve family,” explains Hughes.

“They decided not to keep the cash themselves but, instead, are a great example of paying it forward at a time when people are doing it tough. They’ve been using the money they’ve earned to purchase coffee cards for the frontline workers at the Austin Hospital.”

“People have joined this program for so many reasons, whether it’s to take some pressure off themselves or to help others. Either way, it’s a win-win situation for everyone who’s involved, including us here at Integra Systems.” integrasystems.com.au

PRODUCT NEWS

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Veolia launches The Barrel Veolia Water Technologies launches new disruptive technology for desalination and water reuse in the Asia Pacific.

Veolia Water Technologies, a subsidiary of the Veolia group and leading specialist in water treatment, announces the Asia Pacific launch of the Barrel, an integrated plug-and-play reverse osmosis (RO) technology.

With increasing demand and rising concerns over scarcity of fresh water in the Asia-Pacific region, the Barrel meets the challenges and expectations of the desalination market while producing fresh water complying with all water quality standards. It is also suitable for wastewater reuse and low-pressure RO applications.

The Barrel was selected as a key technology for the first experiment in Europe in wastewater treatment for the supply of drinking water through the Jourdain programme, in France’s Vendee region. The technology has also been in use at the Oman Sur desalination plant since 2019.

The Barrel is a multi RO element vessel that is designed to be a plugand-play system. The carbon steel pressure vessel is manufactured and tested off-site, and is delivered as a single unit, so installation on-site can be fast-tracked and project schedules shortened. In addition, the modular design of the Barrel makes it highly scalable, offering varying capacities from 400 m3/day to 50,000 m3/day per unit. It can also be used in place of existing RO membranes and nanofiltration skids for a more economically viable, sustainable, and innovative alternative.

Compact and suitable for outdoor installations, the Barrel offers a footprint reduction of up to 25% and does not require a controlled environment. The sustainable solution also provides a reduction in electrical consumption in the range of 0.05 kWh/m3 of fresh water produced.

Beyond sustainability, the unique design of the Barrel also significantly reduces the number of high-pressure piping connections down to just two — the seawater inlet and the brine outlet. This design feature makes it safer for operators and minimises risks on-site during the maintenance and operation phases. Corrosion is less likely to occur as seawater leakage sources found on the multiple high-pressure connections of traditional RO skids are reduced.

The Barrel also has a built-in digitalisation system with smart connectors providing real-time status updates on each membrane’s condition. In fact, their performance can be monitored automatically and accessed remotely — helping operators to make better decisions, whether to shut down, rotate, or replace membranes. veolia.com

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PREVENTING MEDICAL DEVICES’ CYBERSECURITY RISKS AND THREATS Web-connected medical devices can be exposed to cybersecurity threats like any other devices that communicate between networks and the internet. The Medical Technology Association of Australia (MTAA) Cybersecurity Working Group and innovative medical technology devices manufacturers Anatomics and Avicena provide updates to Carole Goldsmith, on their organisation’s advances and guidance on good cybersecurity practices to prevent risks and threats.

Medical devices’ internet and network connectivity, enables information sharing and treatment delivery. It does however expose medical devices to potential cybersecurity risks and threats, advises the Medical Technology Association of Australia (MTAA) on its website’s regulatory summary: Cybersecurity for medical devices.

These threats can be reduced and managed by good cybersecurity practices, with all stakeholders involved in the design, manufacture and use of medical technology, responsible for cybersecurity.

Director for Government Affairs, Australia/New Zealand at Abbott, Paul Davies chairs the MTAA’s Cybersecurity Working Group (CSWG). Abbott is a global healthcare company with a diverse range of businesses and products in diagnostics, medical devices, nutrition and branded generic medicines.

“Any MTAA member can contribute to the CSWG and it’s represented by med-tech majors, SMEs and software developers, whose products are used in hospital systems. We also liaise with the Australian Cybersecurity Centre which provides a link between the Australian Government and the private sector.

“One of the working group’s purposes is to be a clearing house for its participants to share experiences with each other, about what issues we’re confronting in Australia, and globally regarding cybersecurity.

As developers, Australian medical devices are built to very high standards. We always need to ensure that they can operate in the Australian context and be up-to date with the government’s security requirements,” advises Davies.

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A major accomplishment of the working group participants is the guidance document, developed by the Therapeutic Goods Administration (TGA), in 2020, with input from industry. The document Medical device cybersecurity for industry, Version 1-1 March 2021 has since been updated to this 2021 version, by the TGA. “One of the working group’s main focuses is to maintain a dialogue with the TGA about how that regulatory guidance is functioning and ensuring that it reflects any changes in the cybersecurity environment,” says Davies. “It also includes a lot of work that international regulators have been working on for some time.”

Davies adds that when developing products, you need to have systems in place to ensure that information security is maintained in medical devices’ development.

“Medical device developers need to ensure that data produced by their devices is appropriately protected, for example by encryption and identify vulnerabilities in software. Also have a system in place to take corrective action, which requires consultation with the TGA. “We want to ensure that because cyber risks are very dynamic and they change a lot, that we're providing accurate information to customers and patients. We (the CSWG) are also advising the medical devices’ industry on actions required to address those risks. So that’s a really important part of our dialogue with the TGA,” says Davies.

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Anatomics – World leader in manufacturing surgical applications.

of 3D biomodelling and has published and presented over 140 scientific papers and holds multiple international patents.

Melbourne innovative medical devices’ company Anatomics Pty Ltd has manufactured almost 5,000 specialised medical devices for surgeons world-wide since the company was founded 27 years ago. These include both patient-specific and standardised off-the-shelf (OTS) surgical implants and tools.

Anatomics customers include: Neurosurgeons, Plastic and Reconstructive Surgeons, Oral and Maxillofacial Surgeons, Orthopaedic Surgeons, ENT Surgeons and Thoracic Surgeons world-wide. “Our job is to work closely with these surgeons, to understand complex conditions and implement their feedback, to continuously improve our devices,” says Maher. “We incorporate their feedback into our quality management system, to ensure that our devices are the best possible for their patients.”

The patient-specific surgical applications are made directly from the patient’s CT scan, advises Anatomics VP Global Sales and Marketing, Gibran Maher: “Our engineers in Melbourne work with the patient’s surgeon and design the implant from each patient’s CT scan. Many of these are then individually 3D printed in medical polymer at Anatomics’ manufacturing site in Bentleigh, in Melbourne’s east.”

Anatomics has developed one of the world’s most advanced medical polymer implant manufacturing facilities. It has a range of 3D printers, an R&D laboratory, clean room, sterilisation facility, IT development area and office space. Anatomics employs 32 people, the majority are at its Bentleigh head office site with others based in Adelaide, Melbourne, Sydney, Brisbane, Auckland, San Francisco and Singapore.

Founder and Chairman of Anatomics, Professor Paul D’Urso is an internationally recognised Australian-born and educated neurosurgeon, scientist, and innovator. He pioneered the technology

The patient-specific devices are surgically implanted in the patient’s body and often allow tissue integration with vascularisation in as little as four weeks.

Continued next page

Founder Mr Paul D'Urso and Hon Greg Hunt MP at the launch of the Anatomics Headquarters in Melbourne, Australia.

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The StarPore® polymer tissue scaffold developed by Anatomics exhibits extremely good biocompatibility in patients, such that it is used to create new ears for children with microtia (congenital absence of an ear), advises Maher.

The company manufactures a diverse range of devices for neuro, spinal, facial, orthopaedic and thoracic surgeons. “Among Anatomics’ ground-breaking applications are our StarPore® thoracic implants and our SkullPro® beanie which helps the patient protect their brain after head injury surgery, instead of wearing heavy and bulky helmets.

“Anatomics has been working with the CSIRO to make SkullPro® smart by including sensors to monitor the brain and can relay data via 5G and WiFi to enable a brain machine interface using artificial intelligence. This will assist neurosurgeons to remotely determine the right time for reconstructive surgery. We already have SkullPro® 1.0, which is currently available for head injury patients worldwide.

Model 2.0 is under development with the CSIRO. Anatomics is very grateful to MTP Connect which has provided grants for R&D for both StarPore® and SkullPro®.

“The world’s first 3D printed thoracic reconstruction was manufactured by Anatomics in 2015 and now we have developed the next generation version,” says Maher. “Our StarPore® thoracic implants are the world’s only polymer tissue scaffold for thoracic reconstructive surgery and have been successfully implanted in Australia, USA, UK, Portugal and NZ.” StarPore® is the only porous high-density polyethylene polymer used to replace and repair people’s ribcages that are damaged by trauma, tumours or infection. Professor Paul D’Urso says: “Custom ribcage reconstruction was one of many Anatomics worldfirst applications which have revolutionised the way surgeries are performed. Previously surgeons used bone cement and wires to reconstruct the ribcage whilst the patient was on the operating table.”

Cybersecurity and medical implants When asked how Anatomics ensures cyber security of its devices, Maher says: “The most important thing for us is that we are compliant with the TGA cybersecurity guidelines and the USA regulatory standard, according to the Health Information Privacy Act. So, we use a range of software to ensure that we have complete encryption and privacy with all of our data. We outsource our advice to make sure that we're always compliant with the current stringent standards. The data that we get from patient scans is anonymised, so that identifying particulars or details are removed and no one else can ever see them.”

Speaking on Anatomics’ future plans, Maher advises: “The smart helmet SkullPro 2.0 is progressing very well and we now have a working brain machine prototype. We’re communicating with clinicians around the world to validate and verify the prototype and they believe that it will add a lot of value to the care of brain injured patients globally. We are also working with global key opinion leaders in neurosurgery, plastic surgery, rehabilitation and thoracic surgery to ensure the global success of our innovative portfolio.”

Anatomics Medical Manufacturing Facility in Melbourne, Australia.

Avicena Systems – Innovation in biosecurity screening Perth medical technology manufacturer, Avicena Systems has developed a ground-breaking, rapid pandemic scale surveillance screening instrument, aptly named Sentinel, which facilitates pathogen detection, including COVID-19. The Sentinel instrument can process more than 90,000 samples daily with data available in under 40 minutes, up to 10 times faster than the PCR (Polymerase Chain Reaction) COVID tests.

Avicena received a Federal Government $3m grant last July to scale up manufacturing of its Sentinel COVID-19 (and other pathogens) screening system. The device can be deployed at border checkpoints and airports, delivering results within 35 minutes of passenger sampling, enabling enough time to prevent an infectious person from boarding a flight.

“Our instrument is based on a flexible design that enables us to adapt the workflow easily to support screening for pathogens such as COVID-19, influenza, RSV (Respiratory Syncytial Virus), dengue, hepatitis B, malaria and TB,” advises Avicena’s CEO and CoFounder Tony Fitzgerald. “Each Sentinel instrument is a revolutionary molecular assay system designed to deliver over 92,000 samples per day with an average turnaround time of just 35 minutes.

“Avicena’s approach to pathogen screening is novel, because unlike other pathogen screening instruments, which use a batch-based approach to loading and processing, Sentinel uses a continuous random-access methodology, which results in a dramatic improvement in sample throughput and processing economics.”

The company’s Chief Innovation Advisor and electrical engineer, Paul Ostergaard is the Sentinel instrument’s principal inventor. The initial prototyping and testing of the Sentinel took around nine months.

Sentinel’s regulatory applications have been filed in Australia, the UK and USA and Europe has already approved it for test chemistry, advises Fitzgerald. “The Sentinel is being deployed in Perth for surveillance screening in the resources sector, under an exemption from WA’s Chief Health Officer, while TGA evaluation is underway.”

To date, Avicena has manufactured seven of its Sentinel systems and three portable Sentinel Mini instruments at its West Perth manufacturing site. As well as the two in Perth, one is installed in Budapest, Hungary, to screen the Budapest population for COVID and influenza. Another is being shipped to the US for validation trials and one to Victoria for COVID pilot testing.

Biosecurity and Cybersecurity enabled

Anatomics Selective Laser Sintering (SLS) 3D Printing Room used for biocompatible part printing.

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When asked how the Sentinel works, Fitzgerald explains: “The Sentinel uses a nucleic acid amplification technology called LAMP (Loop Mediated Isothermal Amplification) which can amplify the genetic material of a pathogen up to a billionfold. PCR uses a similar approach but LAMP is much quicker and can be equally sensitive.”

“As a biosecurity testing device, the LAMP test chemistry used on the Sentinel can be substituted if new pathogens emerge or there is a big outbreak of a current pathogen such as influenza,” says Fitzgerald. “Because the daily throughput is potentially so high

MEDICAL

Anatomics AcrylicTM Cranial Implant, manufactured from polymethylmethacrylate (PMMA) for placement in a craniectomy defect in order to restore bone structure and contour.

(92,000+ per day), it is feasible to do a population scale screening in the event of a resurgence of the current COVID pandemic or a new pathogen pandemic such as TB which is emerging again in some countries.”

To ensure cybersecurity for Sentinel users, Fitzgerald advises that the Sentinel only requires the barcoded specimen tube ID and the machine does not store any personal information. The association between the sample ID and the candidate is performed through external systems such as the pathology provider.

your

G AT E W AY to a SMARTER FUTURE

“Communication between the Sentinel and the cloud is encrypted, and access requires a multi-factor authentication to help prevent unauthorised access. The firewall provides protection against intrusion and full audit logs are maintained. Access to the Sentinel itself requires operator access through authentication on a peruser basis. Cyber security provisions follow the TGA guidelines for medical devices.”

Manufacturing the Sentinel The Sentinel is modelled using 3D CAD to produce its components which includes: aluminium machined parts, extrusion cut to length, sheet metal fabrication and 3D printed custom parts, explains Fitzgerald. “Detailed design then follows according to the product specifications and often the elements with higher risk are tested using rapid prototyping. In-house 3D printing really helps with quick turnaround.

“The Sentinel’s detailed design in 3D ensures the correct alignment of all parts and eliminates the risk of mechanical interferences. This is really important for a robotic machine with multiple moving axes.

“Assembly instructions are accessed on-line using iPads which ensures the correct documents are always being used. Once an assembly has been built and tested, the assembly procedure is signed off electronically with full traceability of and by whom and when the work was done,” advises Fitzgerald.

Avicena’s future plans are very positive, with a strong emphasis on markets in North America, the Middle East and Australasia. “We are looking at diverse testing of pathogens across the world. If different pathogens are discovered, you have to be able to screen for it rapidly and the Sentinel is an ideal solution.” avicenasystems.com anatomics.com

26 TH INTERNATIONAL SHEET METAL WORKING TECHNOLOGY EXHIBITION • Sheet metal, Tube, Sections • Handling • Forming • Finished products, Parts, Assemblies • Separation, Cutting • Joining, Welding • Flexible sheet metal working • Tube / Section working • Composites • Surface treatment • Tools, Dies • CAD / CAM / CIM systems / Data processing

Anatomics StarPore® Craniofacial Implants, manufactured from an advanced porous polyethylene (HDPE) polymer tissue scaffold for the repair or augmentation of contours in the skull and face.

2 5 – 2 8 O C TO B E R 2 0 2 2 H A N OV E R , G E R M A N Y www.euroblech.com

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RMIT research commercialisation trailblazer Professor Calum Drummond awarded CRA Lifetime Achievement Award.

Professor Calum Drummond, RMIT Deputy Vice-Chancellor Research and Innovation and Vice-President, has been awarded a Lifetime Achievement Award for Contribution to Industry-Research Collaboration by Cooperative Research Australia (CRA) at its Excellence in Innovation Awards at Parliament House in Canberra on Thursday night (March 31).

The Lifetime Achievement Award recognises Professor Drummond’s remarkable 35-year professional career advancing industryresearch collaboration, and outstanding contributions to research and innovation through leadership, governance, and researcher development.

Professor Drummond is an Officer of the Order of Australia (AO) recipient, and was awarded the Victoria Prize for Science and Innovation in 2015 for his fundamental chemistry research, involving the Australian Synchrotron, that is enhancing industrial products and improving nanomedicine outcomes through drug delivery using lipid nanocarriers.

research translation outcomes that contribute to the prosperity of Australia,” CRA Chief Executive Jane O’Dwyer said.

“Cooperative Research Australia is delighted to award Professor Drummond a richly-deserved Lifetime Achievement Award for Contribution to IndustryResearch Collaboration.”

On receiving the CRA Lifetime Achievement Award, Professor Drummond said: “I have always had the mindset that conducting excellent research is necessary but not sufficient by itself - it is what you do with the excellent research to benefit others beyond the academic community that is most important.

He has worked directly with more than 30 companies adding value to their businesses. As a senior executive at CSIRO, RMIT (since 2014) and London Stock Exchange-listed CAP-XX, he has enabled thousands of Australian researchers to collaborate with companies to solve problems and capture opportunities for Australian industry.

“My research and collaboration efforts, including with CRCs, are driven by the desire to innovate and partner for impact, through understanding and solving problems faced by industry and the community. It is humbling and indeed an honour to receive recognition for our work.”

“Professor Drummond has made an astonishing impact in a remarkable career to date, and has been a steadfast champion of the CRC Program going back 30 years. His approach to conducting and managing research is one which is founded on an uncompromising focus on research excellence coupled with passionate pursuit of

Professor Drummond was one of two Lifetime Achievement Award recipients revealed at the CRA Innovation Awards. Worldrenown hearing expert Professor Bob Cowan from the University of Melbourne is the other recipient. rmit.edu.au

Precision 3D printed implants in the scan to surgery process can halve recovery time for patients In 2019, it has been estimated that 600,000 implants were produced with 3D printing.

Demand driven by an aging population, joints wearing out with sports, bone loss with trauma and medical conditions, it is no wonder the requirement for implants is projected to grow to four million by 2027.

Additive manufacturing has been used since the 1990s to customise patient-specific implants, which makes surgeries easier with 3D printed surgical guides and also leads to better healing outcomes for the patient. Osseointegration is the medical term for the direct structural and functional connection between living bone and surface of a load-bearing implant. Because titanium alloy is around three to four times stiffer than bones, biomechanical engineers must tailor the size and shape of the implant’s lattice structure to adjust the pliability of the implant to be closer to bone’s stiffness. Research has shown the rough texture of lattice structures in implants (that can only be made with 3D printing) promotes osseointegration and facilitates soft tissue and bone regrowth. Metal implants are 3D printed using powder bed fusion technology, including direct metal laser melting, with titanium, cobalt-chromium alloys and stainless steel being the most suitable materials due to their excellent corrosion resistance, mechanical strength, and no cytotoxicity properties.

With advancements in technology that uses artificial intelligence to segment a patient’s radiological scan to create the computer aided design as the precise input for the 3D printing process, surgeons are equipped with 3D visualisation tools for explaining the surgical procedures to patients, enabling more informed decision-making and a peace of mind. AI-powered technology can also segment

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AI-segment spinal vertebrae screenshot, courtesy of Singular Health))

the spinal vertebrae within minutes with an accuracy rate of 95% to design custom implants. Previous segmentation methods required thousands of hours of manual identification and markups to hundreds of computerised tomography (CT) scans. The final approved design is sent through to Additive Engineering for manufacturing. The file is checked to be suitable for 3D printing. The as-printed part is heat treated, surface roughness and measurements checked, sterilised and sealed in a tamper-resistant packaging and sent to the surgeon within days for use in surgery. additiveengineering.com.au

MEDICAL

Sonic advance: How sound waves could help regrow bones Researchers have used sound waves to turn stem cells into bone cells, in a tissue engineering advance that could one day help patients regrow bone lost to cancer or degenerative disease.

The innovative stem cell treatment from RMIT researchers offers a smart way forward for overcoming some of the field’s biggest challenges, through the precision power of high-frequency sound waves. Tissue engineering is an emerging field that aims to rebuild bone and muscle by harnessing the human body’s natural ability to heal itself. A key challenge in regrowing bone is the need for large amounts of bone cells that will thrive and flourish once implanted in the target area.

A magnified image showing adult stem cells in the process of turning into bone cells after treatment with highfrequency sound waves. Green colouring shows the presence of collagen, which the cells produce as they become bone cells. Magnification: 60X

To date, experimental processes to change adult stem cells into bone cells have used complicated and expensive equipment and have struggled with mass production, making widespread clinical application unrealistic.

the stem cells, before we either coat them onto an implant or inject them directly into the body for tissue engineering.”

Additionally, the few clinical trials attempting to regrow bone have largely used stem cells extracted from a patient’s bone marrow – a highly painful procedure. In a new study published in the journal Small, and co-written by with first author and PhD researcher Lizebona August Ambattu, the RMIT research team showed stem cells treated with high-frequency sound waves turned into bone cells quickly and efficiently. Importantly, the treatment was effective on multiple types of cells including fat-derived stem cells, which are far less painful to extract from a patient. Co-lead researcher Dr Amy Gelmi said the new approach was faster and simpler than other methods.

“The sound waves cut the treatment time usually required to get stem cells to begin to turn into bone cells by several days,” said Gelmi, a Vice-Chancellor’s Research Fellow at RMIT. “This method also doesn’t require any special ‘bone-inducing’ drugs and it’s very easy to apply to the stem cells,” she said. Our study found this new approach has strong potential to be used for treating

The high-frequency sound waves used in the stem cell treatment were generated on a low-cost microchip device developed by RMIT. Co-lead researcher Distinguished Professor Leslie Yeo and his team have spent over a decade researching the interaction of sound waves at frequencies above 10MHz with different materials.

The sound wave-generating device they developed can be used to precisely manipulate cells, fluids or materials. “We can use the sound waves to apply just the right amount of pressure in the right places to the stem cells, to trigger the change process,” Yeo said.

“Our device is cheap and simple to use, so could easily be upscaled for treating large numbers of cells simultaneously – vital for effective tissue engineering.”

The next stage in the research is investigating methods to upscale the platform, working towards the development of practical bioreactors to drive efficient stem cell differentiation. The multidisciplinary research, across the RMIT schools of Science and Engineering, was supported by funding through Australian Research Council Discovery Project grants.

Story: Gosia Kaszubska rmit.edu.au

IMCRC collaboration is developing laser for cutting edge robotic dentistry A collaborative project between the Innovative Manufacturing Cooperative Research Centre (IMCRC), dental technology company Dentroid Technologies and Griffith University is bringing us one step closer to comfortable, pain free dentistry.

The research project will develop a high-power laser micro-electromechanical systems (MEMS) mirror (or “micromirror”) for the world’s first in-mouth laser-enabled robotic assistive device. By replacing the traditional drill mechanism with gentle lasers, the innovative device will help dentists to provide patients ultra-precise and needle-free dental treatment with unprecedented convenience and speed. The project is worth $650,000 in research effort.

Dr Jason Coonan, IMCRC’s Deputy CEO, said that with automation and robotic assistance in dentistry still in its early stages, IMCRC was proud to be co-funding the development of this tremendously exciting technology as well as laying the foundation for manufacturing the MEMS mirror in Australia.

“This research collaboration has wide-ranging impacts, from improving oral health for many populations across the world to leveraging Australia’s position as a global leader in dental excellence,” he said.

“As this project demonstrates, effective collaboration between industry and research partners is the key to delivering mutually beneficial translational research outcomes that grow Australia’s medical technology manufacturing industry and create global export opportunities.”

Dr Omar Zuaiter, CEO of Dentroid Technologies said that the IMCRC research collaboration would enable Dentroid to deliver a device that would meet the growing demand for quality dental care and improve access for remote and disadvantaged communities.

“We’re excited to join forces with IMCRC and Griffith University to develop this world first micromirror. IMCRC’s funding will enable us to ultimately manufacture the in-mouth robotic assistive device that will herald a new era of accessible dentistry,” he said. “Because our in-mouth device is compact, portable, and easy to use, it can facilitate early screening and diagnosis of dental issues, and then help administer the right treatment at the right time. The device will also enable remote and mobile dentistry, a game changer when it comes to improving access and quality of oral healthcare across Australia.” Griffith University Professor Dzung Dao said he was delighted to be collaborating with IMCRC and Dentroid to assist with the development of such a cutting edge and impactful product.

“This collaborative research and development model means Griffith University can leverage our resources and technology to help Dentroid overcome barriers and develop, scale-up and deploy a locally made product of global significance,” Dao said. imcrc.org

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The race to manufacture Ellume’s COVID-19 rapid diagnostic tests In an Australian manufacturing success story, Ellume is in the process of automating the high-volume production of its rapid COVID-19 home test using the latest technologies from Bosch and Rockwell Automation.

The COVID-19 pandemic has rapidly spread to all parts of the globe. There have been more than 395 million cases around the world and this figure continues to rise rapidly. Healthcare systems are overwhelmed and continue to face a multitude of challenges as they work to manage demand while providing high-quality care.

Communities, governments and industry around the world are now recognising the importance of minimising the requirement for widespread lockdowns and travel restrictions, which have been the main line of defence against COVID-19 since the start of the pandemic.

As countries around the world move towards a new post-pandemic normal, rapid diagnostic testing has an integral role in reducing disease burden, managing outbreaks and community transmission, and reducing pressure on healthcare systems.

Ellume, a Brisbane-based digital diagnostic company, has recently developed a rapid COVID-19 home test which detects the SARSCoV-2 antigen and complies with Centers for Disease Control and Prevention (CDC) reporting requirements. Accurate results are provided within 15 minutes, providing users with quick results, and helping communities to return to a ‘new normal.’ With a growing list of orders, predominantly from the United States, ensuring supply was a key priority for Ellume.

The project utilised more than 160 robots, 200-plus visions systems and more than 60 PLCs

Ellume called on Bosch Australia Manufacturing Solutions (BAMS), a leading supplier of factory automation for the medical device industry, to automate the high-volume production of its COVID-19 diagnostic tests. This involves 27 new production lines in total – three new lines for Ellume’s facility in Brisbane, Australia and 24 production lines for their facility in Maryland, U.S. “We are providing Ellume with 18 fully automated assembly lines for manufacturing the home COVID-19 analyser unit. This also includes an end-of-line test system which communicates to the analyser unit over Bluetooth and completes a functional check to ensure the quality of the part,” said Bradley Trewin, Programme Manager, BAMS. “BAMS is also manufacturing nine lines for the production of the ‘dropper’ which will fully automate the assembly and packing of this product,” he added.

Ellume invested in new manufacturing lines for their facilities in Australia and the US.

Scaling up production To meet the consumer demand for COVID-19 home tests, Ellume has invested in new manufacturing lines for their facilities in both Australia and the U.S. “COVID-19 isn’t going away anytime soon and as communities and economies continue to open up there will be increased need for rapid antigen tests which is why automating our production is vital to meet a surge in consumer demand,” said Sean Parsons, founder and CEO, Ellume.

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Once complete, the production capacity will be nine parts per second.

MEDICAL

Next generation technologies The Bosch manufacturing experience and factory automation know-how has benefited this project immensely. The production lines are being manufactured at Bosch’s headquarters in Clayton, Victoria. More than 160 robots are being utilised on this project, there are also 200-plus vision systems which are cameras that inspect and evaluate the line, and more than 60 programmable logic controllers (PLCs).

“We are delighted to bring the BAMS automation expertise to support Australian med-tech manufacturing for a global market – a real positive for local manufacturing, and a positive for the testing and medical diagnosis of COVID-19,” said Gavin Smith, President of Bosch Australia.

Ellume’s rapid COVID-19 home test provides accurate results within 15 minutes.

An Australian manufacturing success story Ellume’s technology addresses the unprecedented global demand for accurate and rapid diagnostics as accessible, reliable, and fast diagnostics become increasingly critical to the COVID-19 response.

Given the widespread supply shortages resulting from the pandemic, Rockwell Automation has prioritised their global supply chain to applications and machines that can help in the fight against COVID-19. “Our priority is to support local manufacturing, helping to ensure that we are able to provide much needed assistance to those requiring it urgently,” said Anthony Wong, regional director, Rockwell Automation.

“By working with local innovative companies such as BAMS and Ellume, we can deliver next generation technologies to help mitigate the risks of COVID-19 while also strengthening the Australian manufacturing industry,” he said.

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The new Ellume manufacturing facility will be one of the largest of its kind in the Southern Hemisphere. The production lines for Ellume’s Brisbane facility are undergoing final testing and likely to be operational by the end of February, whilst the first U.S. lines departed in November 2021. The final lines for the US are expected to be installed and operational in mid-2022. Once complete, the production capacity across the whole Ellume project will be nine parts per second.

“We’ve spent the last decade perfecting our technology, and now, in the midst of the COVID-19 pandemic, the role of rapid, accurate diagnostics has never been more important. Ellume is pleased to be working with Bosch to bring their world-leading automation know-how to our manufacturing process. This will allow Ellume to manufacture best-in-class diagnostics that can be relied on in a health crisis,” said Dr Parsons.” ellumehealth.com

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MATERIAL REMOVAL

Grinding robots market size to grow

by AUD$74m by 2026 The latest grinding robots market report by Technavio infers that the advantages of grinding robots over CNC machines is driving this market's growth, resulting in market growth of the equivalent of A$74m from 2021 to 2026.

The grinding robots market is fragmented and the vendors are deploying growth strategies such as technological innovations to compete in the market. 3M Corp., ABB Ltd., Accord Corp., Acme Manufacturing, Danbach Robot Jiangxi Inc., Daru Technology Suzhou Co. Ltd., Epica International Inc., FANUC Corp., Force Robots, Heinz Berger Maschinenfabrik GmbH and Co. KG, Kawasaki Heavy Industries Ltd., MESH Automation Inc., MIDEA Group Co. Ltd., Mitsubishi Electric Corp., NACHI FUJIKOSHI Corp., PushCorp Inc., Reichmann and Sohn GmbH, Seiko Epson Corp., Teqram BV, and Yaskawa Electric Corp., among others, are some of the few key vendors competing to maintain their market position in the market, at least in the European and US markets.

In the manufacturing industry: Market dynamics in some major processes and discrete industries are changing drastically, and manufacturers are gradually feeling the brunt of excessive demand fluctuations. The fluctuating prices of oil and gas and metals in the global market and the shortage of a skilled workforce worldwide have directly affected the profitability of manufacturing companies.

A sudden and unexpected shift in market dynamics can drastically impact manufacturing processes and investments in capital goods.

The advantages of grinding robots over CNC machines is notably driving the grinding robots market growth, although factors such as preference for CNC grinding machines among SMEs may impede market growth. Our research analysts have studied the historical data and deduced the key market drivers and the COVID-19 pandemic impact on the grinding robots industry. The holistic analysis of the drivers will help in deducing end goals and refining marketing strategies to gain a competitive edge.

Key Grinding Robots Market Driver One of the key factors driving the global grinding robots market growth is the advantages of grinding robots over CNC machines.

This includes the relatively lower investment costs, ergonomic benefits due to the smaller footprint of robots, and the ability for grinding robots to carry out other preceding and subsequent multiple applications such as material handling. These robots ensure remunerative ROI and quick payback, as they help in increasing throughput and material yield and reducing labor costs, waste, and cleanup. Apart from these, in CNC grinding machines, there are additional indirect costs associated with a decline in productivity due to operator fatigue and strain injuries, which can cost up to US$20,000. End-users desirous of improvements in production efficiency are increasingly investing in grinding robots as their deployment reduces the number of rejected parts. Such factors will further support the market growth in the forecast period.

Key Grinding Robots Market Trend Advances in force control sensor technologies is one of the key grinding robots market trends that is expected to impact the industry positively in the forecast period. Improvements in grinding robots will include the use of enhanced force control sensors so that the robot slows down to prevent the breaking of the material removal tool and then repositions itself to take off smaller amounts of material automatically in order to maintain the surface finish. For instance, 6D force-torque sensors are increasingly being used to ensure that a defined contact force is maintained between the robot and its environment during any movement. This will further support the market growth in the coming years.

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Key Grinding Robots Market Challenge One of the key challenges to the global grinding robots market growth is the preference for CNC grinding machines among SMEs. Although grinding robots have several advantages over CNC grinding machines, their adoption by small and medium enterprises (SMEs) is relatively low due to the high deployment cost of robots and the budget constraints that SMEs face. The market will see a major threat of substitution from CNC grinding machines owing to the factors such as the low need for programming and specialized maintenance skills, high level of stiffness and rigidity that provide more accurate results, and faster cycle times. The preference given to CNC grinding machines, coupled with the low awareness of grinding robots, will pose a challenge to the market growth during the forecast period. technavio.com/report/grinding-robots-market-industry-analysis

MATERIAL REMOVAL

Suck it up with seven horses EXAIR’s Heavy Duty HEPA vacuum for 205-litre drums EXAIR’s Heavy Duty HEPA Vac is a powerful industrial vacuum cleaner, available to suit ordinary 205-litre (44-gallon) open top drums. With no moving parts to wear out, it requires little to no maintenance, as long as it is supplied with clean, filtered air. The HEPA Vac can be used with any open head steel, fibre or plastic drum that is in good condition.

The Heavy Duty HEPA Vac has a hardened alloy construction making it suitable for use with abrasive materials as well as for general purpose applications. Designed to move more material with less wear, the suction force of this system is the equivalent of around a seven horse-power vacuum. It is extremely quiet at 82dBA (half the noise level of electric vacs), making it suitable for a wide variety of environments.

It has been engineered to filter contaminants to HEPA requirements in dusty environments requiring frequent cleaning. An economical, easily maintained pre-filter stops larger particles, while the H13 class HEPA filter handles the smaller matter. All filters are tested for minimum 99.97% filtration at the 0.3-micron level to meet HEPA standards in strict accordance to IEST-RP-CC-007.

Available from Compressed Air Australia, the Heavy Duty HEPA Vac System comes complete with the Heavy Duty Dry Vac, lever lock drum lid, shutoff valve, pre-filter, HEPA filter, 3m static resistant hose, hose hanger, half-inch quick connect coupling, six-metre compressed air hose, pressure gauge, heavy duty aluminium tools, tool holder and drum dolly. It is OSHA and CE Compliant, and comes with a five-year “Built to Last” warranty. caasafety.com.au

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Models to Suit most Applications including Aluminium Manufactured in Japan by Koyo Giken Co., Ltd MySpot® is produced in a variety of sizes and configurations, including pedestal style.

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Jim’s Machines and Accessories Authorised Sales & Service Agents Australia and New Zealand Call: +61(0) 414 646 212 Mail: info@jimsmachines.com.au

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MATERIAL REMOVAL

EcoClean: precision and ultra-fine cleaning Cleanliness in submicrometer and atomic percent range In many industry areas new and enhanced products lead to very high cleanliness specifications.

Due to changed manufacturing, joining and coating technologies and more stringent regulatory specifications, there are stricter requirements for particulate and film-type part cleanliness. To reach these values in series production in a process-reliable and efficient way, not only cleaning and drying processes meeting demands and suited system technology, also software implementation and cleaning environment must be adapted accordingly.

Whether production equipment for the semi-inductor industry, biotechnology, laser and sensor technology, devices for measuring and analysis technology, components for accumulators and fuel cells, optical systems or metal cutting tools, the requirements for performance and reliability are extremely high. This not only leads to high demands in terms of production precision of the parts, but also their cleanliness. For medical technology products such as implants, instruments, cannulae and endoscopes, particulate and film-type contamination from manufacturing processes is an essential criterion due to regulatory specifications.

Moreover there is a trend for miniaturisation and functional integration with ever smaller and more complex components. These developments entail that particulate cleanliness specifications in the micrometre and even nanometre ranges as well as very stringent requirements regarding residual thin-film contamination must be met by more and more industry sectors.

Depending on components and/or applications, outgassing rates for organic substances and residual moisture may also have to be met, as well as limit values down to the atomic percent range when it comes to surface analyses for residues of prohibited substances. To produce these miniaturized components there is also an evolution towards ever larger integrated manufacturing modules. This also creates new challenges for the cleaning processes and the machine systems required to implement them.

The result is a series of very demanding parts cleaning tasks across the complete manufacturing chain. As a supplier of futureoriented complete solutions, SBS Ecoclean Group of companies covers the whole range of precision and ultrafine cleaning.

This enables them to adapt cleaning processes, their control software as well as the machinery and ambient conditions to the requirements and applications on hand.

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These ultrasonic ultrafine cleaning systems are specifically dimensioned for the application on hand.

Their various treatment stations can be flexibly accessed so that defined processes can be prioritized.

Photo credit: Philips Medical Systems

The right system concept For selection of the suitable cleaning system for a specific task, the first thing looked at is whether the system is to be used for pre-cleaning, intermediate cleaning or final cleaning. Depending on the use and cleanliness specifications to be achieved, the solution may be chamber or multi-tank immersion machine, a flexible ultrasonic multitank machine based on standardized modules, or a customized ulrasonicsbased ultrafine cleaning system. The cleaning chemicals as well as the optimal process technologies such as for example spraying, high-pressure fluid application, immersion, ultrasonic or megasonic treatment, plasma cleaning, injection flood wash, pulsated pressure cleaning (PPC) as well as passivation/preservation as required, are also specifically chosen for the application and the contaminants to be eliminated.

Cleaning processes and systems for ultra-high cleanliness The design of customized ultrasonic multichamber systems and processes for ultrafine cleaning applications are the core competence of Switzerland-based UCM AG. Key factors to be considered are the material and geometry of the parts to be cleaned, the type and quantity of contaminants, the particulate or film-type cleanliness specifications and, where applicable, permitted outgassing rates and maximum acceptable residues of prohibited substances in the atomic percentage rate. Another important aspect is the selection of suitable cleaning chemicals and wash fluid, for example reverse osmosis water or deionized water.

The materials and manufacturing methods used to build the cleaning system and automatic transport system are also selected with the prevention of dirt build-up,

By combining wet chemical and low-pressure plasma cleaning methods for ultrafine degreasing in a single machine, the surface characteristics required for downstream coating or bonding are efficiently achieved. Photo credit: Ecoclean

MATERIAL REMOVAL In the immersion/spray rinse tanks specifically developed for ultrafine cleaning processes, the parts are sprayed off as they exit the bath. This enhances the rinsing result. Photo credit: Zeiss

re-contamination and cross-contamination already in mind. Outfitting with clean roomgrade components and interfacing with clean rooms are also possible.

Standard equipment installed in precision and ultrafine cleaning systems are multifrequency ultrasonic systems that offer flexible adjustment of ultrasonic frequency and intensity to the requirements of different parts to be cleaned. With parts that present complex geometries, capillary structures or porous surfaces, such as for example sintered metal components or

additive manufactured components, the PPC method comes into play. Features such as multi-side overflow in all wash and rinse tanks as well as the immersion/spray rinse technology specially developed for ultrafine cleaning systems contribute to the reliable meeting of very severe cleanliness specifications.

The decision which parts are taken to which wash and rinse tanks as well the part-specific process parameters such as temperatures, ultrasonic output and frequency, intensity of PPC, dwell time

in the various wash and rinse tanks, are defined during the process development phase. Depending on the complexity and heat absorption capacity of the parts, drying is mostly done using infrared or vacuum technology. The resulting partspecific cleaning programs are stored in the machine controller. The softwarecontrolled implementation of the cleaning sequence plays a decisive role in this context. It ensures among other things that the specified dwell times in wash and rinse tanks are precisely observed, and that prioritized sequences - e.g. for very fragile parts - can be programmed.

The best system and process solution from a cleanliness and economic efficiency point of view can be determined through cleaning trials with original parts in Ecoclean’s and UCM’s Precision Cleaning Technology Centres. ecoclean-group.net

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AUSTRALIA’S PREMIER MANUFACTURING SOLUTIONS EVENT

AMW SYDNEY ’22 NOW OPEN TUESDAY 7-FRIDAY 10 JUNE, 2022 Tue: 10am-5pm • Wed 10am-5pm Thu: 10am-4.pm • Fri 10am-4pm INTERNATIONAL CONVENTION CENTRE SYDNEY

IT’S NOT TOO LATE – REGISTER HERE NOW!

DON’T MISS OUT! Australian Manufacturing Week is proudly owned and operated by AMTIL

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AUSTRALIA’S PREMIER MANUFACTURING SOLUTIONS EVENT

SHOWCASING THE LATEST IN MANUFACTURING TECHNOLOGIES AND PROCESSES ACROSS 6 PRODUCT ZONES

AUSTRALIAN MANUFACTURING WEEK is the industry exhibition encompassing all aspects of manufacturing in Australia. AMW will showcase the latest in manufacturing technologies and processes, with a strong focus on innovation and digital transformation.

AMW will be a week-long celebration of manufacturing in Australia today.

For more information visit WWW.AUSTRALIANMANUFACTURINGWEEK.COM.AU

LEARN ABOUT AMW MELBOURNE 2023

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PREVIEW

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Multicam CNC routing machinery Multicam Systems has over 30 years of experience in the manufacture of flatbed CNC routing machinery.

Multicam CNC routers have been used in various engineering industries since inception. We are excited to be able to demonstrate how Multicam CNC routers can be a solution for Engineering companies in the plastics, metal and composite products industries at this years’ event.

Multicam Heavy Duty CNC Routing machines are proudly made in Australia. Designed for profile cutting sheet product and extrusions including metals, plastics, composite materials, and timber products, they are used in the manufacture of Aluminium boats, Aerospace components, Truck body parts, Caravan & Motor Home components, Kitchens, Furniture or any other flat sheet product.

They are used extensively in the ACM and HVAC industries and include many unique design features aimed specifically at making the processing of ACM cladding and ducting and insulation materials easier and more efficient.

Other specialist features ensure that Multicam machines are an excellent alternative to Plasma and Laser machines that typically have higher running costs and greater servicing demands.

Multicam CNC routers are available in a range of sizes with process areas starting from 2400mm x 1200mm with larger and custom sizes available. Multicam machines can be supplied with a variety of accessories including vacuum hold down beds, fully automatic tool changers, automatic loading and unloading attachments, mist cooling/lubrication system, chip extraction, multiple drill heads, tangential-oscillating knife attachments and more.

Multicam Systems has over 30 years of experience in the manufacture of flatbed CNC routing machinery and has been

providing CNC routing solutions through our offices in Newcastle, Melbourne and Brisbane. Multicam CNC routing machines are backed up by a highly skilled team of factory trained technicians ensuring the best possible level of advice and service.

The ability to link with software programs such as Fusion360, Mastercam, SoldiCAM, Surfcam, Rhino, Pytha, ARTCam, Enroute and numerous other products makes Multicam CNC routers an obvious addition to any engineering company.

Multicam CNC Routing Machinery Stand MT22 multicam.com.au

Air Liquide leverages energy and environment transition Providing the right gas is just the start of the journey. Air Liquide’s ambition is to lead its industry, deliver long term performance and contribute to sustainability.

A world leader in gases, technologies and services for Industry and Health, Air Liquide is present in 80 countries with approximately 66,000 employees and serves more than 3.6+ million customers and patients. Oxygen, nitrogen and hydrogen are essential small molecules for life, matter and energy. They embody Air Liquide’s scientific territory and have been at the core of the company’s activities since its creation in 1902.

Air Liquide’s ambition is to lead its industry, deliver long term performance and contribute to sustainability. The company’s customercentric transformation strategy aims at profitable growth over the long term. It relies on operational excellence, selective investments, open innovation and a network organisation implemented by the Group worldwide.

Through the commitment and inventiveness of its people, Air Liquide leverages energy and environment transition, changes in healthcare and digitisation, and delivers greater value to all its stakeholders.

Air Liquide Australia Limited provides innovative, responsive and customer focused services to our product range, which improves

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the performance of our customers while helping protect the environment.

Air Liquide goes beyond simply selling molecules of gases. They believe in learning the customers' businesses to provide them with true value. They ask key questions and listen to the answers. That dialogue continues throughout the business relationship with their customers as they seek to contribute ideas to help them improve their operational processes, both business and manufacturing, while improving their own business process.

They commit themselves to understand and fulfill the customers' requirements and expectations.

Air Liquide also carries out their activities in a manner which uses the ISO 9001 Quality Standard to verify the quality and continuous improvement of their policies, procedures, work instructions and management systems, and ensures that their products and services satisfy the highest standards, through the application of best practices.

Air Liquide Australia Ltd Stand WT12 industry.airliquide.com.au

PREVIEW

Panel benders look to the future The panel bender is the machine which more than any other, represents the Salvagnini spirit. This unit is a solution able to combine cutting-edge technology with productivity, autonomy and flexibility.

The Salvagnini panel bender confirms its place as the undisputed protagonist in the world of smart manufacturing. The unit is fully automated and adaptive, with 11 different models available.

Over 4,000 installations in 76 countries, the world’s largest panel bender manufacturing plant and over 40 years of experience and competence speak for themselves: Salvagnini is an authority on ‘panel bending 4.0’, a flexible process the likes of which have never been seen before, with application boundaries now extending to sectors and environments that have always been considered poorly suited to this technology. At the Australian Manufacturing Week in Sydney, Salvagnini is proposing its compact P2-2120 panel bender, one of its most successful models, which is able to natively combine productivity and flexibility, producing an average of 17 bends per minute. The P2 doesn’t need re-tooling, because the upper and lower blades, the counterblade and the blank-holder, are universal tools, able to process the whole range of thicknesses and machinable materials. The automatic blankholder adapts the tool length according to the size of the part being produced in-cycle, without machine down-times or manual retooling. But the P2 also automatically adapts to changes in material.

“The Salvagnini panel bender is an automatic machine in every aspect, and as such is ideal for a modern smart factory,” explains Nicola Artuso, Salvagnini Product Manager for bending technologies. “The P2 we are presenting today, in addition to its consolidated features such as the maximum height and length of the bend, which reach 203 and 2,180mm respectively, or the overall footprint of less than 35m2, also has several interesting innovations such as MAC3.0.”

MAC3.0 is a set of integrated technologies – sensors, formulae and algorithms – to make the P2 even more intelligent. MAC3.0 allows the P2 to adapt to the material being folded by measuring the tensile strength in real time and comparing it to the reference values of some of the most common materials on the market.

If the mechanical characteristics of the material being machined are within ±25% of the reference value, compensation is fully automatic.

MAC3.0 reduces the risk of obtaining faulty parts and eliminates rework-ing and material waste – a highly significant detail in the current economic situation, where each kilogram of raw material saved represents a considerable economic benefit.

“The functions of MAC3.0 do not end here,” Artuso continues. “If necessary, MAC3.0 also makes it possible to define new materials simply and intuitively. This new material can then be called up in a few clicks: the panel bender adapts the bending force as necessary to keep working within the parameters. These newly defined materials can also be used as the starting point for new adjustments and new materials. This is an extremely interesting solution and is particularly relevant in today’s raw material supply chain where sourcing difficulties, along with the dynamism of the market and the need to comply with set delivery times, force companies to accept compromises on sheet metal quali-ty, risking significant increases in waste.”

Salvagnini Italia S.p.A Stand MT79 salvagninigroup.com

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Applied bringing the Yawei pressbrake at AMW New handheld fiber laser welder one of several products Applied will be exhibiting at Austech as part of AMW. Applied Machinery will again be showcasing a diverse range of machines at Austech.

Taking centre stage on the Applied stand will be a 9-Axis Yawei CNC pressbrake.

Yawei pressbrakes offer manufacturers access to affordable, precision CNC bending. With a range available from 35 ton up to 3000 ton there are virtually no limits to what can be bent. The Yawei pressbrake on display is a PBH Series with a 160-ton bending capacity. It features a Delem DA-69T Controller, 6-axis CNC backgauge and a servo driven hydraulic system. An automatic tool clamping system, CNC bending help and robotic integration are amongst the additional options that are available. Over the past decade Yawei has built a loyal following; establishing an enviable reputation for quality, performance and outstanding value for money. In addition to pressbrakes, Yawei has an extensive range of fiber lasers, turret punch presses, guillotines, and smart-factory automation solutions.

Also on the stand will be a Weber grinding and deburring machine.

Weber is a German-based company with an impressive 100 years’ experience in grinding machine manufacturing. Weber grinding machines grind, round, deburr and descale lasered, punched

and nibbled parts, to ensure a consistent, brilliant surface finish for either final use, or preparation for additional processing. One of the most innovative products that will be on the Applied stand is the new Fanuci handheld fiber laser. Handheld laser welding machines are increasing in popularity for the many benefits they offer compared to conventional welding. The Fanuci fiber laser welder provides high speed welding coupled with a far superior, smoother weld line. It features low heat input, small deformation, large penetration depth and good repeatability. The unit offers low energy consumption and is virtually maintenance free.

“There has never been a more important time to support Australian manufacturers. We’re proud to be able to play our role by supplying high quality, value for money products that boost productivity, improve quality and allow companies to expand their market offering,” Mr Fisher concluded.

Applied Machinery Stand MT46 appliedmachinery.com.au

Machinery Forum has been supporting Salvagnini's customers for decades Latest and best Salvignini Panel Benders and Cutters will be on display.

For over 50 years, Salvagnini have been offering innovative technologies that allow for automatic and flexible solutions to transform sheet metal into a great variety of products for daily use.

The Salvagnini Group designs, manufactures and sells flexible machines and systems for sheet metal processing, punching machines, panel benders, bending machines, fibre laser cutting machines, FMS lines, automatic warehouses and software. The P1 is the electric Panel Bender that Salvagnini offers as an alternative to traditional folding designed to occupy only eight square metres, designed to consume three kW and equipped with patented kinematics. The P2 produces a great variety of pieces in a short time and automatically without machine stops, without waste and with reduced consumption. The P4 has for 40 years has been the flagship of the Salvagnini brand.

Fibre Laser Cutters L3 and L5 The L3 Fibre Laser Cutter is a productive versatile solution. The L3 utilises the mechanical compass system making it possible to cut at high dynamics with high quality over a wide range of thicknesses.

Brake Presses B3 and Roboformer B3 designed by combining the features and benefits of electrical and hydraulic solutions with in-depth automation software, mechanical and electronic skills. The B3 is the ideal brake press for dynamic production. From two to five metres and from 60 to 400 tons. Roboformer is a non-traditional solution that combines the dynamics of the press benders with the intervention of a robot designated to manage work activity in complete autonomy.

Punching Machines S1 and S4 S1 implements numerous innovative and original elements which make it a solution with a wide field of application that is more

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extensive than simply a punching machine. Laser cutting is integrated. S4 is a multi press head for multiple and independent punching. An integrated shear for kit production and an automatic manipulator for precise intervention and optimised control.

FMS FlexCell and S4 + P4 line FlexCell combined features of a panel bender and brake press and represents a unique solution on the market to obtain the maximum value from bending.

S4 + P4 line. For more than 30 years has represented the most efficient flexible manufacturing system on the market. One of Salvagnini's most successful solutions.

Industry 4.0 indicates the use of cyber-physical systems (CPS) and digital technologies (Cloud, IoT, Big Data) to improve working conditions and to increase the productivity and production quality of the plants by creating collaboration between all the players involved in the production process ie. operator, machines and tools. In 1985 the first automatic factory (AIS) operating with the lights off with built consisting of 12 interconnected systems and communicating with the MRP. Today AIS indicates a set of Salvagnini systems orchestrated by the OPS process software for intelligent integration between the machines and the customers ERP. Machinery Forum has been supporting Salvagnini and Salvagnini's customers in Australia and New Zealand for several decades.

Machinery Forum has highly-skilled service engineers. For nearly 60 years, Machinery Forum has been in full support of local manufacturing and has made a significant contribution over it's many years of operation towards that goal.

Machinery Forum (VIC) Pty Ltd Stand MT79 machineryforum.com.au

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4KW Laser

650x450mm Structural Steel Saw

QLD - 07 3279 3344 NSW - 02 8801 3375 E - sales@completemachinetools.com.au W - www.completemachinetools.com.au Your Partner in Innovation

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Achieve innovative motion control solutions with ANCA Motion’s tubular linear motor technology A new interactive linear motor demonstration will be live at ANCA Motion’s stand at this year’s Australian Manufacturing Week in Sydney.

The new demo showcases how ANCA Motion’s innovative linear motor technology can solve multiple very challenging issues in food and packaging industries, such as throughputs, flexibilities and harsh operating environments. It also shows how easy it is to build a full-feature user interface with ANCA Motion’s Commander software. Smart motion solutions consider the control of the flow and speed factory operations as well as the requirements of various industries. Using magnetic flux to create motion, ANCA Motion’s LinX motors offer a higher performance linear motion system at lower cost.

Adapt as production needs evolve with flexible and accurate positional control Modifications when required are simple, the setting of LinX can be changed by simply editing the parameters within the drive configuration, directly by the operator, saving valuable time and cost.

Sensor-based sorting functionality, as displayed in the new demo is sought after by industry-critical applications in food processing, integrated post-harvest solutions, distribution, packaging, mining, recycling, waste management, chemical, and plastic industries.

Simplicity in machine design leads to unlimited possibilities Compared to traditional automation systems, the streamlined design of LinX® avoids the need for additional belts or screws, complex

pneumatic air systems or bearing components.

This translates to tangible benefits such as low maintenance and ownerships costs and it is retrofit friendly. At AMW, the team’s V-structure robot demo highlights the beauty, efficiency and creativity that can be achieved using tubular linear motors. The twin LinX M-series motors join to create a V-shape parallel robot, revealing that the uses for this technology are only limited by imagination.

Suitable for harsh environments and washdown applications, ANCA Motion’s linear motors have an IP66 or IP67 rating and a fully potted body. With no contact between the forcers and shafts, grease or lubricant contamination is eliminated. The solution is ideal for clean environment applications such as in the food, beverage, and pharmaceutical industries.

Tried and tested technology ANCA Motion specialises in high precision control solutions for CNC and automation. Australian owned and operated, the company offers local design and manufacture with experience spanning over 45 years. The passionate team’s global network of 125 engineers create custom solutions, partnering with customers across a range of industries on bespoke technology solutions to meet individual needs.

Anca Motion Pty Ltd Stand RA72 ancamotion.com

CIVAN – a new high power laser for better welding Manufacturers are increasingly replacing traditional mechanical machining and thermal welding systems with laser processing tools. Compared to traditional thermal welding processes, laser-based techniques require less heat input due to the beams’ high energy.

All welding methods involve melt-pool formation and subsequent rapid solidification, which can alter the properties of the welded metal. The high energy of laser welding, however, not only melts the material but also evaporates it, creating a vapor capillary in the material called a ‘keyhole’. This gives laser welding the advantage of a very high aspect ratio, defined as a high ratio of penetration depth to weld seam width. Compared to thermal welding methods, which generally provide wider and shallower weld seams, laser welding’s high aspect ratio translates into potentially lower part distortion.

To meet the demands of modern manufacturing CIVAN has developed a High Power Single Mode Laser with dynamic beam.

This innovative product enables different beam shapes, beam steering, and fast movement of the focal point, all electro-optically controlled with no mechanical movement. For example, CIVAN’s unique beam shaping allows uniform penetration in aluminium welding with constant depth and very low porosity. Inbuilt software allows beam shaping design in minutes, while beam steering with a small dynamic spot makes for clean fast cutting, efficient welding of a large gap or welding dissimilar materials. In this highly sophisticated laser system Coherent Beam Combining, of CBC, provides advantages for welding applications making available a

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whole new set of parameters for laser welding to meet the needs of to-days welder.

The new Dynamic Beam Laser provides countless new applications for materials processing, an opportunity taken up by Valeo one of the world’s largest car battery suppliers.

This European company designs innovative solutions for vehicles with a particular focus on reducing CO2 emissions and turned to CIVAN for a laser system to improve production.

Due to the growing demand for an increase in the travel range of electronic vehicles, Valeo wanted to improve their battery cooler manufacturing process in order to make larger battery coolers. Valeo had been using a brazing method to join parts and were looking for a system which was more environmentally friendly system, more cost effective, with reliable strong welds and, importantly, produce no leakage of the large sealed cooling plates. Using the new Dynamic Beam Laser their processes were tested in CIVAN’s application lab. By answering the latest market challenges, CIVAN’s technology opens new horizons for better material joining control, new applications and welding new materials previously not possible.

Raymax Applications Stand MS35 raymax.com.au

PREVIEW Bosch bringing the future of robotics and automation to their stand at AMW As the manufacturing industry continues to evolve, new technologies, competition, and opportunities arise.

This change is creating a new set of challenges for manufacturers.

Bosch Australia Manufacturing Solutions (BAMS) provides 135 years of Bosch quality and expertise to Australian manufacturers.

Offering custom machine building, engineering, manufacturing support, and consulting services for Australian manufacturing operations, BAMS is helping to elevate Australian manufacturing.

Based in Clayton, Victoria, BAMS has over 100 engineers and support staff servicing Bosch plants locally. Over the past five years, BAMS has become one of the country’s leading factory automation companies, working with a diverse array of blue-chip, mid-tier and start-up manufacturers to automate their manufacturing. In 2021, BAMS opened a new Manufacturing Automation Centre at the Bosch headquarters in Clayton, a purpose-built facility to house the growing automation business.

With over 65 years of lean manufacturing DNA, Bosch Australia Manufacturing Solutions is a leading partner for manufacturers, ready to collaborate and navigate in these challenging times. BAMS combines its proud heritage and relentless innovative spirit to deliver premium quality machines and services and produce efficient and reliable solutions for our customers. Bosch Australia Manufacturing Solutions are the preferred supplier to help manufacturers scale up their business.

To assist their clients, BAMS provides an array of solutions and services: •

Robotics & Automation: extensive experience in designing and building a range of robotics and automation applications including automated assembly, packing, palletising, labelling, vision, welding, grinding, polishing and high precision mechanical assembly.

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Production Line Systems: providing complete end-toend solutions including logistics (stock movement and management), complete IT, ERP and MES systems.

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Test & Measurement Systems: testing equipment built to be fully integrated, ensuring the manufacturing achieves maximum value with minimal disruption..

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Machine Servicing: specialised services including mechanical design, process engineering, electrical and software design, robot programming, I.40 consultation, test systems, tailored training, and collaboration.

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Consulting Services: customised lean manufacturing consulting services including lean assessment, design for manufacture and assembly, value stream mapping, and lean line design.

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Factory of the Future: Bosch are a global provider and user of I4.0 Solutions, focusing on technology that allows the organisation to work smarter not harder. Industry 4.0 paves the way to the factory of the future and in doing so also makes new business models possible — for industries and companies worldwide.

Robert Bosch Australia Stand MT71 bosch-manufacturing-solutions.com.au

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Workholding and clamping answers from Romheld Automation Romheld Automation is pleased to present some of the latest developments in workholding and clamping from leading European, American and Japanese manufacturers.

These days, batch runs are generally smaller so set up and changeover times become proportionally more expensive, to the point where they can make a job uneconomic unless volumes increase. Add to the mix the current supply chain issues being experienced worldwide and the ability to be more flexible becomes a priority. At the same time the need for repeatable workholding raises additional challenges.

To grow in the current manufacturing climate you need fast and accurate setups and changeovers, so enabling smaller production runs. Originally based entirely in the automotive industry, Romheld Automation understands the requirements of modern manufacturing. “Before the car industry shut down we moved into industrial automation, mainly supplying end of arm tooling (EOAT) for packaging and machine tending,” says Peter Hope from Romheld.

“This experience enables us to offer a wide range of tooling suitable for both machining and robotic processes.”

Hainbuch Gmbh manufacture precision collet chucks easily capable of 15 second collet changes without any clocking up required.

Now, Hainbuch offer a full range of accessory tooling that is simply bolted into position, again without clocking up. These accessories including expanding mandrels, two and three jaw chucks, magnetic chucks and face drivers. With changeover times of two minutes or less you can be more competitive on both long and short runs.

Roemheld GmbH manufacture world class hydraulic clamping equipment. Hydraulics can be problematic when machining carbon

fibre and other composites, so Roemheld developed electronic swing clamps to eliminate the risk of oil contaminating the product.

These clamps are fully self-contained with a built in brushless 24V DC motor with gear drive to actuate the swing and clamp movements.

The control is integrated within the clamp, requiring only two cabes.

IO link is available as an option. We will show an example of an electric swing clamp, as well as our very popular hydraulic Bore Clamps for ID gripping. The Roemheld group also manufacture Stark zero-point clamp tooling which provides extremely accurate, fast changeovers of fixtures and stationary clamping tools using springs to clamp, and air or hydraulics to unclamp. The group also offers Hilma precision machine vices and mould/die clamping and handling tooling, some of which will also be on display.

Romheld Automation Stand MT45 romheld.com.au

Sheetmetal Machinery Australia Sheetmetal Machinery Australia to showcase the all new EvoBend long length folder at upcoming AMW. Sheetmetal Machinery provide the latest leading-edge solutions to remain competitive in today’s market. Sheetmetal Machinery prides itself on commitment to customers, as such exceptional sales and service is offered on the range of machinery supplied. Sheetmetal Machinery is supported by a team of qualified in-house service engineers throughout Australia and New Zealand. Engineers receive regular OEM training and certifications, combined with a comprehensive inventory of spare parts to ensure the best possible support.

Australian Manufacturing Week will be first Australian exhibition to showcase the all-new long length folder from EvoBend. The product line features up/down folders (D300, D400, D600, D800) utilising a patented folding technology combined with unique operator safety system. The patented double bending system enable unrivalled freedom of bending with a maximum capacity of 2mm mild steel and 3mm aluminium. Unlike most long length folders, the Evobend is completely electric. The absence of hydraulics provides several advantages in terms of energy consumption, accuracy, reliability, speed, maintenance, and noise. In terms of energy consumption, you can expect a reduction of up to five times less than a hydraulic long length folder.

Operator safety is paramount for any machine, this is an area where the EvoBend excels without compromising speed and performance. A first glance you will notice that the folding beam does not pivot or swivel towards the operator, but rather “rolls” around the material. This allows the Evobend to utilise complete machine covers reducing the number of potentially dangerous

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intervention points. In addition, modern mobile safety fences are used in combined with laser finger protection at the clamping point to create a flexible solution for operator safety. A inherit feature of all electric machines is their speed and performance, there is no requirement for additional servo valves, double hydraulic pumps or the like. Simply put, the EvoBend provides the fastest possible bending speed available on the market.

Evobend has re-defined the traditional long length folder and delivers a cutting-edge product line with significant benefits. If you would like to learn more, our highly skilled team are available throughout Australian Manufacturing Week.

Also on display and for demonstration: • •

Q-Fin Advanced set F1200 + WES6000 SafanDarley Press Brake

Sheetmetal Machinery Australia Pty Ltd Stand MT50 sheetmetalmachinery.com.au

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Dimac for workholding Dimac Tooling is Australia and New Zealand’s leading supplier of accessories and workholding solutions for CNC milling and CNC turning machine tools.

Dimac will again showcase the leading productivity solutions for owners and users of CNC machine tools. On show will be the latest releases in workholding from the industry innovator, Lang (Germany) for secure and flexible holding of workpieces in your machining centres. Also see demonstrations of rapid and accurate tool setting and pre-setting with ability to directly communicate with your CNC controller from Zoller (Germany). With live demonstrations you will see how to keep your coolant filtered, clean and healthy with the rugged and portable coolant cleaning system from Freddy (UK). On show will be the standard and custom Top/Soft Jaws from Dimac’s design and manufacturing facility in South East Melbourne that can solve just about any workholding challenge on your CNC lathe.

Dimac is motivated to continually finding more effective, safe and productive ways to hold and machine workpieces. They manufacture Soft Jaws, Hard Jaws and Custom Jaws in their own CNC equipped machine shop and this capability, coupled with over 30 years experience doing so, ensures they will provide the right workholding solution for you. When you visit Dimac’s stand, you also can discuss automation solutions to overcome production and skill shortages where you can start with very simple and basic tools and devices through to full turn-key solutions. Dimac looks forward to welcoming you to the Dimac stand.

Dimac Tooling Pty Ltd Stand MT06 dimac.com.au

Integra Systems still riding high The last time Integra Systems appeared at Australian Manufacturing Week in 2019, the team was riding high as finalist for the Leader in Industry 4.0 category at the Victorian Manufacturing Hall of Fame Awards. Now, they’re keen to show us their progress in the digitisation of manufacturing with an eyeopening display at this year’s event.

While dealing with the disruptions caused by a global pandemic, Integra Systems took the opportunity to hatch a dream that was three years in the making: their K4.0 Kiosk concept.

The concept was so successful it’s been commercialised so other manufacturers can now revolutionise their enterprises with this fully customisable, fully digitised system.

Designed to meet the goals of the circular economy, the K4.0’s operational design replaces mountains of manual tasks and paper trails with integrated digital workflows, completely reimagining traditional manufacturing processes. It comprises a series of easyto-use and customisable kiosks that can function as virtual ‘job bags’ for industrial applications operated via touchscreen or even touchless ‘gesture’ control. The K4.0 Kiosk will feature on Integra’s stand at Australian Manufacturing Week where other manufacturers can see how to take the evolutionary leap into Industry 4.0. Having functioned as their own guinea pigs, Integra is eager to share their expertise and help you benefit from the increased appetite for Australian manufacturing while successfully transitioning into the industry’s next new, exciting phase.

Along with the K4.0 Kiosk design, Integra will showcase two standout examples from their WorkSMART Collection: AeroSMART Industrial workbenches and BioSMART Mobile workstations.

Given today’s strict OH&S compliance in workplaces, WorkSMART Collection overcomes ergonomic challenges while significantly increasing user satisfaction. From office to factory floor, these two designs offer a new way of working that is fully adjustable for maximising productivity and minimising risk. Furthermore, they’ve been designed and created according to the reduce, reuse, recycle and redeploy principles of circularity, similar to the K4.0. While AeroSMART, BioSMART and the K4.0 will be demonstrated on the Integra stand, bear in mind, what you see is not necessarily what you have to get.

That’s because everything Integra creates is fully customisable in the truest sense of the term – you ask for it, Integra builds it.

Based on their past appearances, we’re positive Integra Systems will have something for manufacturers to get really excited about at this year’s Australian Manufacturing Week. As well as their Industry 4.0 innovations, the team is ready to chew the fat with you about industry challenges and support you to help ‘Make Your Vision Real’ – as their tagline goes – with bespoke product development and advanced manufacturing services.

Integra Systems Stand MP45 integrasystems.com.au

Ultimate LED shining a light Demonstrating continuing improvements of the LED Workplace Safety Halo System.

Ultimate LED is an Australian Family Business established in 2012 in Coffs Harbour, NSW. Director Warren Hodder has always been in the motor vehicle and transport industries. The company is consistently looking outside the box for special safety products to pro-vide a safer workplace. Back in 2016 Warren developed the LED Workplace Safety Halo System, since then he has improved the performance of the LED red line beam and through some special help created a safe class 2 Laser red line beam for workplace safety.

This is the first of its kind in the market globally.

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Pushing the boundaries of where lights can be shone, LEDs have long life, are incredibly energy-efficient, resistant to vibration and moisture incursion. LEDs are easy to install and are much faster to reach full intensity than standard light bulbs. This translates into an added safety benefit for using LEDs for your trailer's stop lights.

Standard stop lights take a quarter of a second to reach full intensity whereas their LED counterparts take less than half this time.

Ultimate LED Stand MS87 ultimateledlights.com.au

AIR LIQUIDE is here for you

Discover How. Air Liquide is keeping its customers safe while maintaining its reliable and competitive services.

ESSENTIAL SMALL MOLECULES FOR LIFE, MATTER & ENERGY

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Power Machinery brings in the sawing machines Power Machinery has partnered with MEP in the Australian market for over 25 years.

Power Machinery is excited to be back on home turf at such a fantastic venue. Darling Harbour Exhibition Centre is a great location, not just for the show but also for visitors and exhibitors after hours.

The restrictions opening means that our friends from MEP in Italy can join us again, which is good news. And since it has been a few years since our last show, we are excited to have a new range of Metal Cutting Bandsaws and the opportunity to chat with old customers and new ones. Produced in Pergola, Italy, since 1964, the product range includes Metal Cutting Bandsaws, Metal Cutting Coldsaws and aluminium Cutting Saws.

There are a few reasons why it might be time to upgrade to a new Sawing machine.

• • • •

Improved reliability Increased capacity Improved safety Improved repeatability

Or perhaps it is because as much as you love your old MEP saw, 25 years of faithful service has finally taken its toll.

Power Machinery has partnered with MEP in the Australian market for over 25 years. We have factory trained engineers ready for service and a full complement of spare parts available for even some of the pre-2000s machines. They are our most active and dynamic supplier. MEP is continuously looking to evolve and innovate and never resting on its laurels. The recent acquisition of the American Saw manufacturer added another string to their bow and gave the group new capacity in the over 300mm market. The range of MEP saws is comprehensive, covering everything from 200mm handoperated saws to massive fully automatic hitch feed saws with 1000mm capacity.

Any fabricator that has used a MEP Shark Saw, whether a manual CCS version, a Semi-Automatic SXI or Automatic AX or NC Evo, is unlikely to be satisfied with any other brand. The unique combination

of traditional cast-iron structures and the latest technology makes MEP saws the market leaders.

On display will be a range of Sawing machines.

MEP Shark 230NC 5.0 is a straight-cut double column automatic metal cutting hydraulic bandsaw. A “Full In Box” design with cast iron bow and band wheels. The protective guards fully comply with the latest machinery directive AS4024 and EN13898/2007.

This model is highly robust and capable of continuous cutting at maximum capacity of 230mm solid bar. It can also automatically feed material until only 70mm of material remains. Operation is by a 180mm touch screen control. It is simple to use and program with a Windows CE based CNC that manages all cutting parameters and functions in real-time.

The MEP Shark 331-1 NC 5.0 Spider is an automatic hydraulic bandsaw built in a cast iron construction to cut from 0-degree right to 60-degree left. The metal cutting saw is a compact design with a minimal footprint with a 180mm Touch Screen control. It is simple to use and program. The Windows CE based CNC manages all cutting parameters and functions in real-time. The cutting head and feeding vice can also be positioned manually by the joystick control. The Bar feed is by ballscrew and stepper motor. You can program different lengths and batch numbers on one length of material. There will be three Semi-Automatic versions. The Sharks 282SXI,382-1SXI and 512SXI. All models cut from 45° right to 60° left with four modes of operation; Manual, Dynamic, Semi-Automatic and Cycle Down Up. Each with a centralised control panel provides all information required by the operator, including alarms, diagnostics, pieces cut, cutting time and blade tension.

We will also have one saw fitted with the latest programmable length stop from Arostop.

Power Machinery Stand MT38 powermachinery.com.au

Two sides to every business Acra Machinery successfully bringing the new and refurbished machinery into the Australian manufacturing sector Acra Machinery provides an array of metalworking machinery to the Australian manufacturing industry including, but not limited to, sheet metal, fabrication, defence, construction, transportation and healthcare sectors.

They assist and consult businesses, both small and large, in advancing in their machinery and automation technologies to promote growth of manufacturing capabilities throughout the whole of Australia.

Established in 1977 with a team of fully qualified, full-time service engineers, they have been able to create and maintain a reputable name throughout the industry as a premier supplier of capital equipment with a top-tier level of aftersales service and support.

Acra Machinery is a certified dealer of high-quality European equipment with full support from their international partners.

In 1986 Acra Machinery bought the manufacturing rights from Leeton Steel Works for all Acra products, including spare parts.

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It was about that time Acra Machinery became a company with the intention of continuing to build Acra Machines in Australia, however economic reality at the time made this dream impossible.

However, the second-hand side of the business was growing larger each year, and Acra still needed a supplier of quality new machines.

Acra traveled to Europe and America several times looking at all the machines available until they finally partnered with a previously unheard-of Manufacturer in Turkey, Durmazlar in 1994. Since then, Durmazlar has grown to be the largest Press Brake manufacturer in Europe and the second largest in the world, spanning an impressive 155,000 square meters of factory. They are now manufacturing over 5,150 high quality machines annually. Going forward ACRA are committed to the further expansion of our range to cater for the Australian sheet metal, machine tool and steel building industry.

Acra Machinery Pty Ltd Stand MT03 acra.com.au

WHAT MAKES SWI DIFFERENT FROM OTHER EQUIPMENT MANUFACTURERS?

Visit SWI at Stand MT20 at AMW to find out.

100% MADE IN AUSTRALIA. All manufacturing processes are performed in-house at our manufacturing facility in Warrnambool, Victoria including CNC machining, electrical assembly and hydraulic assembly. Complete control over the manufacturing process means that SWI can offer very high quality equipment at an economical price.

Service has also been a key ingredient of SWI’s success. In Australia, we have 2 permanent service technicians on the road and we have established relationships with dozens of contractors both in Australia and abroad. It’s rare that an SWI machine would be out of action for more than 24 hours.

SIMPLEX & DUPLEX FOLDERS

MARXMAN PLUS & MARXMAN PRO

Our Duplex folder is built with the same philosophies as our incredibly popular Simplex folders: robust design, simplicity, serviceability, and high quality electrical & hydraulic components.

Plus, enhanced folding geometry enables profiles not possible on some European machines. The Gen III Duplex has proven exceptionally popular with many repeat customers ordering 5, 10, or even 20 Duplex folders.

Based on the famous SWI Marxman, the Marxman Plus & Marxman Pro have the added benefits of 8 pairs of auto slitter knives, auto nesting, scrap minimisation and a huge range of flexible operation modes. Marxman machines can import data from a range of SQL-based softwares. Both machines have the ability to print barcoded labels that can be scanned at the SWI folder to upload job details direct from the production database.

Simple Operation for new & experienced operators.

Fold speeds faster than 3 seconds from 0° to 90° and back to 0°.

Part Cut allows ANY slit part to be separated individually without damage to adjacent parts.

8 sets of slitting blades can be automatically set in as little as 45 seconds.

SWImachinery.com | Stand MT20 at AMW | +61 3 55645333

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ELECTRONICS

3D electronics enables greater integration 3D electronics is an emerging manufacturing approach that enables electronics to be integrated within or onto the surface of objects.

While 3D electronics has long been used for adding antennas and simple conductive interconnects to the surface of 3D injectionmoulded plastic objects, more complex circuits are increasingly being added onto surfaces made from a variety of materials by using new techniques.

Furthermore, 3D additive electronics enables complete circuits to be integrated within an object, offering multiple benefits that include simplified manufacturing and novel form factors. With 3D electronics, adding electronic functionality no longer requires incorporating a rigid, planar PCB into an object then wiring up the relevant switches, sensors, power sources, and other external components.

A recent IDTechEx report assesses the competing 3D and additive electronics technologies that will enable PCBs to be replaced with integrated electronics, saving space, weight and reducing manufacturing complexity. 3D electronics is an emerging approach that uses additive manufacturing to enable electronics to be integrated within or onto the surface of objects. While it has long been used for adding antennas and simple conductive interconnects to the surface of 3D injection-moulded plastic objects, more complex circuits are increasingly being added onto surfaces made from a variety of material by using new techniques.

Furthermore, in-mould electronics and 3D printed electronics enable complete circuits to be integrated within an object, offering multiple benefits that include simplified manufacturing and novel form factors. With 3D electronics, adding electronic functionality no longer requires incorporating a rigid, planar PCB into an object then wiring up the relevant switches, sensors, power sources and other external components.

The most established approach to adding electrical functionality onto the surface of 3D objects is laser direct structuring (LDS), in which an additive in the injection-moulded plastic is selectively activated by a laser.

This forms a pattern that is subsequently metallised using electroless plating. LDS saw tremendous growth around a decade ago and is used to manufacture 100s of millions of devices each year, around 75% of which are antennas. However, this metallisation method can only be applied to injection moulded components with an additive, and only enables a single metal layer to be deposited thus limiting circuit complexity.

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Given these limitations, other approaches to applying conductive traces to the surfaces of 3D objects are gaining ground. Extruding conductive paste, a viscous suspension comprising multiple conductive flakes, is already used for a small proportion of antennas and is the approach of choice for systems that deposit entire circuits onto 3D surfaces. Aerosol jetting and laser-induced forward transfer (LIFT) are other emerging digital deposition technologies, both of which have higher resolutions and rapid deposition of a wide range of materials respectively.

In-Mould Electronics In-Mould Electronics (IME), in which electronics are printed/mounted prior to thermoforming into a 3D component, facilitates the transition towards greater integration of electronics, especially where capacitive touch sensing and lighting is required. By enabling multiple integrated functionalities to be incorporated into components with thermoformed 3D surfaces, IME offers multiple advantages relative to conventional mechanical switches, including reduction in weight and material consumption of up to 70% and much simpler assembly.

IME is an extension of well-established in-mould decorating (IMD), in which plastic sheets with a decorative coating are converted to three dimensions via thermoforming and subsequent injection moulding. IME differs from IMD through the initial screen printing of conductive thermoformable inks, followed by deposition of electrically conductive adhesives and the mounting of SMDs (surface mount devices, primarily LEDs at present).

The long-term target for IME is to become an established platform technology, much the same as rigid PCBs are today. Once

this is achieved getting a component/ circuit produced will be a simple matter of sending an electronic design file. Along with greater acceptance of the technology, this will require clear design rules, materials that conform to established standards, and crucially the development of electronic design tools.

Fully printed 3D electronics Arguably the most innovative approach to additive electronics is fully 3D printed electronics, in which dielectric materials (usually thermoplastics) and conductive materials are sequentially deposited.

Combined with placed SMD components, this results in a circuit, potentially with a complex multilayer structure embedded in a 3D plastic object. The core value proposition is that each object and embedded circuit can be manufactured to a different design without the expense of manufacturing masks and moulds each time.

Fully 3D printed electronics are thus well suited to applications where a wide range of components need to be manufactured at short notice. The technology is also promising for applications where a

ELECTRONICS Comprehensive analysis and market forecasts customised shape and even functionality is important, for example, medical devices such as hearing aids and prosthetics.

The ability of 3D printed electronics to manufacture different components using the same equipment, and the associated decoupling of unit cost and volume, could also enable a transition to on-demand manufacturing.

The new IDTechEx report “3D Electronics/ Additive Electronics 2022-2032” assesses the competing technologies that will enable PCBs to be replaced with integrated electronics, saving space, weight and reducing manufacturing complexity. It covers electronic functionality to 3D surfaces, in-mould electronics (IME), and fully 3D printed electronics.

The challenges for fully 3D printed electronics are that manufacturing is fundamentally a much slower process than making parts via injection moulding since each layer needs to be deposited sequentially. While the printing process can be accelerated using multiple nozzles, it is best targeted at applications where customising offers a tangible advantage. Ensuring reliability is also a challenge since with embedded electronics post-hoc repairs are impossible – one strategy is using image analysis to check each layer and perform any repairs before the next layer is deposited.

The report includes multiple company profiles based on interviews with major players across the different technologies.

There are 10-year market forecasts for each technology and application sector, delineated by both revenue and area. It also forecasts the gradual decline of LDS and growth in extruded paste for consumer electronic antennas, and increased use of extrusion and aerosol, especially for automotive applications. The most substantial growth is predicted for IME, which is predicted will be widely adopted in car interiors and the control panels of white goods.

IDTechEx.com

Wearable power generators whip up watts while walking

The one stop online shop for engineering plastics Wide range of engineering plastics Free delivery nationwide for orders over $150.00+ gst 24 hour operations for live orders Best business to business pricing

Researchers from Loughborough University in the UK and the University of Moratuwa in Sri Lanka have developed a new, scalable manufacturing technique to create wearable fabrics embedded with small power generators known as triboelectric nanogenerators (TENGs).

The technique, detailed in the journal ACS Applied Electronic Materials, enables the creation of energy-generating textiles using established methods such as yarn coating, dip coating and screen printing to apply triboelectrically active solutions.

The wearable, TENG-containing fabrics are similar in texture to knitted materials used to make jumpers and T-shirts, but can produce electricity to operate low-power electronics using our natural body movements.

TENG devices collect static charges, like those that make a balloon stick to a wall when rubbed against a jumper. Once attached to the human body or clothing, TENG devices ‘slide’ or ‘vibrate’ with movements to create an electrical signal through a process called electrostatic induction.

The new technique overcomes these issues by combining new conventional textile materials and carefully engineered TENG device designs. These devices display improved electricity generation and meet most of the comfort and durability requirements for textile products — a balance that has been very difficult to achieve so far in TENG research.

The 4x4cm, lightweight TENG textile the researchers created produced over 35V using mild artificial movements that replicated slow body movements, which could potentially power low-power health sensors, environmental sensors and electronic devices in the near future.

Study leader Dr Ishara Dharmasena, from Loughborough’s School of Mechanical, Electrical and Manufacturing Engineering (MEME), said the technology will be “massively beneficial for future smart textile and wearable electronic applications” and could support the global shift to remote health monitoring.

      

Acetal Cast nylon 6 HDPE PTFE UHMWPE Poly Carbonate – AR2 abrasion resistant 2 sides PEEK

“This work will lead to further research on how we can convert the common textiles into energy-generating clothing for various future applications including health care, communication, sports and personal electronics,” Dharmasena said.

Dharmasena and his team are now looking at practical applications of TENG technology and are keen to hear from industrial and academic collaborators in the areas of smart textiles, health sensing technologies, nanotechnology and fabrication. lboro.ac.uk

1800 215 216 www.epol.net.au AMT JUN 2022

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ELECTRONICS

Smoke free cabling World cabling authority clears up confusion about where to choose low smoke, halogen-free cables for improved safety.

Recently, Scott Ziegler, Product Manager at LAPP Group offers the insights of a world authority cabling and connectivity solutions company to clear up clouds of confusion about where industrial infrastructure automation, resources, food and beverage processing, telecommunications, computer and electronics companies should choose low-smoke, halogen-free cabling to protect life, technology and vital private and public infrastructure.

While halogen-free wires and cables have been widely used in Europe for some time, they’re now starting to gain relevance further afield in places such as the United States and Australia.

Products containing halogen – such as wires and cables, conduits, routing ducts and more – are receiving attention domestically due to the negative effects they impose on both industrial workers and machinery. And the push to reduce halogen usage is now reflected in UL and other domestic safety standards.

In the event of a fire, halogenated wires and cables give off toxic fumes that can cause serious health concerns if inhaled, not to mention they also destroy expensive electronic equipment. As industrial companies become more conscious of these problems, they’ve begun taking a closer look at the benefits of halogen-free cables.

Here’s a guide to some places where it makes sense to use halogen-free cables, and why you might want to consider them over halogenated cables in many applications.

Safety first with halogen-free cables Halogen-free wires and cables are used in various petrochemical, transportation, utility, electronic and semiconductor applications. Advocates of halogen-free cables fear that during a fire, air-handling distribution systems like heating and airconditioning ducts can act as circulating air conduits and transmit toxic fumes.

Since halogen-free wires and cables don’t produce toxic corrosive gases in fires, they help minimize damage to electronic equipment and aren’t threatening to workers in surrounding areas. (see Figure 1) On the other hand, proponents of halogenated cables believe that there wouldn’t be any safety issue as long as the installed cables meet the required smoke and flame resistance requirements.

Adding halogens to compounds gives wire and cable the ability to perform well during flame testing mandated by the

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Figure 1

NFPA (National Fire Protection Agency).

Also, halogens provide a cost-effective, highly-efficient flame retardant component mechanism to compounds. However, keep in mind that while it sometimes makes sense to use halogenated cables, be aware that ingesting their fumes can be harmful to human life.

Hazardous fumes from halogenated elements. In the wire and cable industry, there are three main halogenated elements—fluorine, chlorine and bromine— which are found in various types of cable insulation and jacketing compounds (see Figure 1). Fluorine is present in varying amounts of certain high temperature compounds, such as Fluorinated Ethylene Propylene (FEP Teflon®) and Polyvinylidene Fluoride (Kynar). Chlorine is a component part of Polyvinyl Chloride (PVC). And bromine is often used as part of the flame retardant package used in thermoplastic cable insulating compounds.

In addition to the carbon monoxide they release while burning, these three material categories also release additional toxic gases that are dangerous for humans to ingest. Carbon monoxide itself can be lethal. But if you add either hydrofluoric or hydrochloric acid to these fumes, you get an even more dangerous combination.

Irreversible damages can also hurt your computer circuitry.

During a fire, components containing halogen wires and cables emit both smoke and toxic fumes which, when combined with moisture, become hazardous. Up to 80% of all deaths from fire come from inhaling toxic fumes and smoke. These fumes are acid gases—such as hydrobromic, hydrochloric

and hydrofluoric—that can cause severe damage to body parts. They’re also known to cause confusion and disorientation, which can prevent victims from finding safe escape routes. From the viewpoint of expensive electronic and electrical equipment, these corrosive fumes also attack and degrade sensitive components.

The damage from these fumes can cause component malfunction and make the equipment inoperable.

Smoke testing When looking at the differences between halogenated and halogen-free cables, another factor to consider is smoke, which can also cause fatalities and extensive damages to property and expensive electronic equipment. The UL 1685 smoke test performance chart shows the results of smoke release testing done per UL Standard 1685 during FT4 cable burns with different insulation and jacket combinations (See Figure 3).

While the results in Type 2 show a significant improvement when compared to Type 1, the peak Type 3 indicate full compliance with these requirements.

The resulting data confirms that using a halogen-free insulation and jacket results in less smoke release during a fire than a halogen insulated wire and cable.

Halogen components cost less.

With all this in mind, there are still sometimes where halogenated components are the right choice. Using these components is a cheaper way to give thermoplastic cables the properties to guarantee performance characteristics of the insulating compound.

Let’s take Polyvinyl chloride (PVC), for

ELECTRONICS

Since it’s filled with low smoke, this flame chamber has full visibility.

shouldn’t exceed the critical point of 0.2% under this standard specification for shipboard use.

Toxic fumes cause fatalities and ruin equipment The following three examples are times when corrosion and toxic fumes emitted by halogenated materials during a fire have attributed to human fatalities and the destruction of equipment: Figure 3

example. Containing chlorine and produced at a low cost, PVC provides the electrical, mechanical and physical characteristics necessary to fulfill industry performance requirements.

The source of chlorine in the PVC comes from two inexpensive commodities: water and salt. Since these raw materials are available in high abundance and achieve the desired properties, it’s not hard to understand why PVC is the primary insulation choice in today’s wire and cable industries. In short, PVC provides product performance required by UL, CSA and Interek at a much lower cost than halogenfree insulations and jackets.

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IEC 60754-2: Shows the ph levels to determine the poisonousness of the gases during a fire. This standard approaches acidic levels that arise when halogenated components are burned and react with the moisture in the air.

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IEC 61034-2: Concerns the amount of light you can transmit while testing to determine the smoke density generated during a fire. High numbers show the effectiveness that a lighted pathway creates in a smoke-filled area.

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While these standards are all different, and may vary in detail from local standards, they’re used to provide some determination concerning halogen-free or low smoke zero halogen cable requirements: •

IEC 60754-1: Details the amount of halogen acid gas measured from a specified amount of raw material. This test isn’t performed in the finished product wire or cable form, and compliance comes from not exceeding the mg/g that’s specified within the

A subway station fire took place in 2003 in Daegu, South Korea with intense toxic fumes and heavy black smoke preventing firefighters from quickly rescuing the people who were trapped. Almost 200 people were killed at this event, and another 150 injured.

While it was deemed that inadequate emergency equipment didn’t help lessen the disaster, the use of PVC cables in the trains and subway station didn’t help the situation either.

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In 1996, a fire at the Dusseldorf Airport in Germany led to 17 deaths and 72 injuries when toxic fumes rapidly spread from smouldered PVC-covered cables in a cable ventilation shaft, emitting cyanide, chloride, dioxin and carbon monoxide into the air.

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The Illinois Bell office in Hinsdale, IL experienced a fire in 1988 that remains the worst disaster in telecommunications history. Corrosion and toxic fumes caused equipment destruction and loss of human life.

The recovery costs were estimated to be several million dollars, and about 35,000 Chicago customers were without service.

standard.

Industry standards A number of industry standards evaluate the cable fume toxicity produced during a fire. Each standard is unique because they approach the subject of determining cable fume toxicity through different evaluation parameters. They’re used to quantify smoke levels, light transmittance, levels of acid gas, concentration levels of toxic gases and halogen content.

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NES 713 Part 3: Determines the toxicity index of materials through complete combustion methods and analysis of the emitted gases.

Measured in PPM, the gases must follow the highest values indicated, while concentration levels shouldn’t exceed the amounts for the 14 specified gases.

UL 1685: This standard involves both the flame spread and fire resistance of cables, as well as methods for measuring smoke release. It establishes some pass/fail criteria, especially in the areas of peak and total smoke release. Lower numbers are desirable here, signifying the amount of smoke released.

MIL-DTL-24643: Approaches the cumulative total contents of halogens in a cable by using X-ray fluorescence to determine amounts, giving an overall amount of concentration of halogen levels in a cable. Levels

To summarise Choosing between halogenated and halogen-free cables can be confusing.

But just remember that if your application requires a high efficiency cable that performs well in NFPA flame testing, halogenated cables are a suitable choice.

If you’re looking for a cable that’s safer for your workers and machinery, you’ll want to go with a halogen-free cable. lappaustralia.com.au

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Monash University opens world-class robotics research facility The Monash University Faculty of Engineering has launched a new world-class robotics research facility to train the next generation of engineers and global innovators, and drive the emerging Artificial Intelligence (AI) economy.

The $6.5m investment into Monash Robotics furthers the work of Monash University in the development of a world-leading robotics precinct, which includes the Makerspace, Monash Smart Manufacturing Hub, Data Futures Institute and Monash Generator.

Monash University President and ViceChancellor Professor Margaret Gardner AC said the launch of the research facility is an important step in advancing AI knowledge and innovation.

“Robots are changing and improving the lives of people across the globe every day. This investment shows our ongoing commitment to world-leading research and education in this important and dynamic field, and aligns with our goals and ambitions within Monash’s Strategic Plan, Impact 2030, to address the great challenges of our time through innovative and excellent education and research.”

The Monash Robotics research facility will enable researchers to be at the forefront of Robotics and AI innovation, to support and enhance impactful robotics research by bringing together top researchers to work on developing robots that can improve our economy and wellbeing. The innovative lab will foster collaboration and

effective robotics development, providing experimental space and equipment to enable realistic experimental validation.

“This is a very exciting step for Monash University. Robotics and AI will deliver the next generation of breakthrough technologies and will rapidly change the way we live and work, and help shape our future,” says Professor Elizabeth Croft, Dean of the Faculty of Engineering.

Robotics deployment across the world is rising rapidly, with the International Federation of Robotics reporting that three million industrial robots were operating in factories around the world in 2021.

Governments are now roadmapping and investing heavily in robotics research across the world. With the launch of the Robotics Research Facility, Monash University is taking advantage of the immense research and industry collaboration opportunities.

Professor Dana Kulic, Director of Monash Robotics and an ARC Future Fellow, says the lab will be focussed on four key areas of innovation: design and manipulation, electronic modelling and control, perception and learning and human-robot interaction, with the work applied across a wide range of industry sectors including manufacturing, transportation, construction, medical and

surgical, mining and agriculture and both assistive and service robotics.

“It is a very exciting time for robotics research. Robotics is at the cusp of driving the next wave of innovation in society. Research undertaken in our lab will develop the next generation of humancentred robots, capable of supporting and empowering people at work, in the home and in exploration,” Kulic says.

“I’m excited to build on Monash’s existing research strengths in robotics to develop an integrated and interdisciplinary approach to robotics research and education. Not just traditional robotics in industry and manufacturing, but robotics that work in human environments with and for people,” says Professor Kulic. monash.edu

Charging ahead with making electric vehicle components The Andrews Labor Government is supporting the creation of dozens of new advanced manufacturing jobs in Victoria’s electric vehicle industry.

The Labor Government is supporting Nissan Casting Australia’s $15.5m expansion of its Dandenong South facility, which will design and manufacture electric vehicle components for carmaker Nissan. The locally made parts will be used at assembly plants around the world, including in Japan, Thailand and the United States.

Nissan Casting Australia’s Dandenong South facility produces aluminium diecast components used in Nissan’s electric vehicle models sold around the world, including the Leaf.

The investment will create 41 local jobs in engineering, management and production, and allow the company to boost its automation and robotic operations – building Victoria’s skills base. The facility can produce around 2.6m metal castings

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each year. This latest investment follows the Government’s support for sister company Nissan Australia to build its national headquarters and technical training centre in Mulgrave.

The centre is used to train engineers and technicians from Nissan sites around Australia and New Zealand with a focus on the company’s new and emerging electric vehicle range. Since November 2014, the Government has provided more than $184m in support to the manufacturing industry, creating more than 8,000 jobs and generating almost $2bn in private investment.

Victoria’s manufacturing businesses employ more than 290,000 workers and the Government is making sure new jobs continue to be created in the sector.

“We’re backing companies like Nissan Casting to expand their operations and make more products for export,” said Minister for Industry Support and Recovery Martin Pakula. “Victoria is Australia’s leading advanced manufacturing state, and we’ll keep investing in the sector to grow the economy and create local jobs.”

“We are delighted to receive strong support to continue to expand our Australian manufacturing expertise,” said Nissan Casting Australia Plant Managing Director Peter Jones. “With nearly 40 years of operations in Melbourne’s south-east, this will help us to expand our production of Australian-made electric vehicle components to the global market.” nissan.com.au

ELECTRONICS

Energy Renaissance batteries pass 90% local government goal with new Australian suppliers Energy Renaissance, a pioneer in the invention and manufacturing of Australian lithium battery technology has appointed three Australian companies to provide key components that will be used to manufacture its superStorage™ family of batteries.

Through long term framework agreements and preferred supplier relationships, this forms part of the company’s move towards achieving 100% onshoring of its manufacturing of batteries in Australia and contributes to 92% of components in their batteries sourced from Australian companies.

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Academy Sheetmetal, a family owned sheetmetal manufacturer in Newcastle, NSW, will supply the steel cabinetry that is used for the Renaissance superRack™ and superPak™.

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GPC Electronics, one of Australia’s largest contract electronics manufacturers in Penrith, NSW, will supply the printed circuit board assemblies that are used in the Battery Management Systems (BMS).

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B&C Plastics, an Australian plastic moulding injection manufacturer in Brisbane, QLD, will supply the plastic components that are used in the packs.

Almost all of the 35 components that make up a superStorage™ battery are produced in Australia, validating Energy Renaissance’s commitment towards strengthening its local supply chain, creating local jobs and opportunities for all Australians. The running of electronics in Australia, and everywhere else, depends on future-proofing the storage of energy, using advanced electronics.

“Energy Renaissance is dedicated to onshoring manufacturing in Australia so we can protect our customers against global supply chain constraints,’ Mark Chilcote, Managing Director of Energy Renaissance said, “and unexpected price increases that come with increased freight costs.”

“We started our business with a target to have 100 percent of our manufacturing completed in Australia. However, this target can only be achieved with a longterm partnership with local suppliers who will invest in business to grow in line with our production requirements.

Energy Renaissance is strengthening local manufacturing and, in the future, securing our supply chain for critical battery minerals when we commence the manufacturing of battery cells in Australia.”

Mark Chilcote, Managing Director of Energy Renaissance

The team of electricians at Energy Renaissance.

Energy Renaissance’s strategy includes:

procurement

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Supporting both small and medium businesses to large corporations.

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Partnering with values-based organisations who are committed to their customers, workforce safety, diversity and a quality assurance process.

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Working closely with Australian companies to reduce the cost of producing components needed for superStorage™ batteries. In the longer term, this will make it more cost competitive for components to be manufactured locally as Australia competes with global manufacturers.

“While negotiating for supplier agreements, we found local manufacturers who are price competitive with similar components made with a higher quality standard than what we would have to import,” Chilcote said. “This has challenged our views on sourcing for components globally and highlighted that we do have many local companies who share our passion of onshoring manufacturing.”

Energy Renaissance continues to negotiate local supply agreements as it ramps up the production of Australian-made batteries. energyrenaissance.com

The portable, affordable solution to improve quality, reduce scrap, and increase the productivity of any workshop.

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For full sales, support, installation and training of all your metrology needs contact Met Optix:

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Knaus Tabbert AG bets on the post processing solution, S1 from AM Solutions Absolutely clean 3D printed components for recreational vehicles with a fully automatic operation.

A significant quality improvement of the de-powdering and cleaning operation for 3D printed components at lower costs and shorter cycle times! A leading manufacturer of recreational vehicles is fulfilling this goal with the purchase of the automated post processing system, S1 from AM Solutions – 3D post processing technology.

With their innovative designs and powerful drive systems the motor homes, caravans and panel trucks of the Knaus Tabbert AG allow safe, comfortable and sustainable travelling. At its German headquarters in Jandelsbrunn, Bavaria, the company is using its knowhow to continuously improve the materials and designs of its vehicles.

Naturally, this also includes the employment of new manufacturing technologies such as additive manufacturing (AM). Mario Meszaros, development engineer at Knaus Tabbert explains: “On the one hand we are using the 3D printing technology for creating prototypes. On the other, we are also using additive manufacturing for producing standard components in volume such as the bracket for an alarm system or the hinge mechanism for the swing-out shower stall.”

Mario Meszaros

A challenging post processing task To date the de-powdering and cleaning of PA 12 components, produced by a powderbed printing system, was done manually in a blast cabinet. Since this post-processing operation required not only a lot of labour and time but also produced highly erratic and inconsistent results, the company was looking for an automated alternative.

Therefore, comprehensive processing trials were run with different components in the Customer Experience Centre of AM Solutions – 3D post processing technology.

This division of the Rösler group specialises in post processing solutions for 3D printed components. After conclusion of the highly successful processing trials the customer chose the S1 shot blasting system.

This shot blast machine was specifically developed for the post processing of plastic components produced with the powder bed printing method. The plug and play S1 is the only machine on the market that allows the time-saving and costefficient de-powdering as well as surface smoothing and homogenisation of 3D printed components in one single machine.

All that is required, is a simple change of the blast media, for example, from glass beads to plastic spheres.

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The S1, equipped with a basket that rotates during the finishing operation and allows easy, ergonomic loading and unloading of the work pieces, allows fully automatic batch processing. Throughout the entire process the basket remains in the machine housing. This, combined with a special door sealing system, prevents any powder spillage into the immediate surroundings.

The control panel allows an easy and quick switch to manual operation without any retooling. “More and more companies from different industries are choosing the S1 for post processing of their 3D printed components. This is a confirmation for our product strategy. It shows that our 3D post processing products are in full compliance with the requirements of the market”, says Manuel Laux, Head of AM Solutions – 3D post processing technology.

Perfect cleaning results and quick amortization “The fact that after surprisingly short cycle times the components came out of the machine perfectly clean and without any powder residues was very impressive,” Mario Meszaros says. “With the underlying operating data, I prepared a ROI calculation. The results quickly convinced

our management: Even with only three print jobs per week in the S1, we already achieve a return on investment after roughly two years. However, it is safe to assume that the quantity of 3D printed components will increase significantly. This will drastically reduce the amortization period.”

High process stability and operational safety The benefits of the S1 are not only limited to the excellent processing results and the quick amortization. In its standard version it also features a system that automatically monitors and records all relevant process parameters. The integrated blast media cleaning and recycling system represents another reason for the high process stability. It ensures that irrespective of the media type the media is always available in perfect condition. Another plus is the explosion protected design of the shot blast machine with ATEX compliant motors and valves. “I am absolutely convinced that the simple, effective and efficient post processing possibilities of the S1 will further promote the use of additive manufacturing in our company,” Mario Meszaros adds. solutions-for-am.com

ADDITIVE MANUFACTURING

KAW Engineering to 3D print metal parts in the Pilbara Next-gen metal 3D printing gives strong boost to Industry 4.0 manufacturing in the Pilbara.

KAW Engineering of Karratha, has taken delivery of the first commercial Markforged Metal X Gen 2 in Australia bringing faster metal printing with fully sintered parts in 28 hours. KAW Engineering is a specialised engineering services business caters to the local Oil and Gas, Mining and Construction Industries of Karratha, in Western Australia’s Pilbara Region. Commissioned in October 2021, KAW now have printing capabilities in a range of material from carbon fibre to tools steels and copper.

Managing Director of KAW Engineering, Jared Fitzclarence, comes from a background of specialised Mechatronics Engineering and has followed the progress of Boston-based Markforged for several years and has been waiting for the right technology advances and local market fit.

KAW Engineering will be able to offer Australia’s first regionally-based 3D Print Service of both Metal and Carbon Fibre, utilising the Markforged Metal X, X7 and Mark Two 3D Printers.

Henri Crisp, Additive Business Development Manager at SFDesign said, “the need for sovereign advanced manufacturing capabilities in Regional Australia is met by new advancements from Markforged and this investment from KAW Engineering will bring a huge boost in supply chain resilience and turnaround times for the Pilbara. SFDesign is proud to partner with KAW Engi-neering to get this regional-manufacturing-first capability off the ground.”

This investment will see two non-metal industrial 3D printers (Markforged X7 and Mark Two) and Markforged’s latest Metal Printing offering, the Metal X (Gen 2) with supporting Wash and Sinter-2 setup in a purpose-built facility alongside one of KAW’s existing fabrication facilities in Karratha.

KAW has built a standalone 3D printing facility alongside their main workshop in Karratha’s industrial estate to keep equipment and operator at a reasonable temperature in an environment not unfamiliar with 45-degree weather and strong winds – covering everything in sight with a striking red dust.

Jared Fitzclarence of KAW Engineering said, “When it comes to manufacturing in the Pilbara, there are a number of challenges for our customers being so remote. This includes limited spare part availability and the need to produce a wide range of custom parts with fast turnaround times. Our new 3D printing offering helps address these challenges through a wide range of high-strength materials and much lower setup costs than traditional manufacture for these components.”

"We are very excited about bringing Markforged’s Digital Forge to KAW engineering to support maintenance, repair and operation needs,” Richard Elving, Director of Sales Asia-Pacific at Mark-forged said. “Supply chain issues can be costly and time-sensitive, and with these tools in place, KAW will provide a competitive advantage to its customers that enables faster turnaround and will result in shorter downtimes, lead times and reduce costs.” kawengineering.com.au

+61 3 9359 3133 www.integratransform.com.au integratransform@integrasystems.com.au

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Automated post processing of 3D printed metal and plastic components Post processing solutions that meet the requirements for volume production.

Companies across many industries have concluded that additive manufacturing will make them less dependent on traditional supply chains. However, an essential pre-condition for this approach is that the post processing operations must comply with the requirements for volume production. AM Solutions – 3D post processing technology is meeting these challenges with new solutions for the automated post processing and refinement of 3D printed metal and plastic components. In parallel, the division AM Solutions – Manufacturing service partner supports the development and production of AM components with comprehensive services.

Additive manufacturing offers companies the potential to become less dependent on traditional supply chains and, at the same time, make their production operations much faster and more flexible.

However, the post-processing of 3D printed components is frequently a stumbling block against achieving these goals. On the one hand many post processing steps still require costly manual work, and on the other hand the post processing operations are limited to handling single components or extremely small production lots. This does not allow compliance with the established standards for volume production, namely consistent and repeatable product quality, process control, cost-efficiency, and sustainability.

AM Solutions – 3D post processing technology, a division of the Rösler group that specialises in the automated post processing of 3D printed components produced in large volumes, now offers new equipment that allows a way out of this dilemma.

Safe and stable post processing of plastic components in 24/7 operation With the new S2 system AM Solutions – 3D post processing technology offers the so far only continuous flow shot blast machine for post processing of 3D printed plastic components produced with powder-bed printing systems. The ATEX compliant plugand-play machine was designed for round-the-clock three-shift operation and is equipped with interfaces allowing its integration into interlinked manufacturing lines. The work pieces are loaded into the machine as complete print jobs. The loading takes place either by hand or automatically. Once in the machine, the plastic components are gently passing through a special feed loop belt in single piece flow. The tumbling action of the components ensures that they are equally blasted from all sides so that any residual powder is consistently and completely removed from the component surface.

Depending on the utilized blast media, the work piece surface can also be homogenized and/or peened. The machine can be equipped with up to four blast nozzles. The number of blast nozzles, the blast pressure and the transport speed can be individually adapted to the respective work pieces. These process parameters can then be stored in the control panel as individual processing recipes.

On average, a print job requires cycle times of 15 to 20 minutes.

Depending on the condition of the raw work pieces, the Ra surface roughness readings can be reduced by up to 13 µm.

To ensure that the blast media remains at a consistently high quality, the compact shot blast machine is equipped with an effective blast media cleaning and recycling system. This, in combination with the integrated electronic reporting tool, guarantees repeatability of the blasting results, complete process control and a high cost-efficiency of the post processing operation. A patent application covering the machine and the process is pending.

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Eco-friendly chemical surface smoothing and application of a colour dye – at low costs The C2, presented as a concept solution, illustrates that AM Solutions - 3D post processing technology has its origins in the development and production of machinery and consumables for volume production. This patent-pending innovation enables fully automatic chemical surface smoothing of 3D printed components made of common polymers and elastomers (including TPU) in series. Thus, the costly single piece handling of the work pieces is eliminated for this post processing operation. The bounding box allows the processing of work piece dimensions ranging from 10 x 10 x 10 to 300 x 300 x 300 mm and a wall thickness of at least two millimetres. In addition, the process includes a newly developed, non-hazardous processing media that was specially developed by AM Solutions – 3D post processing technology. This ensures that the surface smoothing operation is not only eco-friendly but that the subsequent waste disposal is not subject to any environmental restrictions and is cost-effective.

The innovative C2 chemical surface smoothing system, for which a patent application is pending, can be retrofitted for applying a color dye on plastic components. The C2 will be commercial available in the first quarter of 2022.

Specially developed wet blast system for 3D printed components Wet blasting has been a well-established and efficient surface refinement process for metal or plastic components produced in large volumes. With the S1 Wet system AM Solutions – 3D post processing technology has adapted the benefits of this surface treatment method to the specific requirements of additive manufacturing. The highly flexible S1 blast system can be used for cleaning as well as surface homogenization and smoothing of a wide array of work pieces. A key feature of this technology is that the blast media and process water are mixed to create a slurry.

Depending on the initial surface roughness of the work pieces, their Ra readings can be significantly reduced. To a certain extent this is even possible on internal surface passages and cavities. Since the water in the slurry creates a protective layer on the components, the process is very gentle. It also prevents media particles from penetrating the surface of components made from plastic and soft metals. Another advantage of the wet process is that it maintains the dimensional integrity and prevents the warping of delicate work pieces with complex shapes and thin walls. Wet blasting also prevents the creation of dust and, therefore, requires no protective ATEX accessories.

ADDITIVE MANUFACTURING

Manufacturing service partner – support from the idea to post-processing Another feature of the compact plug-and-play S1 Wet system is its small footprint. On a space of only 2.6sqm, it offers everything that is required for an efficient and sustainable operation. Integrated into the machine is not only the control panel but also the monitoring of the blasting system to ensure a repeatable process, the air filter unit and the wastewater management. The discharged wastewater flows into a settle tank to collect most of the sludge.

This sludge-type material can be further de-watered by an optional process water cleaning and recycling system integrated into the S1 machine. This reduces the water consumption and waste disposal costs significantly. Additional equipment options, perfectly adapted to the respective processing tasks, allow the utilization of the S1 Wet ranging from the manual treatment of single components to the fully automatic processing of complete work piece batches.

AM Solutions – Manufacturing service partner specialises in services related to additive manufacturing. The range of services covers the entire AM process chain and is also designed to meet the requirements of series production. To this end, the Italian-based company of the Rösler Group covers all phases of the product creation process, from the basic conception and testing of the product idea, through technical and economic feasibility studies, product development and the creation of prototypes, to largescale production, including post-processing. The aim is to exploit the advantages of additive manufacturing in a component-specific manner through the optimal use of state-of-the-art technologies and comprehensive know-how, so that innovative parts are created in significantly shorter development and time-to-market periods. solutions-for-am.com

www.rigbycooke.com.au

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Sandvik adds 3D printed cemented carbide Sandvik has expanded its AM offering with the introduction of 3D printed cemented carbide. With superior wear resistant properties, the components are crafted using a patented process from Sandvik's AM experts.

Sandvik continues to expand its additive offering through introducing 3D printed cemented carbide – with superior wearresistant properties. This is enabled by a unique powder, crafted through a patented process developed by the company’s leading experts along the additive value chain.

With 160 years of leading materials expertise and the widest range of metal powders on the market, Sandvik has been working with cemented carbide since 1932. Today, Sandvik is a world leader in hard materials, providing for instance metal cutting- and mining tools such as turning inserts, end-mills, and drill bits. Now, the materials authority is broadening its offering to also include 3D printed components in cemented carbide.

Cemented carbides have a unique character because of their composite structure – a wear-resistant phase bonded together by a ductile binder metal – and are widely used across multiple For faster and food, moreand convenient industries such as metal cutting, agriculture, oil and gas. handling of all your Due to its inherent hardness, cemented carbides can be challenging to machine, not least in complex geometries. Leveraging its century-long materials expertise, Sandvik can now offer 3D printed cemented carbide on a commercial scale – based on a tailor-made powder attained through a proprietary process – with the design freedom, decreased material waste, and fewer replacements that comes with additive manufacturing technology.

In its “Plan it, Print it, Perfect it” approach to additive manufacturing, Sandvik states printing is just one of the seven steps you have to master in order to succeed with the industrialisation of AM – and that obtaining the most optimal material, tailor-made for your AM process and end component, is the first and perhaps most important step.

Anders Ohlsson, Lead Product Manager at Sandvik Additive Manufacturing

“The most critical component in our process is working with powders that have the just-right properties,” says Anders Ohlsson, Lead Product Manager at Sandvik Additive Manufacturing. “Above all, high density crucially impacts the quality achievable in terms of material properties and geometry. Sandvik has developed both a powder and a process that are unique. My view is that with commercial powders, you can make things that look cool – but don’t really work. Our powders are optimized to print components that look great, work well – and are fit for use in actual applications, demanding environments, and serial production. It’s also well worth mentioning the ability to 3D print cemented carbide speeds up our time-to-market rather dramatically. Prototyping used to take six to 12 months – and now our lead time to date is a matter of weeks.”

“Cemented carbide is one of the very hardest, if not the hardest material available in 3D printed shape as of today. When implementing additive manufacturing into your business, you basically eliminate all previous design restrictions – enabling you to focus on designing components based on operational needs and requirements, without having to adapt to a specific shape or form.

One example is this wire drawing nib from a recent R&D project in our workshop. The closed loop spiral coolant channels enable efficient cooling of the nib, while the wire remains dry. This would have been impossible to achieve without additive manufacturing.”

A key differentiator compared to other hard materials is the fact that these alloys are often brittle, to some extent – while cemented carbide, with its’ matrix structure consisting mainly of cobalt and tungsten carbide, is uniquely tough. Thanks to the extreme durability of the material, the printed components are well suited for most industries looking to optimize production efficiency – including those operating in challenging environments.

“The main enabler behind us continuously building on our additive offering is the fact that at Sandvik, innovation never stops,” says Mikael Schuisky, VP and Head of Business Unit Additive Manufacturing at Sandvik. “Thanks to our longstanding experience in materials technology paired with our expertise along the additive value chain, made even stronger by our partnership with the BEAMIT Group, we can innovate at a speed few others can. This makes us uniquely positioned to drive the shift toward the industrialization of 3D printing, and prove sustainable manufacturing isn’t just possible – it’s already happening. 3D printing in cemented carbide is a natural next step for us having perfected these materials for decades, and we are very pleased to offer additively manufactured components that can revolutionize the performance throughout our customers’ businesses.” additive.sandvik

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ONE-ON-ONE

Neo-Bionica specialises in developing, manufacturing and testing bioelectric and neurotechnology devices for use in targeted therapies and diagnostics. Paul Hellard spoke to the Neo-Bionica CEO, Mr Ludovic Labat (PhD).

AMT: Can you please describe what is involved in bioelectric and neurotechnology device development?

Ludovic Labat: Simply put, we develop neurotechnologies and bio-electronics medical devices for our clients. There are devices which are used in patients to either stimulate a nerve or to read activity on a nerve as a way of treating a variety of diseases and conditions. Historically, the most commonly known electric devices are the pacemaker and the cochlear implant. There are now many other applications for a range of diseases, such as epilepsy and Parkinson’s disease. The cochlear implant is another very common application for the technology. There are now many more other applications in the field of epilepsy and Parkinson research and treatment, and many other medical arenas.

AMT: With the development of a neurotechnology devices, talk about Neo-Bionica’s part in that area of manufacturing.

LL: Our clients are all developing technologies for new treatments.

We initially help our clients with ideation and concept development.

We then develop prototypes to work out the feasibility issues the technology may be facing. And then we converge toward defining the product, executing the detailed design of the product. These prototypes are tested intensely in verification testing before moving into clinical trials.

There are many iterations of prototypes, and the first models are always a benchtop model where you don't have any physiology attached. That’s a good way of progressing fast and verifying that the device is safe. Safety of the product is the first aspect that must be verified. The efficacy of the expected clinical intent from the devices is then proven.

Being able to produce prototypes for first in-human testing in Australia and the facility that we’ve built, fills that gap in the supply chain for the market.

AMT: Tell us about a couple of your recent successes.

LL: We currently have a dozen clients and the business is only just nine months old. And from those clients, there are two pretty significant projects. One for a big multinational corporation in the US and one for a mid-size company. And the feedback from these clients is tremendously encouraging. Everybody’s extremely pleased with what we bring and the pace at which we move and the co-location in between the Neo-Bionica facility and St. Vincent’s Hospital in Melbourne. The fact that our engineers are

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working with clinicians on a very regular basis is very well received.

This is proof that the vision from the founders of Neo-Bionica is now proven. There was a gap in the market. And our clients people are really interested in us delivering on these needs.

One of the key attributes of our business is discretion. And we really wanted to differentiate ourselves from research organisations. Our clients come to us with their IP. If they are young start-ups, they may be raising money and they may want the publicity. We are working with a company named Nirtek, in Melbourne. They are very pleased to share that we work with them, but many clients ask us to be extremely discreet as the work we are doing for them is highly novel.

And part of the offering is to respect that, but the type of product we are developing at the moment for our clients are really places where new technologies are going to the next step. There are some pretty significant clinical challenges that the clients are trying to solve, and we help them solve these clinical challenges through engineering solutions. This is the type of neurotechnology that we will begin to see on the market in seven to ten years.

AMT: What's your view on where Medtech industry is right now?

LL: I've been very fortunate to work in many industries. I did my PhD in the Aerospace Industry and then worked in the Automotive Industry for a few years. And I've been a general manager at Tektronix, working in test-and-measurement solutions and so I’ve seen quite a bit of industry and here in the medical devices industry.

And there's significant maturity coming naturally from the fact that we are so highly regulated. I would say it is a young and fast growing industry, but very mature.

AMT: What would you say to engineers and manufacturers wanting to be part of the creation of these medical devices?

LL: There's no typical product, but there is a typical process. We are extremely strong on having a defined process. Some of our team members come from the medtech industry, some of our team members come more from an engineering background, and some have clinical expertise. And so those who are coming from the industry bring that very defined and repetitive process. We always start from the unmet clinical need. Product definition must start there. And we spend time with our clients, understanding what they are trying to achieve from the patient point of view.

And that's where the co-location with the clinical world in the St.Vincent hospital is a massive, unique advantage for our clients.

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We listen to these needs and translate these very quickly into a set of requirements. Working, creating concepts in very fast-moving cycle of designing, testing, learning. And going into the verification testing which is far more structured especially when we are in the Class Two and Class Three medical devices.

What we do at the core is produce electrodes and electronic systems for implanted devices and so a key focus is safety and longevity of devices. We put in a lot of effort into manufacturing and fabrication techniques, and consideration into material choices. Choosing the right material is critical to ensure safety and the long-term reliability of the unit. And so that, that's a big, big part.

Also, understanding all the aspects of biocompatibility requires specialised knowledge. There's a limited subset of materials that you can use as implants for example, silicones and certain polymers.

These materials will have their own mechanical properties, their own electrical properties. Depending on where the implant is set and its purpose, there are challenges in selecting the right materials – and so having the right people on your team with expertise in this area is critical.

And as our team have experience in taking medical device prototypes through to pre-clinical and clinical testing, often these clients come to us as they know we have the expertise to make sure the device systems and hardware work together seamlessly and that materials used in the device subcomponents - such as stimulators, electrode arrays and leads - are biocompatible and safe.

AMT: What makes you most excited to be working in the medtech field?

LL: You know, the day I decided to sign for this job, I watched a YouTube video where a baby was receiving their first cochlear implant and hearing the voice of their mother for the first time. And firstly, it’s difficult not to cry because it’s extremely moving, but as an engineer you have an opportunity to have a massive impact on the life of real people. We know that engineers can make people travel far or communicate faster, like we are doing right now. But when it’s about the life of a patient and we can see that impact, it’s very special. neo-bionica.com

AMT: Where do you see the Medtech industry going, what is in Neo-Bionica’s future?

LL: Unfortunately, we can’t talk specifically about our client projects, but they are really exciting, innovative technologies across a wide range of applications.

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PLASTICS

Tolerance attainment in micro moulding Much is made of the need for manufacturers embarking on a micro moulding project to partner with experienced and highly capable specialist micro moulders. Aaron Johnson of Accumold gets into the nitty gritty.

The trend towards miniaturisation across industry is accelerating, and in many sectors increasingly small micro parts and components are used in safety critical applications, so the demand is for micronlevel tolerances that can be achieved repeatably and which can be verified to ensure compliance with design intent.

It is only by working with a qualified micro moulder that such repeatable tolerance attainment can be assured, and is also the only way that tolerance creep can be arrested at every point in the product development process. The key is to select a partner with experience that has all stages of the product development process under one roof. In the area of true micro moulding there are only really a handful of companies that can credibly claim to achieve the level of tolerances required, and even less that can prove true vertical integration.

An eagle eye on tolerances When manufacturing micro parts and components, it takes a coordinated team of experts in design, materials, tooling, moulding, validation, and automated assembly to successfully manufacture customer parts at high volume.

When tolerances are measured in microns, it is critical that all involved in the product development process maintain an obsessive focus on mitigating the risk of non-adherence to these tight tolerances.

For the uninitiated, the thought of volume manufacturing parts with tolerances sometimes as low as two microns may seem the stuff of fantasy, but there are qualified micro moulders that do this daily, while at the same time maintaining zero failure rates.

Attention to detail and attention to process is everything, as not only do micro moulders need to make tiny parts with tiny features repeatably and attaining micron tolerances, but they need to do this in a cost-effective and timely fashion. The viability of a project in terms of cost and time means the avoidance of multiple design iterations, constant review and change to manufacturing processes, and above all having to recondition extremely expensive and timeconsuming micro tools. The key is to ensure that areas where most “variation” in accuracy can occur are managed with absolute focus.

Micro tooling Micro tooling is perhaps the key to the success of a micro moulding project, be that its optimal design or its ultimate fabrication. Tooling for micro moulding projects does not require an extrapolation of the rules governing tooling in traditional injection moulding. Features in micro moulded parts often exceed the allowable tolerances in traditional injection moulding, and similar issues are confronted in the areas of venting and tooling mismatch. Micro moulders must be in a position to employ an array of moulding technologies, including the latest CNC machining technologies, and also — as is often required — EDM

When looking at tolerance creep, if tool design and fabrication is not optimal, then the project may be lost at this stage. Tooling is a true enabling technology when micro moulding, and the ability to fabricate tools significantly within final tolerance requirements of a part and to accommodate tolerance loss in other areas of product development is vital but beyond all but the most experienced of micro moulders.

Metrology and Validation Metrology has a key role to play in any micro moulding product development process, and it is vital to use measuring technologies that are able to validate end-use products with feature sizes that are always extremely tiny. In a micro moulding scenario, it is hugely important to establish confidence in the accuracy and reliability of the chosen measurement system(s). While other sources of measurement variation exist, the two key sources are equipment variation (repeatability) and appraiser variation (reproducibility).

Evaluation of the measurement system in terms of Gage R&R should be an important element of any continuous improvement activity, especially with micro moulding applications where any variation in the repeatability and reproducibility of the measurement could crucially eat into the low margins for error in terms of tolerance attainment. The evaluation builds trust in the instruments, operators, and processes.

Material Considerations Ultimately, material choice has a direct influence on end-use part functionality and it affects tolerance attainment, the achievement of dimensional objectives, and strength parameters. It also has a direct and obvious impact on the cost and timeliness of manufacturing.

Summary Micro moulding projects are by their very nature complicated, and the fact that many require the repeatable attainment of extremely high tolerances demands that there is a collective focus on accuracy when looking at micro tool fabrication, moulding, validation, and automation processes. However, material selection and design for micro moulding (DfMM) are also hugely important. It is because of this that manufacturers work with micro moulders as close to the beginning of the product development process as possible, as accessing expert micro moulding design insight early is the key to cost-effective, timely, and right-first-time manufacturing.

Aaron Johnson is the VP of Marketing and Customer Strategy at Accumold. accu-mold.com

Other tooling issues specific to micro moulding are requirements for an understanding of polishing for micro-mould cavities, and the heating and cooling implications when dealing with extremely thin steel inserts that can be negatively affected by temperatures involved in many moulding applications.

I addition, as many micro moulding applications use high temperature, high performance materials, such as bio-resorbables, liquid crystal polymers, and PEEK, it is necessary to use and understand the nature of tooling materials such as stainless steel rather than traditional tool steels which may not be able to withstand the high temperatures necessary, and can corrode.

AMT JUN 2022

Giving an idea of scale, these are manufactured micro moulded parts for industry.

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PLASTICS

Cutting plastic to size Engineering plastics can rescue production when manufacturing and maintenance pincers put the squeeze on bearing replacement.

One of the last things any operations manager wants is extended stoppages caused by bearing failures as manufacturers and primary producers get squeezed between the pin-cers of expanding production needs and narrowing maintenance windows.

Avoidance of such issues is particularly important now throughout Australasia and the Asia-Pacific, as production begins to ramp up after the easing of COVID restrictions in many places and as companies look for ways to avoid supply chain issues to ensure their machinery runs without disruption as markets and exports expand.

One proven way to address bearing failures causing disruption – or fears of incipient problems developing – is the use of split plummer where production and process staff want to minimise disruptions to production caused by the need to replace bearings quickly.

Plummer blocks – or pillow blocks, as they are sometimes called – are the pedestal mounts used to provide support for a rotating shaft on bearings. Frequently they are one-piece metal structures, which present handling issues, OH&S hazards, and removal and installation delay.

Sometimes they are split structures, to facilitate handling with fewer such issues.

“Making split plummer blocks from engineering plastics takes the benefits of the split design a step further, because the workpiece is strong, self-lubricating, lighter, and quicker to install,” says AsiaPacific engineering plastics authority Laurie Green. “The easily handled and engineering plastic spilt blocks can be produced from polyurethane – or other specialist engineering grade plastics for diverse materials handling applications, often involving processing machinery with multiple bearings and inline shafts where it would be costly to close down the entire line for removal and installation of heavier and more complex bearings,” he says.

Where the split blocks are used in particularly corrosive or aggressive environments, such as those typically encountered in food and beverage, primary processing and materials han-dling applications, split plummer blocks can be engineered from a range of high-performance plastics formulated to suit the particular tasks.

“Such plastics can be formulated to increase hardness, eliminate porosity, resist chemicals, and provide outstanding hygiene,” says Mr Green, Managing Director

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Laurie Green, left, with Hercules Engineering General Manager David Booty.

of Cut To Size Plastics. Green has more than 40 years’ experience in employing tough, light, and hygienic engineering plastics to replace metals where plastics have major benefits, including in primary processing, food and beverage, resources, and manufacturing.

“The company engineers some of the world’s most respected brands of engineering plastics in its machinery component fabrication,” says Green. “We don’t claim engineering plastics are right for every application – but these super tough materials have evolved brilliantly in recent decades to the point where they are the natural solution to many issues encountered in processing.”

“Split plummer blocks manufactured from engineering plastics have several natural advantages over metal alternatives. In addition to hygienic surfaces that are easy to wash down, there are often significant cost advantages in fabrication and speed of replacement,” Green adds.

“Often engineering grade polyurethane bearings, with a shore hardness of 75D, can be used to provide an excellent interim solution that saves time and money, while in other situations they provide a highly cost-effective long-life solution.”

Cut To Size Plastics is continuously investing in technology to offer prompt, precise and cost-efficient service throughout the AsiaPacific. One of its latest investments is a Morbidelli Author M100F heavy duty CNC router and machining centre.

The high-speed, vibration-free Italian technology – which offers unmatched finishing quality and rapid production turnaround – complements the company’s comprehensive CNC machining facility at its HQ in Yennora, Sydney.

The Morbidelli is coupled with GibbsCAM and SolidWorks software to optimise the company’s ability to produce high-quality product from customer specifications and design briefs for local application or export, including the split plummer block designs. cuttosize.com.au

PLASTICS

Shot peen surface finishing and blasting technology RUAG Australia invests in future manufacturing capability, upgrading to the latest custom designed Rösler International shot peen machine.

In the midst of a pandemic in 2020, the pursuit of continuous improvement and growth didn’t stop for the Aerostructures team at RUAG Australia, with decisive action taken to upgrade manufacturing machinery at its hydraulic centre of excellence in Bayswater, Victoria.

RUAG Australia are dedicated to maintaining the quality of all equipment and machinery to continue providing high quality service to customers. The fully integrated automated shot peen system is one of the largest of its kind used in Australia for Defence and Aerospace applications.

The system uses blast media whereby small steel beads impact the target surface to create a compressive stress layer on the surface, leading to improved durability and structural integrity, so the substrate is better able to withstand failure. The typical components to be manufactured using the shot peen machine include air frame components, hydraulic landing gear actuators, undercarriage components and structural components for military aircraft.

The RUAG Australia engineering team approached international experts in surface finishing and blasting technology, Rösler

International (Rösler) to upgrade their shot peen machine. Rösler worked closely with the team for over 12 months to develop a custom-designed system, configured specifically for RUAG Australia’s application requirements. RUAG Australia employees met with Rösler in France to inspect and check machine specifications, before it was manufactured and shipped to RUAG Australia’s Bayswater facility in Victoria, where it was installed and is currently being commissioned. Employees at Bayswater received thorough training and were inducted on how to effectively utilise the advanced robotics capabilities of the machine too.

With support from parent company RUAG International and the technical expertise from Rösler, RUAG Australia successfully invested in this significant equipment upgrade to its Bayswater facility.

The addition of this fully integrated system further supports RUAG Australia’s goals of becoming an Industry 4.0 focussed company. Since the machine was installed in 2021, the projected increase in capacity is promising, with capacity for up to four parts to be processed simultaneously within

the one set-up. This will result in improved efficiency, process stability and repeatability, reducing the chance of process failure and improved turnaround times for customers.

The team can offer this fully integrated NADCAP-approved manufacturing solution for Defence customers, offering improved special processing of complex aircraft components.

“This new capability elevates RUAG Australia to the forefront of innovative aerospace manufacturing in Victoria, further solidifying our position to support sovereign industrial capability and establishing us as a reliable partner for the Defence supply chain, locally and internationally,” said George Atkinson, Manager, Aerostructures at RUAG Australia.

“This level of investment demonstrates RUAG Australia’s commitment to its customers in enhancing our capabilities and services. Investments like this are critical in maintaining our position as a reliable partner for global defence and aerospace supply chains,” said Aidan Butler-Bonnice, Senior Manager, Business Operations at RUAG Australia. ruag.com

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PLASTICS

Using plastic dent restoration tools 3D Printing gives way to plastic dent restoration tools using BASF Forward AM Material.

Plastfix, the automotive industry’s leading plastic restoration and specialty tools supplier, cooperates with Forward AM, the brand of BASF 3D Printing Solutions to deliver an innovative, yet simple, 3D printed set of plastic repair hand tools to be used on automotive plastic parts such as bumper covers.

The tools named ‘PlastiPush’ have been designed and used with great results by the Plastfix Team across their USA, Australian and New Zealand client base. They evolved to their present form through continuous improvement and are now ready for market. Led by industry pioneer Mario Dimovski, the Plastfix Team has worked through various prototypes of tool designs and 3D printing materials to identify the best combination for restoring damaged automotive plastic parts to their original OEM condition.

3D printing has accelerated the process in a way that would not have been possible through traditional injection moulding with the ability to develop various prototypes for testing and small batch endproduct runs.

The tools give collision repair technicians the ability to push out impacts using heat and manipulation to restore thermoplastics like polypropylene back to their original shape. This is different from the traditional approach by most of the collision repair industry of using fillers or generic hand tools that can damage the plastic after heating.

On the other hand, the Plastipush tools provide technicians with the ability to deliver a quality filler free repair process giving the plastic part the same characteristics and performance capabilities as intended by the OEM. The PlastiPush Tools set comes in three separate sizes, with two custom tips on each end engineered to not stress the plastic part during the repair process at the point of contact, though messaging the damaged part back to its pre accident condition with the 3D printed material absorbing some of the pressure during use.

“What a great occasion this is for the collision repair industry,” said Mario Dimovski. “We not only bring these tools to the broader market, but also highlight the benefits of 3D printing.” Dimovski is a 30-year Master Plastic Repair Technician and owner of Plastfix Industries. “This allows a small company like Plastfix to launch

AMT JUN 2022

an innovative solution, with the support of the material experts at Forward AM,” he added.

“At Plastfix, our goals are to drive innovation and promote the better management of plastics waste across the collision repair industry,” he continued. “We are focused on reaching into new markets and areas of innovating the repair process. One market identified, and now a critical part of our growth plans, is 3D printing. It includes the creation of our Plastfix Labs division in Europe featuring our talented R&D staff, led by Andrej Markoski, Director of 3D Printing and Systems. With the launch of these products, we are able to extend our influence providing 3D printing services across the industry and beyond.”

The environment is a big winner with the introduction of such new tools, as repairing more plastic parts encourages sustainability.

The average plastic part weighs over 3kgs. Diverting repairable parts from the waste stream is significant and paired with a reduction in collision repair shop waste costs. The collision repair industry is the second largest generator of polypropylene waste worldwide and has developed a culture of replace over repair for plastic parts that part blame could be directed at the growing skills shortage the industry faces.

In an industry lacking a proactive approach to waste management, we can now make a better choice for our businesses as well as our planet using these tools and supported by the Plastfix online training courses.

Plastfix will take a leadership position, addressing a growing social trend to be better stewards of our planet. If every collision repair shop repaired one extra bumper bar cover per week, that would divert over 36,000 tons of plastic waste from landfill every year.

Plastfix Industries has finalized its testing program and IP protection processes. It has started accepting orders from their networks of collision repair shops and distribution partners, with the PlastiPush tools being released to the broader market in September supported by the ever-expanding Plastfix online training certification platform. plastfix.com

BUSINESS MANAGEMENT

Five top tips on creating trust in international business Mistrust is a tough monkey. It influences business decisions worldwide. Most unfortunately, in business deals that cross international borders. Cynthia Dearin attempts to clarify and educate, in the hope she can dispel the fears of business being lost in translation.

Many businesspeople around the world worry about working with foreign companies and people … because they don’t trust them.

Americans are reluctant to work with folks from the Middle East, Australians describe Indonesia as a ‘hard market’ and Brits worry about dealing with the French. Not many people are willing to extend trust, and it’s a problem.

What is trust and why does it matter?

Trust is confidence in people, their integrity and abilities. Without trust, we suspect other people’s motivations, capabilities, integrity … and their ability to produce results. You only need to think about the relationship that you enjoy with someone you trust and contrast it with your relationship to someone you don’t trust to feel how different they are. It’s not just the difference in how we feel about these different kinds of relationships that matters. There is a strong business case for the importance of trust in commercial settings, because it affects two outcomes – speed and cost. When trust decreases, speed decreases and costs increase. When trust increases, speed increases and costs decrease.

No trust … what cost?

Whether the cause is unethical behaviour or ethical, incompetent behaviour, low trust causes friction. It creates hidden agendas, politics, interpersonal conflict, interdepartmental rivalries, win-lose thinking, defensive and protective communication – all of which make relationships more difficult and business clunkier and more expensive. If you’ve done an international business deal you’ll probably recognise these problems. When we begin working with people who are different to us, we often wonder: “are they telling the truth?” “will they do what they say they will do?” “how do I know that their motives are good?”.

Uncertainties create suspicion, lead to delays in decision-making and cause people to second-guess the real meaning of what a foreign business partner or colleague says. They can also unnecessarily complicate contracts or even cause a deal to break down entirely. Conversely, trust speeds things up, produces results, builds loyalty, creates a winning culture, makes customers buy more and refer more people, products and services to their friends.

In the context of international business it can encourage people to ‘think big’, plan ambitiously and move quickly. So, how do you create trust?

1. Develop strong interpersonal relationships Embarking on an international business deal, it can be tempting to focus on the mechanics of the commercial transaction and forget about the people involved. Don’t do it! Getting to know your counterparts as people will go a long way to increasing the flow of trust between you. Make the effort to create a real relationship with colleagues and partners that extends beyond the immediate boundaries of the work at hand. Share meals, find out about their families, their goals, aspirations and what motivates them. Look for shared areas of interest and common ground that you both understand, whether it’s antique clocks, tenpin bowling or mountain climbing.

2. Understand expectations When you deal with someone from another culture, it’s vital to understand what their expectations are likely to be, at the outset.

Misunderstandings around expectations can damage trust quickly,

by colouring how people perceive each other’s intentions and competence. This is particularly important when you are dealing with someone who has different standards around time, for example.

3. Demonstrate respect In many cultures, showing overt respect is evidence of a good upbringing … and the casual manners of Western businesspeople may come across as abrasive or rude. Understanding a cultural difference like this one is critically important to building trust across cultures. You can demonstrate respect by genuinely caring about the person across the negotiating table, taking an interest in who they are and what they need. Thinking about your counterpart as a person (and not just a means to a deal) is a good start. Showing that you care about them in the words that you use and how you act is a great way to follow up. Make sure it’s genuine though, there are few things more insincere than fake concern.

4. Listen before you speak To build trust, you need to really hear what your foreign colleague says, so that you correctly understand what they are trying to communicate before you start putting across your point of view.

Don’t assume that you know what matters most to others and never presume that you have all the answers.

5. Extend trust It’s often contrary to how we feel when working with foreigners, but extending trust is key to building trust. I’m not suggesting that you blindly trust every person who proposes a business deal, but I believe that it’s better to begin with a mindset which is open to trusting people. When you extend trust first, it’s likely to build trust with your international business partner or colleague much more quickly, which should help to speed up whatever you’re trying to do.

Cynthia Dearin, author of Business Beyond Borders: Take Your Company Global, is an international business strategist, advisor, and keynote speaker with 22 years of international experience as an Australian diplomat and management consultant. She is the founder and managing Director of Dearin & Associates and the International Business Accelerator, helping companies to scale internationally and amplify their impact in the world. Her previous book is Camels, Sheikhs and Billionaires: Your Guide to Business Culture in the Middle East and North Africa. dearinassociates.com

AMT JUN 2022

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WELDING

Collaborative automation to end welding woes Universal Robots has cited an uptick in demand for collaborative robots, called ‘cobots’. These are robots that can work safely alongside humans, in welding applications.

Speaking to AMT about the prevalent labour shortage on local shores, Masayuki (Masa) Mase, Country Manager for Universal Robots Oceania, says that the industry is on the hunt for qualified welders and that cobots are beginning to fill the gaps. “Traditionally, more skilled welders were available, but over the past two years – due to COVID-19 travel restrictions – the industry has noticed a sharp decline in skilled welders. Finding a skilled welder who isn’t employed remains a challenge. Finding the right skills is critical to remaining competitive.”

“A cobot adds flexibility, efficiency, and freedom to welding processes,” says Masa. “Cobots empower change in the way work is done. In addition, when the task is completed, a cobot can easily be redeployed to other areas where it can add value.”

A recent study by Weld Australia highlighted the need for additional qualified welders. This skills shortage is compounded by a rapidly ageing welding workforce, with approximately 30% of Australia’s existing welding workforce aged over 45 years.

Speaking of the welding tasks in question, Masa says that cobots can handle Arc, TIG, laser, MIG, and spot welding, as well as soldering. “Cobots can be easily integrated into new and existing systems. While the processes of integration may be little more than just ‘plug and play’, welders will soon learn that they can extend their welding expertise to automated solution using cobots - even with no prior backgrounds in robotics. This once again comes down to Universal Robots’ mission statement that encourages people to work with robots, not like robots.”

Trusting cobots with these important tasks comes down to one factor: Trust. “Our company’s proven track record with welding applications around the world instils customer confidence,” says

AMT JUN 2022

Masa, “and proves that Universal Robots is committed to helping customers remain successful in this area.”

He adds that the patented technology used in Universal Robots’ cobots limits the force of contact when it comes into contact with a person. “Cobots can also be programmed to operate in reduced mode when a human enters the robot’s work area and resume full speed when the person leaves.”

Masayuki (Masa) Mase, Country Manager for Universal Robots Oceania.

For small medium enterprises (SME’s), cost may be a factor, but Masa urges customers to keep the big picture in mind and consider the salary of a welder and the scarcity of labour before jumping to conclusions. Cobot deployment is a solution that delivers lowered integration costs, quicker installations, and increased efficiencies. Letting a cobot handle simple welding tasks frees up experienced welders’ time to focus on more complex tasks that can benefit the company’s bottom line.”

Welding success Masa highlights two international success stories. “Universal Robots helped automate small batch welding at Montana Solar in the US.” MT Solar in the US designs and manufactures mounting structures for solar modules of all sizes. A DIY vectis cobot welding tool powered by a UR10e cobot now handles a wide range of welds, enabling quick changeovers and optimised production.

WELDING

“MT Solar overcame labour shortages and freed staff from repetitive welding tasks while successfully handling a 300% surge in demand” he adds.

Another recent success also showcased collaborative automation in welding applications. Universal Robots collaborated with worldrenowned ASSA ABLOY – a leader in door opening solutions.

Their branch in Romania required variability and several different configurations of product, resulting in a higher demand for automation. “They were also experiencing a shortage of labour and required automation to work across an array of applications

including welding, stamping, riveting, screw driving, grinding and machine tending,” explains Masa.

The company now operates four UR3 and six UR5 robots with Robotiq 2-finger adaptive robot gripper a UR+ solution and custom made end-effectors.

To conclude, Masa advises any local company’s wishing to automate their welding processes to jump straight in. “Regardless of the company’s size, automation can provide immense benefits. It’s time to empower change in the way which work is done,” he says. universal-robots.com

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Precision Metals Queanbeyan adopts a special spot welding solution Based in a regional area of NSW, Precision Metals Queanbeyan has developed into a successful business by providing high level services and products to their customers across the nation.

Started in 1984 to support a fledgling electronics business with metal brackets and enclosures, demand from local small businesses for bespoke metal work increased rapidly over the next few years, and as growth continued, Precision Metals Queanbeyan realised the need to invest in technology if they were to meet the demand. As early adopters of CNC equipment, they were able to compete for larger contracts throughout Australia, supported by their highly trained staff to provide first class sheet metal products to all sectors of industry.

Today, Precision Metals Queanbeyan continues to develop highly skilled tradesman, via their constant apprentice intake, and providing them with advanced tools that include some of the best equipment available, including CAD, CNC laser cutting, CNC folding, and all the welding and finishing equipment usually found in a sheet metal fabrication business.

But it was an unusual investment that has really made a standout contribution to capability and productivity. Bob Campbell, founder of Precision Metals Queanbeyan, remembers the first time he saw the MySpot Table Spot Welding Machine at the Austech exhibition at Sydney in 2006.

MySpot can be described as a machine with a large flat copper table, which is also the lower electrode and a free moving articulated arm as the upper electrode, guided into place by the operator to the exact weld position required, and then performing the perfect spot weld. That was a standout of the machine! I clearly remember, the quality of the weld, it was so impressive.

“I was initially thinking that this type of machine wouldn’t be able to do any of our parts.” The concept is the opposite of what we do on a traditional type of spot welder, holding the workpiece between the electrodes while trying to keep it in place and level, while many times unable to know exactly where the weld will take place because the welding position was facing away towards the machine. Some parts were particularly heavy and awkward in shape, hard to handle, and then the distortion and surface finishing, dressing the electrodes, it was all hard work, and not everyone was able to do it properly. It was time consuming, and a lot of rework was required constantly.

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“However, once I understood the MySpot concept, we invested in the model with the largest table available. Instantly we realised that most of our existing spotwelding work could be done faster and better on the MySpot. The table provides a perfect location to assemble and weld the components together. The distortion is gone, the weld quality is exceptional, and surface finishing before powder coating is now rarely required. And no more rework!

The MySpot Table Spot Welder is now one of the most trusted machines in our shop.

So much so, we purchased a second machine featuring a vertical gun as well as the horizontal gun to provide us with additional capability. Any of the team can use our machines due to the MySpot Touch Screen Controller that provides access to programs to weld all the materials and thicknesses we need to weld.

“All welding parameters including tip pressure are assured, just select the material and then the thickness, and start welding. The upper electrode system consists of a long horizontal gun that allows access into deep parts, and the vertical gun that can reach into items not suitable for the horizontal gun. The machines are supplied with a variety of shanks and

consumable caps, that are easily changed over if required. The cap system is actually very good as the water cooling goes right to where the welding happens, keeping the cap cool to touch. This not only improves the weld result and consistency, it also extends the life of the electrode.

“Dressing is done by the supplied pneumatic tip dresser at predetermined intervals as set on the controller. Overall, by introducing such a unique machine we have been able to improve our spot welding on existing parts, as well as attract new customers due to the productivity achieved, and by being able to assist in the designing of their projects to include spot welding rather than MIG and TIG welding wherever possible. This not only improves turnaround time, but it also greatly reduces the input costs of labour. “ MySpot enables Precision Metals Queanbeyan to compete for work against competitors based in larger population centres despite the disadvantage of being regionally based.

Our MySpot machines were locally supplied by the Australian and New Zealand Agent Jim’s Machines and Accessories. precisionmetals.com.au

WELDING

Telwater upgrades to BOC welding gear brings results BOC welding equipment upgrade sees iconic boat manufacturer deliver quality results and training Delivering a high-quality product in an efficient, safe way is key to the success of Australia’s leading aluminium boat and trailer manufacturer, Telwater.

The iconic boat building company opened its doors in the Gold Coast in 1988 and has become synonymous with its innovative designs, advanced technology, and range of aluminium boat models. Telwater designs and manufactures four of Australia’s leading aluminium boat brands including Quintrex, Stacer, Savage and Yellowfin Plate. The team consists of expert welders and painters, research and development technicians and many other trades, all committed to the highest quality workmanship.

To maintain its reputation as a leading manufacturer, Telwater invests in new solutions to improve efficiency, safety and reliability across its substantial manufacturing operations.

Manufacturing multiple boats per day, often to tight deadlines, the team at Telwater relies heavily on welding equipment and gases to deliver high quality aluminium welds.

“If we don’t have a good end-product, there are lots of warranty claims which can be extremely time-consuming for our customers and employees. That is why we continually invest in the latest welding equipment and processes,” said Robert Potts, Welding Supervisor at Telwater. “We use welding equipment to manufacture every part of the boat so having efficient, reliable and updated technology is crucial.

The benefits of changing welding processes and investing in new equipment are significant and shouldn’t be understated.”

After a review of the market, Telwater started using BOC’s liquid argon to support its welding. BOC’s Air Separation Unit, located within an hour of the factory, was key for reliability of supply for Telwater. As part of this, BOC offered the Telwater team training on the MIG and TIG projectors which were set up onsite at Telwater. The training worked through identifying welding defects and setting of parameters, which helped the Telwater team better understand how to set up their welding machines and maximise productivity.

After working with BOC for just over one year, Telwater switched to BOC for its welding wire.

“We use a great deal of welding wire per boat so it’s really important we were using a wire

that is reliable and high quality. That’s why we switched to BOC’s premium aluminium wire,” said Potts.

With 65 welders on site every day, Telwater’s welding machines became dated with low usability. Given the success of the gas mixtures and aluminium wire, Telwater decided to work with BOC to review their welding machines.

In 2016, Telwater commenced a welding trial and after a couple of weeks of testing, the Telwater team knew that to keep up with demand while consistently delivering a highquality product, they needed to make the jump.

As the exclusive distributor of EWM welding machines in Australia, BOC delivered 74 EWM PICOMIG 355 Pulse Multiprocess welders and the 11 EWM TETRIX 300 AC/ DC TIG Machine. Ideal for busy workshops involving heavy industrial work, the EWM Tetrix 300 ACDC is designed with EWM patented processes for faster results. The Picomig 355 D3 Pulse is ideal for tough environments and boat building.

Results Collectively, the welding wire, argon shielding gas and EWM machines led to an overall better weld quality for Telwater’s boats resulting in less warranty claims.

The EWM Tetrix 300 ACDC allowed Telwater to be more flexible and specific when it came to its designs as the machine allows the user flexibility in joining different aluminium plates together. The Picomig 355 is a fourin-one multi-process welder that offers MIG/ MAG pulse. Its reliable short-arc welding and pulse welding feature leaves superior results when working with stainless steel and aluminium.

“The weld quality is better, there is less spatter, it’s less time-consuming and we are using less consumables and wire. It’s a winwin for us,” said Robert. “Whenever we have needed something, BOC has always been really good to deal with and would send out a representative within 24 hours. For us, working with BOC means you don’t have to worry,” concluded Potts.

BOC and Telwater continue to work together on quality and productivity improvements, including trialling new shielding gas mixtures that can offer an over 20% cost reduction. telwater.com.au

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Directly from the welding point to clean hall air Extraction torches were often considered unwieldy due to the additional extraction elements on the torch, but this image is changing. Aebi Schmidt Nederland B.V. decided in favour of a torch-integrated high-vacuum extraction system. Several VacuFil systems from KEMPER are now essential components of the new air pollution control concept at the Dutch manufacturer.

The quality of the hall air was already at an acceptable level, but as a rule, it always tended to be very close to the maximum legal provisions. This was clearly not good enough for Aebi Schmidt Nederland B.V. with regard to the health of its employees. It is true that, in an international comparison, the Netherlands already has one of the lowest workplace exposure limits for production plants.

However, the company – located in Holten in the eastern part of the country – wanted to improve the air quality in order to push the concentration of hazardous substances even further below the prescribed limit of 1 mg/m³, particularly in the welding shop.

“One focus at Aebi Schmidt was clearly on improving working conditions”, emphasises Facility Manager Steven Koenderink.

“Air quality was one of the central issues here.” For example, the company wanted to completely ban hazardous substances with lung-damaging, toxic or even carcinogenic effects – precisely those that arise in large quantities, especially in the MIG/MAG welding process used to manufacture the steel-heavy add-on parts – from production. Increasing demand in recent years had generated more welding work. The company’s development into the world’s leading supplier of systems for cleaning and clearing traffic areas as well as maintaining green spaces also brought with it higher protective welding equipment requirements. Aebi Schmidt wanted to continue this history with a healthy and satisfied workforce. After all, arguments concerning employee health are playing an increasingly important role in the competition for the brightest minds. Clean hall air as part of the employer image: In the search for a supplier of extraction technology, KEMPER GmbH from neighbouring Germany came out on top in the end. “Mainly because of the positive test experiences and the comprehensive advice we received in the course of our decision-making process,” Koenderink looks back.

Mobile high-vacuum extraction units for flexible production The requirements were clearly defined: The cleanest possible hall air in line with the needs of production. For example, the intake systems for the hazardous substances generated during welding should effectively extract them while maintaining flexibility in production. A fixed budget defined the framework for the investment in protective welding equipment. KEMPER adhered to these specifications from the outset and put together a customised protective welding equipment concept for Aebi Schmidt. To allow for possible adjustments to the welding shop layout, the manufacturer decided on mobile extraction units. The German company recommended welding fume extraction by means of high-vacuum systems with connected extraction torches. This was due to the following benefits: Firstly, the immediate capture of welding fumes directly at the point of origin and, secondly, the forced tracking of the extraction elements during welding.

As these systems continue to evolve, they are becoming more popular – but to this day their reputation for being difficult to use persists. Despite the initial scepticism, Aebi Schmidt agreed to a comprehensive test. The realisation occurred after just a few days: The VacuFil 250 system used had extracted so much welding fumes that the manufacturer was convinced of its quality within a short time. Aebi Schmidt ordered several units at once (see also: Extraction torch information).

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13 VacuFil-250 units for 26 workplaces After the order was placed, KEMPER quickly delivered a total of 13 VacuFil 250 high-vacuum systems to the Dutch company. Because they can each be coupled with two extraction torches, Aebi Schmidt employees are able to weld safely at 26 workplaces at the same time. The systems are matched to each other in terms of extraction capacity so that the welding fumes are optimally captured without destroying the protective gas envelope. Unlike other extraction systems such as extraction arms, the welders automatically carry the extraction system integrated in the torch. The system reliably extracts the hazardous substances at the point of origin via an extraction nozzle in the torch. This means Aebi Schmidt achieves high production capacity as well as clean hall air for its employees.

Even at high welding intensity, the VacuFil-250 units extract high levels of smoke and dust in continuous operation with a maximum output of 250 m³/h – without any loss of quality, even when two employees are welding at the same time.

Thanks to the particularly high filter quality provided by the special KemTex® ePTFE filter cartridges with surface filtration, the systems permanently filter out more than 99.9 percent of the captured welding smoke particles. Even particles smaller than 0.1 µm have no chance of escaping back into the hall air after extraction. Another highlight during the welding process: Automatic filter cleaning.

This means that the welders do not have to interrupt their work; instead, as the filter becomes saturated, the hazardous substances enter a special disposable container equipped in the systems. The containers are changed contamination-free. To further save space in production, Aebi Schmidt suspended some systems at relevant positions in the production area. In principle, however, the company retains its flexibility to relocate them at any time and use them on the ground as mobile units.

Information: Extraction torches The closer to the point of origin the better: This is the unanimous advice of protective welding equipment experts for effective welding fume extraction. This is because if they are extracted directly at the point of origin, they cannot enter the welder’s breathing zone and then escape further into the hall. Accordingly, extraction torches are superior to other systems because the collection elements are closest to the point of origin. But there’s a catch! The extraction capacity must be individually designed for each torch so as not to interfere with the welding process. This depends on various torch parameters. With this in mind and in order to create more transparency for these parameters that are highly relevant for torch extraction, the German Welding Society (DVS) has recently launched an appeal: Accordingly, torch manufacturers are to make their data freely available on a platform created specifically for this purpose. As far as this necessary data is concerned, KEMPER has already done preliminary work in recent years. On its own measuring stand, the manufacturer has measured more than 100 torch types from different manufacturers, thus establishing a unique database.

It is an integral part of the VacuFil high-vacuum product series from KEMPER. At the push of a button, these units provide the correct extraction capacity for the torch in use and automatically adjust this capacity continuously during operation. kemper.eu

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CUTTING TOOLS

Future trends in aerospace Partnership and collaboration will be crucial to aerospace’s post-COVID-19 recovery For decades, aerospace has been an industry characterised by growth. There have been crises over the years, but never one so deep and heavy as COVID-19.

Now that the markets have returned to levels of growth last seen in 2006, how can aerospace manufacturers get back on track? The answer lies in more sustainable manufacturing. Here, Sébastien Jaeger, Industry Solution Manager – Aerospace for cutting tools specialist Sandvik Coromant, explains how collaboration will play a vital part in the recuperation of the aerospace industry.

The aerospace industry had been growing consistently for 14 years when the pandemic struck. There’s no doubt that trends and the future of aerospace have been immensely affected by the unprecedented coronavirus pandemic. There has been exponentially reduced business or vacation travel, while airlines have had to adjust to substantially lower levels of profitability.

It isn’t all bad news. The aerospace sector has seen some improvement in the first half of 2021; but success is tied to several factors like vaccinations and the global economic outlook with Chinese economic prosperity, business and holiday travel recovery also having an influence.

Projections estimate the industry will be back to where it was, pre-crisis, within the next two-to-three years. The speed of this recovery will vary in different countries and regions. Nevertheless, over the long-term, the number of new aeroplanes could still be decreased by 25% by 2040.

Another big change, from an engineering perspective, is that aeroplanes will be single aisled rather than twin aisled and therefore less wide-bodied. They will also be required to have a longer flying range. Engines and frames are closely connected: one doesn’t go without the other but with engines we can say the focus is on sustainability. This means reduction of weight, noise and emissions and higher efficiency with less consumption. These single aisled craft must satisfy a wide range of uses, without increasing the size or quantity of engines.

There are different ways of approaching these design challenges. One is to find alternative fuels using existing engine tanks, such as synthetic fuel, biofuel or hydrogen.

Then you have new engine architecture with large manufacturers presenting new types of engines, which is a longer-term approach. Then we have alternative forms of engines that are electrified, batterydriven or electromagnetic, or hybrid engines where current engines are assisted by electric power motors.

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Challenging materials If we look at the automotive industry, it is already making great progress with new electrified and hybrid systems. Aerospace original equipment manufacturers (OEMs), meanwhile, are still working on these systems and many of these developments are not expected to find widespread use before 2035. With smaller aircraft, which hold two-to-ten people for example, these technologies could appear earlier.

Reductions in noise, weight and emissions will of course affect how these electric systems perform, but there are challenges.

If there are issues in an electric vehicle (EV) like an automobile, then it can stop at the side of the road — that’s not an option 10,000 feet up in the air. What’s more, batteries are heavy when designers and engineers want planes that are lighter to travel longer distances. So, there are technical obstacles to work with.

For a component like the aircraft’s fuselage, OEMs are going in two different directions. On the one hand, we are seeing increased use of aluminium, although aircraft components require new types of aluminium with greater strength, fatigue resistance and other attributes. This approach adheres to traditional aircraft designs where you have, to put it simply, a big tube with wings and an engine.

Another approach is to explore other shapes of aircraft like delta shape, blended wing body and strut braced wing, or where the engine is more integrated into the fuselage. Here, engineers will more likely turn to composite, or composite-ceramic combinations and mixed materials. Whether these designs become popular remains

for be seen. For now, we can be sure that more aluminium will be used and also heat resistant super alloys (HRSAs). HRSAs are typically used for aircraft parts that face extreme performance demands. Their high strength at elevated temperatures means the materials can retain their hardness when facing intense heat.

However, even the best aircraft component manufacturers can be inexperienced in manufacturing these tougher materials.

This is where Sandvik Coromant’s expertise has proved useful.

Component solutions Sandvik Coromant offers component solutions in response to the growing pressure on machinists to multi-task.

Rather than focus on one machine, today’s engineers can operate four or five machines at a time, which gives them less time or opportunities to focus on specific processes. But, what do we mean by a component solution? It refers to taking a more holistic perspective, which means it’s not just about the tools Sandvik Coromant provides but also about assisting with the complete process.

That was the case when a Sandvik Coromant customer in aerospace was experiencing challenges when machining HRSA materials. The customer’s existing approach required multiple machine tools, with poor chip control and long cycle times. There were issues with inconsistent tool life and unreliable processes, and the machining operation often required full-time monitoring by an operator.

For high-value projects like these, the component solution from Sandvik

CUTTING TOOLS

Coromant consists of several stages.

They include looking at the machine requirements, time studies to examine the cost-per-component, and analyzing production methods at the run-off related both to Methods-Time Measurement (MTM) and end-user processes. It also includes computer-aided manufacturing (CAM) programming and project management of local or cross-border projects.

These analyses revealed that we needed to change the customer’s programming strategy to solve its chip breaking problems. In combination with the tool, Sandvik Coromant’s specialists developed a new strategy with dynamic drive curves, which allowed us to control the chip breaking in every moment. We called this new approach scoop turning and now have a patent over it.

Scoop turning resulted in very good savings for the customer. Besides great chip control, the customer also achieved an 80% cycle time reduction and doubled tool life. It was able to reduce its use of four machine down to one, reducing the need for multi-tasking with more secure machining processes and green light production.

This shows how a more holistic approach can benefit a manufacturer’s bottom line. Software also plays a vital role, such as CoroPlus® Tool Guide, that is part of Sandvik Coromant’s digital portfolio.

Customers can make crucial decisions on the choice of tool and cutting parameters before they have even commenced production.

More sustainable turning Aerospace manufacturers are taking different approaches to tackling sustainability.

Nevertheless, Sandvik Coromant found it is possible to develop a bespoke solution for one customer that has since benefitted entire industries.

To help the customer perform better turning operations on HRSAs, Sandvik Coromant’s

response was to develop the S205 turning grade. The insert is coated with second generation Inveio coating for high wear resistance and long tool life, while post treatment technology strengthens the S205 insert by modifying its mechanical properties. The material has an Inveio layer characterised by tightly packed, uni-directional crystals which create a strong protective barrier around the insert.

This maximizes thermal protection and improves crater wear with better flank wear resistance.

The grade is well-suited for machining components such as aircraft engine turbine discs, rings and shafts. Our customers have reported 30 to 50% higher cutting speeds with S205 compared with competing HRSA turning grades, and these results were achieved without compromising tool life. S205 has since benefitted several manufacturers in aerospace and other industries. These results were achieved with a holistic approach, specifically with Sandvik Coromant’s PrimeTurning ethos that allows all-directional turning for maximised productivity.

The PrimeTurning methodology is based on the tool entering the component at the chuck and removing material as it travels towards the end of the component. This prioritises all-important metal removal rates for faster, quality production and changeovers. In some cases, our customers have completed production runs with just one tool changeover when, with a competitor’s tool, they would have needed five.

Aerospace may be facing one of its biggest crises yet, but there is light behind the clouds. Sandvik Coromant continues to support all the leading aerospace OEMs to support their post-pandemic recovery, marrying sustainability with better tools and optimised cutting parameters with a holistic approach to tooling. sandvik.com

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Get the most out of your flap disc Selecting the right shape of flap disc will help operators get the job done faster, allowing them to achieve a smoother and more uniform finish without gouging the workpiece.

Whether you are looking to grind down or remove welds, deburr, bevel, or prepare a paint-ready finish, flap discs are most likely your go-to solution. Metalworkers rely on them for their comfort, versatility, high productivity, quality finish and long product life.

Enhance both quality and productivity when working with heat sensitive metals by using specially formulated flap discs.

Each task and applications have their own unique challenges. Having the right tools for the job can help manufacturers, metalworkers, and welders achieve significant time and cost savings. Using the wrong abrasives can lead to a poor removal rate, affecting the surface finish, as well as the wheel being discarded before it has been fully used. A long, unproductive process can also result in increased operator fatigue.

When considering a flap disc, the operator must consider three main factors: • • •

Productivity Quality finish Safety and comfort

Maximise productivity Flap discs come in a variety of abrasive materials. Opting for a flap disc made from zirconia alumina will result in a long product life and provide the lowest overall cost of use when factoring in the longevity of the products. It allows the operator to save time and money due to the fewer disc changes and high removal rate. If you are looking to maximise your productivity, flap discs with premium self-sharpening ceramic grain provide a faster removal rate, which makes them ideal for heavy-duty applications. Discs that are made with cold-cured glue that is air dried at room temperature have a longer service life as the abrasive flaps’ properties are not altered during the heating process.

Selecting the right shape of the flap disc, flat (type 27) or conical (type 29) will help you get the job done faster. For blending, finishing and general applications on flat surfaces, using a type 27 will lead to the best performance. If you are looking to remove a lot of material quickly, type 29 flap discs are ideal for contoured and edge work, as well as other finishing applications. They provide a high stock removal given their increased angle of attack.

Trimmable flap disc backings made from less dense wood fibre composites are designed for easy and safe trimming. It also extends the life of the disc by allowing fresh cloth to be exposed to the workpiece, which again gives you a fresh new cutting edge.

Although most flap discs with a plastic backing can be trimmed, it does not mean that all discs can be trimmed safely. Trimming a plastic backing not marked trimmable could cause failure. The WALTER flap discs specially marked “Eco-trim” for trimming have a special blend for the backing material to gradually shear rather than chip or break away.

Remove material faster and achieve a smooth finish in fewer steps with the ENDURO-FLEX 2-IN-1 TURBO. The low heat generating sanding flaps are designed for cool cutting and high removal rate.

Blendex flaps offer surface conditioning materials that blend scratches without smearing or contaminating the workpiece, allowing you to blend and finish the surface in one step.

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Flap discs allow operators to achieve a smoother and more uniform finish without gouging compared to a grinding wheel.

What sets flap discs apart from bonded abrasives is their layered construction. These flaps can either be made from a single material such as cotton and polyester or from a combination of two different materials (sanding and Blendex flaps) — making them ideal for blending down welds and finishing a workpiece at the same time.

For a quality finish, ferrous-free abrasives guarantee that there are minimal traces of iron, sulphur or chlorine to meet quality control objectives in sensitive operations. You may already know what finish you can expect from different grits (i.e., 40, 60, 80, 120, etc.), but certain premium flap discs offer a unique dual grit 36/60, which removes the material quickly but leaves a finer paint-ready finishing, saving you a valuable step in your finishing process. Premium flap discs also offer specific and specialised solutions designed for stainless steel, aluminium and non-ferrous metals. Integrating those specialized solutions in your processes will guarantee a consistent finish without discoloration and avoid clogging.

Backing pad designs are also important as they can contribute to ventilation, improve discs durability, and reduce discolorations.

By funnelling in air, it minimises heat transfer to the surface which keeps the workpiece cooler and increases the disc life.

Experience safe and comfortable blending Metal shops are recognising the importance of workers being able to do their jobs more efficiently, comfortably and with less fatigue. Flap discs are quieter and create less vibration and dust, making them more comfortable for operators to work with, which reduces the requirement for rework. To ensure the safety of the operator, make sure the flap disc is balanced and complies with ANSI B7.1 standard. This will guarantee vibrationfree weld blending leading to greater performance and operator comfort. walter.com Courtesy of Fabricating & Metalworking fabricatingandmetalworking.com

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COMPANY FOCUS

Eilbeck Heavy Machines lifting above its weight.

Charlie Eilbeck is out on a warm March morning, showing writer Brent Balinski around some of Eilbeck Heavy Machinery's recent investments.

Tom Eilbeck (left), and Charlie Eilbeck.

Charlie Eilbeck heads the machining business of Eilbeck Cranes, the parent company which commands 75% of the bespoke overhead crane market in Australia. The machining division opened in 2015 at the site we are touring, which has done well enough to grow its headcount to 40 and open a second workshop (also in Ingleburn).

Eilbeck Heavy Machining (EHM) has brought more and more crane component manufacturing in-house, and gone about chasing projects outside of the company.

“Building these machine shops has a lot to do with the passion of my father, Tom, because he’s a fitter and turner, and he worked in one growing up. So machine shops allow us to be a very flexible business, but they also come from his heart,” explains the younger Eilbeck.

“A lot of what we do is driven by passion. We're not a public company driven by a board of directors where we have to justify when we want to spend three million dollars on a mill. We see opportunity, and we see opportunity in Australia.”

If there’s a couple-paragraph distillation of Eilbeck’s ethos – which he shares eagerly through a freewheeling, no-notes presentation on the company’s history, a tour of the original EHM site with a Q&A, and many extensive asides during both – then that might be it. There’s heritage and a determination to build on it, there’s opportunity, there’s pride, there’s risk, but importantly, there’s a willingness to back the family business.

We pull up next to an Okuma MCR A5CII, a further demonstration of all of the above, then another peek into the culture of the company.

The double-column machining centre was a serious investment, and one big chunk of the $10m the company has spent with the Japanese CNC specialist in the last five years. It was also a leap of faith. But it’s worked out for Eilbeck and his team.

“When we bought this, people told us we were mad. We didn’t really have the work for it… We bought it without a plan and without a doubt it’s now our busiest machine,” he explains.

“We do a lot of bogies for the railway industry… we gain efficiencies with head changing, tool changing, machine output in terms of the power and capacity and the rigidity. Okuma makes 45 of these double-column machines a month at their factory. And when

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we bought this, we said we’d only do it if we could bring all our tradesmen on Business Class to Japan. And they did.”

There is no shortage of challenges to running any kind of manufacturing business in Australia, and that certainly goes for heavy engineering.

One thing that stands out during the visit is the emphasis on staff, whether they’re being sent to Japan or kept happy back at Ingleburn, in the manufacturing heartland southwest of Sydney.

The capital and the staff aren’t cheap. The competition from imports is strong. Many of the raw products that come in to be machined can’t be made locally, and the international supply chain challenges of this era are well-known. But the biggest issue is around attracting help.

“The workload is there but the people aren't,” is the essence of it.

Fortunately, only one member has left the EHM team since the division opened in 2015.

Blue and green The Eilbeck group has been making cranes since the 1980s, after Tom Eilbeck bought it from his father as a single-person operation making fencing wire.

Charlie is the fourth generation involved in the business, and if he succeeds his father, he will be the first non-Tom to run it. The first Tom, who was also one of the first engineering graduates from University of Western Australia, began T Eilbeck & Son in 1907 as a blacksmith operation on Western Australia’s Swan River.

Rather than being a departure from crane-making, Eilbeck says it’s a return to the machine shop business his family operated for a couple of decades beginning in the 1960s and then moved out of. There’s even the occasional reminder of that era, when machine tools were something the company produced.

“Sometimes we’ll get a call up now from an extremely old person, somewhere, with a 50-year-old Eilbeck Cranes band saw or machine, asking if we’ve got spares,” he shares, with a pause for effect.

“We don’t.”

099 The team at Eilbeck Cranes

“They [range] from structural, mechanical, draftsmen to electrical, so complete engineering inhouse. Complete fabrication inhouse: painting, assembly, electrical, wiring, building panels,” says Eilbeck.

“We have flexibility to design what people want. All those wheel blocks behind you? They’re a bit of an odd size that wasn’t available on the market. So they’re all going to a customer in Panama. A simple product, but we can export.”

While engineers of various disciplines are highly-respected at Eilbeck, it’s impossible to miss the enthusiasm for tradespeople – unsurprising given Tom’s and Charlie’s training as boilermakers.

The tour rolls up to a Goratu GT5 G4 flatbed lathe, which a secondyear apprentice would be operating if he wasn’t at TAFE. It is used to build between 100 and 150 rope drums a year, which in a previous era would be subbed out to other Sydney shops.

In November 2021, the 10,000th Eilbeck crane was installed. The group’s headcount has grown to 350-people, with manufacturing operations at eight sites.

The younger Eilbeck credits the expansion to his father’s drive, with an important relationship with ABUS Crane Systems of Germany – which provides hoists and other accessories that feature in the customised cranes by Eilbeck – in the background.

“Thirty-two years ago, my old man flew to Germany. He’d never been on a plane before,” explains Eilbeck.

“And he [stayed in] this person's office until they gave him the Australian agency.

“Basically, ABUS has a catalogue with certain heights, speeds, certain IP ratings – a very standardised product.

“And we import that kit from Germany. So when you go out there, have a look up and you'll look at a green crane with blue products on it. The blue products are a mechanical kit which we buy out of Germany, bring here, and plug into our cranes.”

Flagship projects include the first 500-tonne and 250-tonne cranes built in Australia, used on the Westgate Tunnel, with different components created at the company’s workshops around Australia and then assembled onsite.

“There's so many tunnels going on, basically at every train station where they’re digging a hole… And we've [only] lost one tunnelling contract in Australian history,” says Eilbeck.

“Those cranes didn’t work, so we’ve won every crane since then.

All these tunnelling cranes: and these shops allow us to do that.”

At the time of writing the company is preparing to break ground on a new fabrication shop at Moss Vale, which will be used to assemble slab handling cranes for Bluescope. These were previously imported.

“We don’t have mass production or commonality here, so every tradesman is a skilled operator. They write their own programs,” explains Eilbeck.

“One of the biggest problems we face is finding skilled tradesmen.

Probably 50% of our workers are imported on visas, and we’re continually bringing people in.”

The growing machinery collection has opened the eyes of the company, especially its engineering team, to what can be made inhouse. At the same time, you need capable operators that can run it. Despite local challenges around skills, Eilbeck is bullish about bringing more and more work inhouse, and will continue to invest so it’s able to.

Tom – who lives in Thailand yet manages the Australian business 15 hours a day – sees his company as his baby, according to Charlie.

His father would much prefer to put profits back into the business rather than property or cars.

The site tour is for a meeting of the Nuclear Skills Forum, which EHM is a participant in. Eilbeck believes “the lifting opportunities around nuclear are huge” and is eyeing the potential of contributing to the sector. The hope is that whoever helps build the upcoming submarine fleet will share their IP, and that local manufacturers will get a chance to contribute.

“With the flexibility of the machine shop and the engineering that we have, we can definitely provide a lifting solution,” he affirms.

“On the other side of the fence, for Eilbeck Heavy Machining there’s huge opportunity. Obviously everyone's talking about nuclear subs, and there will be a push to make components here. Hopefully we can assist with making the bigger ones. If someone wants to make a prop shaft here, which is 12 metres long, and they believe in us, we will buy the machine to do it to create that opportunity here.”

“Back then we couldn't make those cranes here, and nobody else could either,” Eilbeck adds.

The event is in the lead-up to the election being called, and the expectation exists that sovereign manufacturing capability will feature heavily. Whether or not it leads to more opportunities to supply big infrastructure, defence or other projects remains to be seen.

“With the factories we're building, with the machines we’ve got, we can.”

For Eilbeck Cranes, there is no choice other than to continue backing themselves – hurdles around skills or anything else be damned.

A further heavy machining and assembly site is under construction at Henderson, WA, with opportunities in mining, defence, and marine infrastructure.

“The machines are hungry. It's going to take a lot of infrastructure in Australia and a drive by Australia to be able to keep the big machines full, but with what's happened in the last couple of years, there's a great push for Australian made,” says Eilbeck.

“In the Australian market there’s a huge need and a growing need for heavy engineering companies.”

Hungry machines Part of what’s made Eilbeck successful in making a growing number of crane-related and other products in-house has been the expansion of its engineering team, based in Sydney and standing at about 35.

“We see it now on government contracts, on defence contracts, where you have to build with Australian steel, you have to build here. So really, the new factory has kind of landed at the right time. And we’re seeing a lot of opportunities for the upcoming years.” eilbeckcranes.com

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Geographe shows it can machine crucial parts to rescue in real world situations.

A fully loaded live sheep transporter idles, stranded off the coast of Western Australia. The ship’s main drive coupling has failed, and to continue its passage the vessel urgently requires a splined hydraulic coupling to be made and cut in a very short space of time. Unless the repair is made quickly, a costly decision to unload the sheep will need to be made.

Cue specialist parts manufacturer, Geographe, invited to assist with the rescue of the stranded live export sheep at sea, characteristically rising to the custom manufacturing challenge to help save the day.

The engineering team worked around the clock to complete the urgent work and the job was completed within five days without the need for costly unloading and reloading the ship.

This professionalism, prompt response, quality of the finished product, and exceptional service is well recognised and widely regarded by Geographe’s diverse client base including in Mining, Oil & Gas, Naval, and Transport.

During the 50 years since Geographe began manufacturing replacements and repairing parts in a modest backyard workshop in Busselton, WA, the company has grown to the large-scale operation it is today with multiple offices, workshops, and distribution partners across Australia. The highly skilled Geographe engineering team always strives to innovate, designing, manufacturing, and repairing parts for heavy machinery and plant equipment, reducing downtime and operating costs for a broad range of clients.

Understanding that every minute of downtime costs its client’s operations, and an unwavering commitment to delivering higher quality parts at a lower price than OEMs, Geographe has earned its reputation as a trusted industry leader in the resource and industrial sectors.

Geographe creates enhanced performance parts for excavators, trucks, loaders, dozers, underground drills, industrial gearboxes and more. That includes all the major OEM brands such as Caterpillar, Komatsu, Hitachi, Sandvik, Atlas Copco, and Liebherr.

Because Geographe takes great pride in refining and redesigning for increased asset utilisation in many components they make, customers ultimately benefit with reduced operating costs and greater productivity across the equipment life cycle.

“Innovation is key to our success, backed by 50 years of experience finding solutions that benefit our clients and the greater industry,” explains Sam Hyder, Geographe’s CEO, who is third generation family member driving the family business into the future toward a goal of saving clients $500m by 2025.

This ethos is matched by the mission of Automated Solutions Australia, striving to deliver solutions. The result, a perfect union has formed, with Automated Solutions Australia partnering with Benson Machines to provide Geographe significant efficiency benefits through an automated system designed to improve throughput.

Not surprisingly, in addition to a team of 140 plus highly skilled professionals, production at the South West manufacturing facility is aided by robotics.

Benson Machines managed the automation project, but also manufactured the parts centralizing device, parts and magnet washing machine and standby stations.

“We required a highly flexible and responsive solution to quickly and efficiently unload and load parts from two pallet locations into a DMG Mori CVG9 vertical grinding machine,” says Hyder.

ASA was tasked with bringing the various items together. The solution includes rapid setup software developed by ASA that allows the handling of new parts to be setup very quickly by inputting part dimensions into the cell controller.

To meet this requirement, Benson Machines, Australia’s leading supplier of grinding machines, brought ASA and Dimac Tooling into the project to purpose build an automated cell to facilitate the grinding of a wide range of Geographe’s parts.

Dimac Tooling supplied the work holding in the form of SAV magnetic chucks and zero-point locators for the chucks within the grinder, the fixture nest and around the cell at the various workstations.

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ASA installed an automated manufacturing cell employing a Fanuc R2000iC/270F robot with a reach of 2655mm and payload of 270kg.

The robot was fitted with Schunk’s Vero pallet gripper attachment to allow it to attach one of four grippers and one of eight magnetic chucks, enabling the robot to cycle parts weighing up to 150kg through the cell.

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STATE SPOTLIGHT

The centraliser is a three-axis device which enables a bush to be centralised on a magnetic chuck within 10 microns whilst simultaneously testing ovality limitations of the part being centralised.

ASA created the centraliser function by incorporating three additional axes to the Fanuc controller, setting them up as a separate motion group independent of the robot and programming the centraliser to measure the absolute position of the part on the magnet at various points to establish both placement offset and part concentricity and to nudge the part with micron accuracy to correct the placement offset.

The Fanuc R2000iC/270F robot has a payload of 270kg which means that it will handle the weight of the part, the pallet, and the gripping device. This robot can handle a mass of 175kg combined gripper/workpiece at a COG of up to 400mm in Z and X from the mounting face of the robot.

ASA manufactured and supplied the overall cell controller for system. The cell controller incorporates an Allen Bradley Guardlogix safety PLC and Ignition SCADA HMI. The PLC and HMI has been programmed to provide a highly functional operator control station and diagnostic terminal for the cell.

The CVG9 grinder is part of Geographe’s automation additions, and along with the FANUC robot, will play a pivotal role in supporting future customer growth alongside their recently installed heat treatment facility. The CVG9 will help sustain Geographe’s industry leading DIFOT as production demand increases.

“Our talented operators have been fully trained up by Automated Solutions Australia and are currently working through grinding our current work in progress list of excavator bushes for Tier 1 miners across Australia, with great results,” adds Hyder.

Geographe’s efforts haven’t gone unnoticed over the years, consistently receiving recognition through notable industry awards acknowledging business best practice, excellence in design, engineering and technology as well as being recognised for the distribution partnerships it has created.

Actively servicing over 100 mine sites across Australia, Geographe works with every Tier 1 miner in the ASX Top 100 and works with a further 300+ customers in Australia and internationally. The company is well on track to meet the long-term vision of saving contracted clients a total of $500m by 2025. geographe.com.au

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Solving northern Australia’s defence infrastructure challenges Stephanie Males and Nick Tate give a detailed opinion on the challenges of defence infrastructure in the Northern reaches of Australia in this piece reprinted from Defence Connect magazine.

Delivering infrastructure projects in the north of Australia brings an array of well-recognised challenges into play across social, economic, geographical and environmental domains. Nevertheless, ensuring that the north’s defence estate is safe, sustainable and fitfor-purpose is a critical national endeavour. PwC Australia’s Canberra managing partner and integrated infrastructure partner Stephanie Males and integrated infrastructure director Nick Tate explore what it might take to deliver adequate defence infrastructure in the region, and what success could look like.

In its 2020 Defence Strategic Update underpinned by the 2022 budget, the federal government committed to strengthening Australia’s defence estate and infrastructure with significant investment over the decade, including key projects such as northern airbase resilience, upgrade of training facilities and logistics infrastructure, and new army watercraft basing. Prior to the 2020 update, much of the language about defence infrastructure had centred on consolidation of existing assets, but it will be interesting to see how this changes in the next Defence Estate Strategy update. Many of the main tenets – for defence infrastructure to be strategically aligned, affordable, safe and sustainable – will no doubt remain consistent. The 2022 federal budget papers identify that $2.6bn will be spent on infrastructure projects across the Northern Territory in coming years. From available reporting, it appears that the Department of Defence alone expects to spend at least $500m per year in the Northern Territory – amounting to close to $6bn over the next 10 years. Yet, delivering infrastructure in the Northern Territory is a very different mission compared with delivering projects of similar scale elsewhere. High transport and service delivery costs; harsh, extreme and often unpredictable weather; a sparse population; competition for skilled labour, especially highly qualified professionals; infrastructure challenges ... these are facts of life in the north.

The key to success will lie in developing a collaborative, cooperative approach that responds effectively to these place-based challenges – including on-the-ground local experience and perspectives when creating plans to develop the defence estate, and engaging with the Northern Territory community as projects progress. Industry, businesses and government (both federal and state/territory) should be better aligned, use consistent data, work together more closely and seek common goals. This isn’t only about ensuring that the governance framework is right; it’s also about getting the right people in the room.

An estate that is safe, secure and compliant While infrastructure resilience is often discussed in the context of climate threats, it must also be considered in terms of security or survivability against potential threats from adversaries, from the nonkinetic, such as cyber, through to kinetic. Urban encroachment is also a concern for defence bases, as surrounding developments and environmental impacts can restrict or curtail defence activities.

As an example, gas/hydrogen facilities and explosive ordinance are dangerous neighbours. With collaboration between Defence Estate Planning, local planning authorities and utilities, encroachment protection plans can be developed and enacted, ensuring functional alignment of land uses in and around defence infrastructure assets.

Working in partnership with traditional custodians and owners will enable appropriate access and continuing connection to the land for traditional landowners, and identification and protection of

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Indigenous sites and objects in and around the Defence Estate.

These partnerships are the pathway to culturally informed mitigation strategies and identifying employment opportunities on country.

An estate that is developed and managed to make the best use of available resources The Department of Defence appears to be bringing forward key infrastructure projects as part of a response to increasing strategic instability. Notwithstanding the joint investment between Australia, the US and Singapore through the Force Posture Initiatives, with the resulting capital budget pressures, we are likely to see an increasing appetite to implement innovative funding models.

Partnering with Aboriginal landowners is critical for successful placebased approaches to infrastructure delivery in regional and remote areas. Opportunities where Defence and the private sector can contribute to reconciliation and Closing the Gap include Indigenous employment and pathway programs, culturally intelligent workplaces, and Indigenous businesses participation and empowerment through the Defence Indigenous Procurement Policy and the Australian Industry Capability program.

Greater use of joint bid approaches offers opportunities to share and balance personnel availability and maximise skills development.

While defence projects have some unique aspects, actively recruiting personnel with complex infrastructure project skills grown outside of the defence sector will deliver benefits.

Australia’s northern bases, ports, airfields, training areas and logistics facilities will be critical to sustaining future military operations and disaster response in Australia’s national interests and in support of our neighbours and allies. The best solutions for the future of this key infrastructure will be citizen-centred and place-based, underpinned by data-driven decisions enabled through technology.

Elegant and effective solutions grow better in an atmosphere of trust – which develops through collaboration. With the defence focus now squarely on operations in the north, it is time to invest in effective collaboration across all levels of government and industry to solve the big challenges ahead for northern defence infrastructure in increasingly uncertain times.

About the authors Stephanie Males is an integrated infrastructure partner and PwC Australia’s Canberra managing partner. Stephanie has over 25 years of experience in professional services, advising on the consequences of delivering a range of public policy measures. She is also responsible for delivering regulation and facilitation services on global trade, infrastructure and supply chain advisory services across the Commonwealth. Stephanie advises governments on global trade; critical, social and environment related infrastructure strategy and their role in supporting businesses build resilient supply chains.

Nick Tate is an integrated infrastructure director based in Canberra.

Nick has over 36 years of experience in delivering infrastructure and logistics services for the Australian government, including national strategic infrastructure planning and managing the early government approval phases for facilities and infrastructure projects. Nick is passionate about helping project owners and industry participants realise maximum value through collaborative program management.

Republished with permission from Defence Connect. defenceconnect.com.au

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The evolution of HMPS: Taking risks and ‘growing with the flow’ HMPS have come a far way since the invention of the first bag-in-box system in the 1980s.

The evolution of this proudly Australian machine building powerhouse was further accelerated by the acquisition of two companies in just two years. “We’re growing our end-to-end production line offering,” explains Mark Emmett, owner and CEO of HMPS Group and Propac Industrial. The acquisition of two reputable companies - Vertical Form Fill Seal machine producers, Propac Industrial and manufacturer of stretch wrapping machines, equipment and systems, Integrated Machinery, have helped expand HMPS’ offering.

The evolution of the company is underpinned by its passion for problem solving and adapting to meet customers’ ever-changing needs. “As our customers grow so do their requirements. We are here to meet these requirements - all along the packaging line,” says Emmett. To further entrench its service capabilities, HMPS has also expanded its footprint through these acquisitions, as Emmett explains: “In addition to our Adelaide head office, we now also have manufacturing and service capabilities in Melbourne and Sydney with a technical office in Brisbane.”

Growth in a Time of Uncertainty HMPS saw the COVID-19 pandemic as a time for opportunity, and their bold strategy paid off. “We decided to take a risk during the pandemic. Supply chain challenges meant more companies were looking to local suppliers. Most of our clients operate in essential services with the supply of food, personal items and pharmaceuticals.

These customers experienced an unprecedented demand as items flew off the shelves. We saw this as a good time to invest to be able to step into the gap and deliver through our local manufacturing capabilities,” Emmett explains.

“Our revenue is up by 30% across the different companies despite the uncertainty and travel restrictions that we experienced. We used this as a time for problem solving and renewal.”

Industry Trends Mark Emmett is passionate about growing (and promoting) local manufacturing. “We want our customers to become less dependent on imported machinery,” he said. “It’s part of our vision to create a sustainable ecosystem right here on our local shores.” While intense competition between local and international machine builders

continues, Emmett notes that an increasing number of manufacturers now have an appetite for local automation.

“I believe Australian machine building can and will compete with the rest of the world and we are already seeing keen interest from the likes of the US.” Furthermore, Emmett believes that customers are looking to streamline. “They’re looking for a turnkey solution - not Mark Emmett, CEO of HMPS just a bagger or case packer but everything for a full production line. The customer wants one supplier and a project engineer who can handle everything from design, sourcing, implementation to final delivery, and not forgetting after-service.”

“We have expanded our service offering and are now able to help with packaging design too,” he adds. “Working with packaging material suppliers gives our customers the best result, which is cost effective, improves the look of their cartons and ultimately their final package design.” The company is also looking into sustainable packaging materials and engineering their machines to handle different types of recyclable and biodegradable packaging materials.

Empowering the Next Generation of Machine Builders Passionate about empowering the next generation of machine builders, Emmett adds that the HMPS expansion and acquisition strategy will further enhance the team’s roles and responsibilities. The idea is to further their skills and providing a fulfilling work environment with more opportunities. “Our team currently comprises around 110 team members across the four branches. We have a host of young engineers, fitters and turners, designers and business development employees,” says Emmett. “Therefore, the bigger we are, the more opportunities there are for staff. We want them to continuously learn and grow.” hmps.com.au

Vegetable Punnet Loader

AMT JUN 2022

FORMING & FABRICATION

VALO expands in South Australia, bringing manufacturing back onshore Premium stadium lighting manufacturer VALO is expanding its operations and has opened an $8m state-of-the-art research, development and production hub at Kent Town.

VALO, which is targeting domestic and international markets in premium stadium lighting, will use Kent Town to ramp up production, bringing its manufacturing back onshore and centralising operations in its new, carbon-neutral facility.

high-performance lighting solutions for other large-scale environments such as airports, seaports, transport hubs and distribution centres, both in Australia and internationally.”

Founder and CEO Aaron Hickmann said VALO had grown its local staff from four to 15 over the past 12 months and was rapidly growing. The company has invested heavily in research and development, plant and equipment – including surface mount technology and an assembly line, VALO is ready to manufacture its most advanced lighting systems in Adelaide. “Having production move back onshore will allow us to increase employment in South Australia and provide economic benefits for the state in an emerging advanced manufacturing industry,” Hickmann said.

“VALO is future focused and we’re constantly researching and developing smart lighting products which will improve sustainability, reduce carbon footprints and provide significant benefits to wideranging communities,” he added. “We’re accelerating the use of disruptive technologies, not just in premium sport stadium lighting, but also in street lighting, and producing cutting-edge,

Hickmann, who founded VALO in Adelaide in 2012, said the company was also exploring opportunities with councils regarding smart street lighting solutions. “We can produce street lighting which harnesses cuttingedge smart technology and is energy efficient, resulting in significant savings and lighting that can harness the internet of things to improve environments, increase safety and collect useful data,” he said.

VALO has partnered with organisations nationally, including Sport SA, Sport NSW, VicSport, Baseball Australia, Adelaide United, the Hawthorn Football Club and Illuminate Adelaide – covering sport, the arts, motorsport, transport and public spaces. “Stadium infrastructure across Australia is ageing, and there’s a need to bring lighting up to broadcast quality in many areas. With major events such as the 2023 FIFA Women’s World Cup on our doorstep, our lighting needs are becoming increasingly important.” valo.com.au

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Customised machine configuration Electric mobility is on the rise. Tube bending machine manufacturer Schwarze-Robitec takes a look at where the industry currently stands.

The key trends in tube bending include lightweight construction, customised machine configuration and automation. The figures provided by Germany’s Federal Motor Transport Authority (KBA) speak for themselves: Among all newly registered vehicles in Germany in the period from January to November 2021, the share of those with alternative powertrains amounted to almost 35%.

The share of vehicles with purely electric drives was at around 11% of all new registrations in this time. But an increase of new electric vehicles (EVs) becomes particularly clear when looking at passenger cars. In that segment, the EV share in all newly registered passenger cars was 6.7% for the entire year 2020. This share has substantially risen to over 25% when looking at the period of January to November 2021. The effects of this shift are being felt not just by the automotive manufacturers themselves but across the entire supply chain. Lightweight construction is a major theme here, since the lighter the vehicle, the less energy it needs. And this increases the range, crucial for EVs. It also leads to a change in requirements for tube bending, with a growing need for compact yet high-performance components, such as thin-walled tubes made from high-strength materials. But lightweight materials such as aluminium and carbon fibre reinforced plastic are usually more expensive and more challenging to process than conventional steel.

Cologne-based tube bending machine manufacturer SchwarzeRobitec is also witnessing a substantial increase in orders that go beyond the bending of typical round tubes. Instead, lightweight construction increasingly requires complex, asymmetrical shapes with diverse cross sections.

Traditional automotive manufacturing usually involves round tubes being bent and then turned into the desired profile shape through hydroforming. This subsequent bending process is often not possible when working with lightweight materials. Carbon fibre reinforced plastic, for instance, cannot be bent when it is cold. As such, the bending profile needs to match the geometry of the final component during the first step, i.e. when bending the tubes. In addition, applying heat is a difficult process for these materials.

An additional issue in the case of aluminium, for instance, is that the material hardens in the air. This means that a prefabricated aluminium profile can no longer be bent after just a few months.

Furthermore, if the desired cross section is not round, it is much harder to adhere to the predefined tolerances, especially when using aluminium. An additional difficulty posed by lightweight materials concerns conductors, with aluminium profiles and rods increasingly replacing traditional copper cables in cars. The layers of insulation cannot be damaged during bending.

Shift towards flexible configuration of tube bending machines With the shift towards electric mobility, the traditional standard tube bending machine with predefined performance parameters is increasingly giving way to product-specific special machines that can be customised according to client needs. Bending performance, geometric measurements such as bending radius and tube length, tool installation space and software can increasingly be aligned with client and product requirements. This shift is already ongoing but will intensify, predicts Schwarze-Robitec Managing Director Bert Zorn. “To be able to realise these sorts of projects, systems suppliers need to not only have the necessary expertise in bending technology but also the requisite knowledge and experience in tool and process design,” Zorn explains. “This is the case from the design stage right up to the start of series production and production support.” Complex tool shapes are

AMT JUN 2022

Schwarze-Robitec Managing Director, Bert Zorn

needed to produce aluminium profiles with different types of cross sections, for instance. The development and correct design of such tools thus becomes increasingly important. Furthermore, when carbon fibre reinforced plastic is used, there must be a possibility of only partially applying heat.

Focus on efficiency and short cycle times Conventional combustion engines still account for the lion’s share of automotive production, however, and therefore remain of huge importance for manufacturers of tube bending machines. The growing cost pressure sweeping across the automotive industry is also being felt throughout the entire supply chain. Short cycle times, maximum speed and a high degree of precision are the order of the day. Companies aiming to remain competitive need to use resources efficiently. This not only includes time and material resources, but also human resources, the individual employee who plays a central role in the manufacturing industry. In this field, userfriendly and reliable processes are a key factor in boosting costeffectiveness.

Manufacturers of tube bending machines need to respond to the challenges of their target industries by supplying high-performance machines that are tailored precisely to their customers’ needs. To achieve this, Schwarze-Robitec is relying on multilevel technology, for instance. Used in combination with customisable multi-radius bending tools, this technology facilitates simple and precise bending with only short lengths of tube between individual bends. The effect of this is clearest to see when different radii, bend-in-bend systems or complex tube systems are being manufactured, as even a few seconds saved per component can have a huge positive impact on production efficiency.

FORMING & FABRICATION The CNC 160 E TB MR withstands the exceptionally high stress of 1xD bending, even over a long period of use.

Another key aspect when it comes to tube bending efficiency is the interaction between operator and machine. The technology must support users wherever it can. For example, the integration of bend former retraction – with bend former and swing arm operated separately – as standard enables users of Schwarze-Robitec machines to adjust and position a wide range of tube geometries during the bending process without any problems at all. The most significant benefit, however, comes from Schwarze-Robitec’s very own smart NxG control system, which continuously and fully automatically monitors the interaction of axes and optimally coordinates their movement. While one bend is still in progress, the axes are already being prepared for the next steps. The Colognebased manufacturer’s solution therefore reduces production times by 20 to 40% depending on the component and the desired tube geometry.

Automation and integration of processes beyond bending In view of the shift toward alternative powertrains, the frequently used buzzword ‘automation’ is more relevant than ever. Manufacturers of tube bending machines need to focus on extensive automation and increasingly integrate work processes that go beyond bending.

This is not just the case for tube bending processes in large-scale series production, but also increasingly for very low volume series production. In (fully) automated tube processing, the various stages of the process are reliable, error-free, repeatable, and fast, ensuring that bending results are consistently of the same quality. Upstream and downstream processing steps are also integrated into the fully automated bending cell – from cleaning, assembly and end-forming to tube measurement. Handling devices such as robots and additional systems for tube feeding and unloading are integrated,

too. The primary task is to precisely analyse which processes are the perfect fit for the application in question. For example, depending on a customer’s requirements, a belt-loading magazine, chain magazine, lifting conveyor or a loose material conveyor might be the right system for the tube feeder. The optimal component must be determined for each individual process. These components can then be put together to form a complete system that optimally meets requirements. This system, along with all process steps, is then controlled centrally via Schwarze-Robitec’s NxG control system in combination with the master computer system.

Even though each additional process step makes the process chain longer, the user does not have to experience any delays as cycle times generally remain the same. The increased complexity of such an automated system means there are greater requirements in terms of control and the integration of bending cells into existing production chains and company networks. That is why it is also important that tube bending machines are already implementing existing and future industry 4.0 technologies. Schwarze-Robitec guarantees the compatibility of the various systems within a fully automated system by using precisely defined interfaces to individual components that are interconnected via a bus system.

“Companies that act flexibly by tailoring their machines to special customer requirements can now work with this strength, as the shift towards electric motors in the automotive industry is driving a change in parameters,” explains Schwarze-Robitec Managing Director Bert Zorn. “Suppliers such as manufacturers of tube bending machines need to be able to respond with flexibility and speed and devise new production methods.” schwarze-robitec.com

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Charging around Australia Printed solar panels will be used to power a Tesla on a 15,000-km trip around Australia in September to make the public more aware of steps to effect climate change.

The Charge Around Australia project is a partnership between British firm Charge Around Britain and the University of Newcastle in NSW. CAB director Stuart McBain, one of the people involved in the Australia project, undertook a trip around the UK coastline in an EV five years ago to prove that there were sufficient charging points for these vehicles.

McBain also drove around the Iceland coastline in a Nissan Leaf to demonstrate that such a vehicle was up to the challenging trip. “More than a billion people around the world today have no reliable access to electricity,” said McBain. “This means that around one in seven people cannot refrigerate food or medicines. They are without a dependable source of electricity to power vital hospital equipment and lack clean, safe energy for cooking and lighting in their homes.”

The portable printed solar cell panels will be used to charge the vehicle offgrid; the technology is known as organic photovoltaics. The solar cells have been developed by Professor Paul Dastoor and his team at the university. They are made from a lightweight, laminated PET [Polyethylene terephthalate] plastic that costs less than US$10 a square metre.

The route to be followed by the Tesla in September circumnavigates the country.

The project is a challenge to drive an electric vehicle, powered by solar energy, some 9,380 miles (15,097km) around the entire coastline of Australia.

He will co-ordinate the research and manage the development and installation for the project. “We will be doing much more than just driving. Our project is also designed to educate and support people and organisations, including schools. We aim to shed light on the fact that the future of sustainable power generation for transport and our wider energy requirements is going to be with new technology. Our project will include challenges, experiments, interviews, research and a STEM (Science, Technology, Engineering and Maths) Roadshow.

The STEM Roadshow will visit remote, rural and regional schools and communities across six Australian states and territories.

Students will interact with research scientists who can inspire them by explaining the science behind solar technology and the Charge Around Australia project – and show them how to build their own plastic solar cells using non-toxic, risk-free materials.

AMT JUN 2022

In addition to the electric car that we drive around Australia on the journey, we will also use a support vehicle. The latter will double up as the team’s mobile home and act as a field station in which we can run experiments and gather data.”

A statement from Charge Around Australia said the technology was in the beginning stages of development and printing processes could be improved.

"Printed solar panels offer us possibilities that conventional solar panels do not. They are ultra-flexible, ultra-lightweight and ultrathin, so they can be used to cover expansive areas. In addition, because they are printed, they can be produced at extremely low cost," it said.

"When efficiency levels are doubled to around 4%, it is possible that the technology will have the capability to generate the cheapest form of electricity on the planet.

The potential of this technology is that every building and structure could have a coating on it that generates power."

Others involved in the Australia drive are Aleksei Esguerra, support vehicle driver and health and safety officer; Dr Xiaojing Zhou, provider of key expertise in device design and development and performance analysis; Dr Ben Vaughan, provider of key expertise in supporting the fabrication and manufacture of the printed solar cell panels; and Dr Michael Dickinson, Provider of key expertise in the generation system design and development.

Past Projects Stuart McBain has been an electric car owner and enthusiast for many years.

He is passionate about sustainability transformation, from using fossil fuels to power cars to using electricity. He has more than 40 years involved in sustainability and finding economically environmental solutions to business issues. He is an enthusiastic advocate of the theory of ‘environmentally sustainable, economically viable’ which helped inspire his previous ‘Charge Around’ adventures.

Charging around Britain was McBain’s first Charge Around challenge. This was a 4,000-mile-long drive around the coast of Britain in his own Tesla Model S, starting and finishing in Liverpool. He took 23 days, visiting several sustainable businesses, including Whitelee Windfarm near Glasgow, run by Scottish Power Renewables and the Centre for Alternative Technology in Powys, Mid-Wales. Stuart covered 3,932.1 electric miles at a total fuel cost of just UKP7.50.

Later that same year, Stuart McBain and his small team Charged Around Iceland.

In a Kia Soul and a Nissan Leaf, he drove the 1332km ring road of Iceland with his 81-year old mother Anita in these sparsely populated routes which included areas where NASA astronauts went for off-planet landscape training. chargearoundaustralia.com

FORMING & FABRICATION

Customised protective visors enabled by closed loop controlled 4D printing A new paper in Nature proposes close-loop fabrication of customised visors for PPE. The COVID-19 pandemic makes protective visors important for protecting people in close contact. However, the production of visors could not be increased greatly in a short time, especially at the beginning of the pandemic. The 3D printing community contributed largely by fabricating visor frames using rapid and adaptive manufacturing.

While there are many open-source designs of face visors for affordable 3D printers, all these designs fabricate mono-sized frames without considering diverse users’ dimensions. In a new paper, researchers Qinglei Ji, Xi Vincent Wang, Lihui Wang and Lei Feng propose a new method of visor post-processing technology enabled by closed loop controlled 4D printing.

The new process can further deform the printed visor to any customised size for a more comfortable user experience. FEM analysis of the customised visor also shows consistent wearing experience in different circumstances compared with the old visor design. The fabrication precision and time cost of the method is studied experimentally.

A case study regarding the reducing, reusing and recycling (3R) of customised visors in classrooms is proposed to enable the customised visors to be manufactured in a more sustainable way.

Since the breakout of COVID-19, the demand for personal protective equipment (PPE) has tremendously increased. In different countries, people have been required to wear protective masks or face visors to reduce the spread of the virus. However, the storage and production of protective equipment was limited, especially at the beginning of the pandemic. Correspondingly, the 3D Printing (3DP) community transferred their rapid prototyping ability to the massive manufacturing of protective equipment like protective face masks and face shields.

For example, at KTH Royal Institute of Technology, Sweden, 3D printed protective visors are donated to the local healthcare facilities in the early months of 2020, when the pandemic started in Sweden. Besides the research community, hobbyists from all over the world are also motivated to fabricate the protective components against the crisis. Open-source models of these components are shared so that people do not have to redesign the 3DP files from scratch.

As the most commonly 3D printed protective equipment, face shields, or visors, are composed of two simple parts: the 3D

printed visor frame and a transparent film.

The visor frame is designed to be 3D printed directly without using any support material and the transparent film is in the size of the A4 paper and can be easily accessed from any stationery store. The transparent film has holes that are made using a standard paper hole puncher. The holes can be fitted in the designed fixers on the visor frame to form the assembled protective visor.

For the 3DP of visor frames, the most commonly used 3D printers are the Fused Deposition Modelling (FDM) 3D printers, which also hold the largest portion of personal owned 3D printers. FDM 3D printers take fusible polymer filaments and the fused material is then deposited to the building plate to form 3D structures. One of the most used materials for FDM 3DP is Polylactic acid (PLA). PLA is a degradable and bio-compatible material which makes it suitable for skin contact applications. It also has good mechanical strength and fatigue performance so that the printed sample can be used for a long time without damage.

Furthermore, the material is cost-effective and can be easily 3D printed without any professional training.

However, most of the open-source models of the visor frames are mono-sized. They are designed with moderate sizes to fit most people, which as a result causes some uncomfortable wearing experiences especially for long term usage. Although 3D printing has customisable and adaptive manufacturing ability, it is unpractical to design and printing customised visors with individual sizes for every user. Head straps can be used to provide the tightening force for the visor frame. The head straps are attached to the visor frame through manually cut slits and the distances of the slits can be adjusted to change the tightening force.

In a related paper it was mentioned that the 3D printed visor frame can be heated by hot water and then manually adjusted.

However, these methods all require users’ careful adjustment, which is not suitable for inexperienced users. Furthermore, no systematic study is performed on how these adjustments can affect the actual wearing tightness.

The paper presents a new manufacturing procedure taking advantage of the thermal induced Shape Memory Effect (SME) of PLA, which belongs to Shape Memory Polymer (SMP). The shape of SMP can change between its permanent shape and the temporary shape. Utilising this property,

two types of 4D printed SMP methods are reported in the literature. The first method introduces the pre-strain during the printing process by tuning the printing temperature.

The printed object has the temporary shape and can then change its shape with temperature stimuli to release the pre-strain after printed. The second method prints the SMP in its permanent shape. The shape is then deformed to a temporary shape with external force when heated above the glass transition temperature (Tg) of the material.

The temporary shape can be maintained when the stimulus temperature goes down and the external force is removed. The SMP can then recover to its permanent shape again with temperature stimulus higher than Tg. In this study, we will focus on the latter method. By implementing Closed Loop Controlled 4D Printing (CL4DP) over the recovery process, the recovery speed of the SMP can be regulated by changing the stimulus temperature applied on the SMP. It is also feasible to terminate the recovery process by decreasing the temperature below Tg. Thus, through monitoring the shape of the SMP in real time and regulating the temperature accordingly, arbitrary shape can be achieved using feedback control algorithms.

In this work, the visor frames are 3D printed in a common manner with the monosize. The frames are then deformed to a temporary shape by heating a local area of the visor. Due to the SME of the material, the shape of the visor will recover to the printed shape when the local area is heated up again. During the recovery process, the local temperature is precisely controlled so that the shape recovery stops at a desired target shape. These post-processing steps enable the visor to achieve any shape to fit the different requirements from users and the new 4D printing method for the visor frame is proved to be more time-efficient than traditional case by case redesign and printing method to enable customization.

Following the Finite Element Method (FEM) analysis, the customised visors demonstrate constant wearing experiences for different users compared with traditional mono-sized designs. Furthermore, the already customised visor frames can be reused in the CL4DP process which makes the visors manufacturing process recyclable and sustainable.

Reprinted with permission from Nature magazine. nature.com/articles/s41598-022-11629-3

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FORMING & FABRICATION

The story behind the Iron Man welding helmet Texas welding school’s fully functioning, voice-activated Iron Man welding hood goes viral on TikTok. What do TikTok, welding, and Iron Man have in common?

The answer is Precision Welding Academy, a Katy, Texas-based welding school in the USA. Why is that? Well, the school’s founder and students are responsible for a couple of viral TikTok posts showing off a helmet identical to the one worn by the Marvel superhero Iron Man that they converted into a welding hood.

The original post has more than nine million views so far and has generated more than 75,000 followers to their TikTok account.

The whole experience has been a whirlwind, said Scott Raabe, founder of Precision Welding Academy, but it’s also provided learning opportunities and has morphed into conversations about how welding helmets can evolve to be more than just a piece of necessary PPE.

I Am Iron Man Raabe started Precision Welding Academy two years ago, right before the COVID-19 pandemic began. After a brief shutdown, the school was deemed essential and allowed to reopen. Currently 35 students are enrolled at the school, which Raabe started to provide a well-rounded training environment.

So, back to the Iron Man helmet …

“I saw it online about a year ago, and it was just a random Iron Man mask that closed and opened and was voice-activated. I was like, ‘Man, that would be pretty cool if we could change that into a welding helmet,’” Raabe explained.

One student, Connor Shelly, 20, agreed and took it upon himself to find and purchase the mask. After experiencing a few delivery delays, Shelly received the mask in early 2022. From there came the challenge of converting it into a functioning welding hood.

The first and most important part was fitting the mask with eye protection strong enough to guard the user against the ill effects of the welding arc. Unlike a standard welding hood with a large viewing glass, the Iron Man mask needed to be fitted with protective glass only around the eyes. The rest of the face was covered by the mask itself. Raabe suggested they use a passive lens made of tempered glass, but the glass cracked every time they drilled into it.

“Next we tried a polycarbonate welding lens. Usually, they’re pretty cheap and I actually had one sitting at the house,” Raabe explained.

“We cut a bunch of eyes out, did some sample runs, and they worked perfectly. They didn’t shatter and they could be shaped any way we wanted. We sealed everything up to make sure no light could get through.”

The mask turned welding hood was ready for action. Unlike standard hoods, the mask is both remote- and voice-activated. The user can either push a button or say the command “Open mask,” and the mask opens fully, revealing the welder’s face. The command “Close mask” encloses the face and the user is ready to weld.

“I said, ‘No, we actually converted this into a welding hood,’” Raabe explained.

A follow-up post showed Raabe using voice activation to close the hood before welding, which has generated a modest 1.2 million views.

With the posts’ popularity, Raabe is certain it has attracted the attention of a few welding hood manufacturers.

“I have no doubt that some hood manufacturer out there will try to mimic it. We’ll see in a year or two if that ends up being true.”

Transforming the Welding Hood Game What started out as a fun social media post has sparked conversations in class about transforming standard welding hoods into wired-in pieces of PPE. One idea, said Raabe, is to make the hood Bluetooth-capable.

Next up? Making the TikTok video.

“We want to see if we can enable it to play music, allow you to answer phone calls, stuff like that.”

“I put the hood on, found a random pipe in the shop that was already halfway rooted, and grabbed some fancy edge welding cups,” Raabe said.

Those ideas have been a springboard into the larger discussions about using Bluetooth to talk to the welding power source, allowing the welder to change amperage with a simple voice command.

With Black Sabbath’s “Iron Man” playing in the background, Raabe’s helmet closes over his face and he initiates the TIG arc.

While students are busy tackling that challenge in addition to honing their craft, Raabe said he has no intention of making a habit of the viral social media posts.

The post has blown up, generating 700,000 likes, nearly 3,700 comments, and almost 50,000 shares so far.

Most of the commenters wanted to know where they could buy one, while others wanted to know if it was indeed voice-activated. Some insisted it was a fake mask and that the user was simply wearing his safety glasses underneath.

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“If I live my life trying to make every post go viral, I wouldn’t be able to run this school.”

By Amanda Carlson. Credit: This feature originally appeared in the May/June 2022 issue of The WELDER, a publication of the Fabricators & Manufacturers Association.

Real Business Real People Real Members John Hart is proud to be a founding member of AMTIL. Our continued and active participation is fostered by the enthusiastic and engaging staff at AMTIL. Their staff have an intimate understanding of our industry from all perspectives and provide a valuable resource of skill, knowledge, and experience.

There are many benefits that come from AMTIL membership, the most valuable of which is its people.

Mark Dobrich, John Hart

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

1311AMTILMD

amtil.com.au

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FORUM EXPORT FINANCE

Unlocking international opportunities for your manufacturing business Yuri Schneider shares three tips to help ensure your manufacturing business is set up to secure the finance it needs to succeed in export markets.

At Export Finance Australia, our team is committed to supporting Australian businesses to succeed in global markets. Whether you need additional working capital to send bulk stock to your export markets or are looking to increase the supply of your inputs, we can help your business to reach new international horizons.

Here are our three top tips to prepare your business for when you need finance.

1. Engage early If you know when you’re likely to need additional finance, liaise with your financier to start the process early.

Communicating early with your lender is key to ensuring you can access the finance you need. This might simply be a conversation to discuss the contracts you have coming up or what challenges you are navigating – it can all help establish the foundation for a streamlined process. Your business is likely to need different financial instruments throughout its export journey. Having these conversations can also facilitate a collaborative approach to building the right products for you. As an example, if you’ve got confirmed contracts, purchase orders or off take, we could provide finance for stock build up.

Reaching out last minute places additional stress on your business and can sometimes mean your finance is not available as early as you might need it.

Case study: tna solutions Our customer, tna solutions (tna) is a food processing and packaging technology solutions provider with a presence in more than 120 countries. To launch a new, complete manufacturing line including processing, distribution and packaging systems, producing french fries, wedges and hash browns, tna required additional working capital, Erwin Mulders, CFO of tna explained.

“In the past we’ve used our own funds for big projects like this and that has its limitations. By working with Export Finance Australia, we could use our own operational working capital for existing needs.”

Saxon Robinson, tna’s Chief Marketing Officer, added that tna is an ideal match for Export Finance Australia. “It’s quite rare that you come across a business that started in Australia and has taken on the world – and succeeded. We're proud of our accomplishments.

There's a nice synergy between our profile and the services that Export Finance Australia offers.”

For Erwin and his colleagues, they see this as the starting point of a longer-term relationship between tna and Export Finance Australia.

2. Be financially organised Knowing what support you need and ensuring you have all of your financial information up to date puts your business in a strong position to secure funding when it’s most needed.

Take the time to do your cash flow forecasting and make sure you know your real financial position. Without this information, your application could be delayed. Supply chain challenges continue to stretch waiting times for supplies and shipping times for deliveries.

Having had those early conversations with your lender, being able to take the next step and begin an application as soon as the need arises will place you in a strong position.

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Case study: Atomos Our customer, Atomos, is a global video technology company delivering award-winning, simple to use monitor-recorder content creation products. With most of Atomos’ video monitor components manufactured overseas, there’s a 16-week lead time between paying manufacturers and making sales.

Atomos Chief Financial Officer, James Cody said, “We needed a loan facility so we could borrow against customer orders – to help fund our working capital.”

Our facility allowed Atomos to keep up with its products’ supply and demand. With our support, Atomos could speed up the manufacturing process and grow its business even further.

After becoming a public entity trading on the ASX, James says the business’ innovative success is due to the product itself as well as the relationships it nurtured.

“We wouldn't be able to make our products without the likes of Sony, Panasonic, Canon, Adobe, Apple, and Avid sharing their software processing and video capabilities with us,” he said.

James is grateful for not only the support of technology partners, but also for the Export Finance Australia team and the support we provided.

“In our earlier stages of growth, if we hadn't had the facility – we wouldn’t have been able to produce as much stock as we wanted to.”

3. Understand your export markets Knowing the ins and outs of your target markets can be challenging, but is crucial to the success of your export operations.

A deep understanding of any cultural differences and how you are going to manage logistics, among many other factors, is important to be able to demonstrate when you are looking to secure finance for an export-related contract.

Quite often, and particularly with travel still restricted, having people on the ground to provide you with insights and a deeper understanding of your markets can be invaluable.

Strong relationships and a direct route to sell into your export market, makes securing finance for international contracts a much smoother process. Connecting with government agencies such as Austrade will facilitate introductions to contacts in your export markets.

Speak to our finance experts. We’re working with Australian manufacturers to take their innovations global.

Call our experienced team on 1800 093 724 or visit our website.

Yuri Schneider is the Associate Director, Business Development, VIC & TAS at Export Finance Australia. www.exportfinance.gov.au

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FORUM IP

Why patent a manufacturing process?

This question is answered by Ben Mott, who explains the process, the different types of coverage, what is patentable … and more.

Q: Why patent a manufacturing process?

A: To guard against price competition.

Some advanced manufacturing processes produce innovative new products. Others make old products more efficiently. In either case: •

profit margin will disappear over time if imitators can compete on price; and

•

competitors are likely allowed to imitate if you don’t patent.

Generally speaking, in the context of Australian manufacturing, others are free to imitate your new products and processes unless you apply for patent and/or design protection. What's the difference?

•

patents can cover functional details of new products and processes; and

•

design registrations cover the appearance of new products.

Q: What about foreign competitors?

A: Australian patents are infringed by unauthorised importation.

Australian patents are infringed by unauthorised activities in Australia, eg. by activities such as making, using, importing and/ or selling either a patented product or a product resulting from a patented process. That is…

…an Australian patent covering a manufacturing process can be used to stop competitors importing product that is made overseas using the patented process.

Q: Is my manufacturing process patentable?

that changing the computer program in a washing machine so the machine gets clothes cleaner and uses less electricity is potentially patentable. Likewise, in the manufacturing context… …a new and non-obvious software change that, for example, reduces cycle time, uses less material or results in a better product, may well be patentable.

Q: Aren’t patents expensive to enforce?

A: Yes, very.

Going to court to enforce a patent is expensive, even compared to many other matters that you might take to court. On the other hand: •

if a competitor infringes a valid patent, the competitor is likely to back down before the matter gets to court, to avoid similarly expensive costs in addition to penalties for infringement; and

•

a quality patent may well deter many competitors from producing similar products without any direct cost to you.

Q: Aren’t patents expensive to apply for?

A: Yes and no.

Patenting a mechanical invention in Australia might entail an initial cost in the ballpark of $6K and a total investment over the entire 20year life of the patent in the ballpark of $35K. Any patent attorney worth their salt would be pleased to have a preliminary discussion without charge to talk through your invention, your prospects of success and the applicable costs.

Q: But patenting takes years?

A: Yes, but you can use the process within a few weeks.

Patents have definitions of coverage known as ‘claims’. Generally speaking, a claim is invalid if it covers any technology that was publicly known before the initial patent filing date, or anything that obviously follows on from that old technology. These are key requirements for a valid patent.

If you can supply your patent attorney with a quality description of your invention, your initial patent application should be filed within a few weeks. Once the application is filed, you can go public with (and/or commercially use) the invention without harming your patent rights in what you have invented to that point. Australia has a 12-month grace period that can excuse premature publication and/ or use, but it’s best not to rely on the grace period.

If you’re interested in patent protection in a long list of countries, a search for relevant old technologies would be a prudent first step. If Australia is the only country of interest, simply filing a patent application and waiting for the patent examiner’s feedback may well be the better approach.

Following the ordinary process, your Australian patent application will be examined in due course and, if you are successful, a patent will be granted on the application perhaps four or five years after the initial filing. It’s usual to let the process take this long, to defer costs amongst other advantages.

It’s a mistake to simply assume that your new and valuable developments are not patentable. The non-obviousness threshold is a low bar.

If at some point during those four or five years there was an infringement, you could accelerate the process which, all going well, would lead to a granted patent within eight months or so.

Q: What about software?

Ben Mott - Patent Attorney and Mechanical Engineer with manufacturing experience. Principal, BRM Patent Attorneys

A: Almost certainly, if it is new and non-obvious.

A: Many software innovations are patentable.

Much has been written regarding software innovations that are not patentable, even if they are valuable, new and non-obvious. It’s a complex area of law that is evolving as courts hand down more case law. The key battle lines relate to software that is purely informational in character. Australian courts have held that innovations such as a certain method of calculating a share-price index and a ‘wizard’ to help fill in certain forms are not patentable.

www.brmpatentattorneys.com.au

In the context of manufacturing processes, many software changes are clearly on the patentable side of those battle lines. New Zealand’s Patent Examination Manual explains, by way of example,

Direct access to experienced professionals, clear cost forecasts, clear communication and responsiveness are hallmarks BRM.

BRM Patent Attorneys is an experienced company of professionals dedicated to guarding Australian innovation from imitation at home and abroad, focussing on engineering-related technologies and securing the most effective IP rights for clients. BRM has extensive experience across manufacturing industries. BRM’s Principal worked for five years as a mechanical engineer before training as an attorney.

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FORUM LAW

The rise of environmental, social and governance issues in the supply chain Andrew Hudson looks at the increasing importance of environmental, social and governance considerations and the consequences for industry.

There has previously been extensive discussion on how the supply chain is moving to include issues beyond merely moving goods from origin to destination, the cost and safety of movement, and the impediments to improving movement.

Recently, that narrow focus has widened to include other issues that demonstrate that the supply chain is not isolated from other, less commercial issues.

The lists of prohibited imports and exports grow every year, and Australia has recently given itself the power to introduce “thematic” sanctions. Those sanctions will not be limited to countries but can be applied to sanction the trade in goods or investment by parties believed to be involved in behaviours that the government considers unacceptable. The current conflict in Ukraine has also led to the introduction of significant global economic sanctions and additional restrictions on trade against Russia and its allies.

Modern slavery An example of corporate social responsibility (CSR) concerns in the supply chain is whether goods or services are the product of “modern slavery” or “forced labour”. In this context, the United States is active in its interdiction against such goods, with legislation enabling the seizure and destruction of goods believed to be the product of forced labour (whether wholly or in part). That lead is being followed in other jurisdictions where, regardless of legislation, companies do not want goods and services which may be the product of forced labour. Those companies are now seeking assurances from the supplier of goods and services that there is no forced labour involved in providing goods and services.

Australia’s position is less intrusive in the supply chain, and our Modern Slavery Act 2018 (MSA) requires larger companies to provide annual reports on their measures against modern slavery.

Still, the government has, to date, stopped short of specifically legislating against the import of goods the product of forced labour.

Legislation prohibiting such imports passed through our Senate and was under consideration by our House of Representatives when the election was called, stopping the passage of the legislation.

While that legislation did not pass, changes could be made following the review of the MSA this year. There is significant pressure for Australia to take more action on forced labour/modern slavery risks, especially with a report entitled “Paper Promises” evaluating the early impact of Australia’s MSA. The report found that companies are failing to comply with the mandatory reporting requirements and are failing to identify or disclose modern slavery risks.

Regardless of legislative amendment in Australia, given the focus on such modern slavery/forced labour issues, it is fair to assume that companies, their officers and in-house counsel will include due diligence on such issues and seek assurances that their supply chains are free from such concerns.

An evolving environment The expansion of the CSR agenda will not stop with modern slavery/forced labour, and the agenda continues to evolve.

A related term being adopted is “environmental, social and governance issues” (ESG) to include environmental sustainability, gender and human rights issues as important in the supply chain

AMT JUN 2022

and part of the governance considerations expected of companies and those providing goods and services to those companies.

In the international context, that includes negotiations for an “Environmental Goods Agreement” led by Australia at the World Trade Organisation, the OECD Guidelines for Multinational Enterprises from 2011 and the United Nations Global Compact.

Further, many of Australia's Free Trade Agreements (FTAs) recently concluded include ESG issues as specific focus areas, such as in the Australia-UK FTA. The importance of ESG is now also being seen in the supply chain.

For example, those providing international carriage of goods are increasingly focused on environmental concerns and solutions.

These include the carbon footprint of air cargo services (and how it can be offset), cargo vessels powered by hydrogen, cargo vessels incorporating sails to reduce reliance on carbon-based fuels, and autonomous vessels run by computers incorporating artificial intelligence no longer requiring human crew.

A shift towards ethical obligations Ultimately, the supply chain and the requirements of parties in the supply chain will continue to evolve over time and shift from traditional supply-chain issues. We could anticipate that ethical considerations will also be imposed.

That evolution will be driven, in part, by governments, their agencies, international organisations, as well as popular opinion, which reaches the wider policy framework.

The imposition of additional obligations requires those in the supply chain to be more flexible and prepared to pivot to new technologies and practices. This will be a challenge to the drafting of relevant agreements to allow for variation to include new and desirable outcomes and who is to pay for those outcomes. Adopting such new practices will also reward those willing to invest in monitoring current and future ESG requirements. Failure to meet ESG standards, whether imposed by legislation or imposed in contractual obligations, could create real and significant problems for many in the supply chain.

All companies must undertake their own due diligence to avoid failing to meet the ESG standards and potential prosecution.

Rigby Cooke’s Customs & Trade team can assist businesses with advice on all aspects of Australian and international trade and customs obligations.

Andrew Hudson is Partner - Custom & Trade, Rigby Cooke Lawyers Ph +61 3 9321 7851 ahudson@rigbycooke.com.au rigbycooke.com.au

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FORUM OHS

Understanding Victoria’s new environment protection laws Brendan Torazzi explains Victoria’s new Environment Protection Act, business obligations and suggestions for compliance.

The Victorian State Government’s Environment Protection Act 2017 gave the Environment Protection Authority (EPA) new powers for protecting human health and the environment. As part of the update, the EPA now takes a proactive approach to protect against pollution or waste. This also means changes to the way that certain businesses operate. Under the new laws, businesses need to perform risk-based assessments for any activities that may pose a threat of harm to human health or the health of the Earth. The goal is to prevent health disasters from occurring in the first place. Here is a closer look at Victoria’s new environment protection laws and how they apply to businesses.

What is the Environment Protection Act? The Environment Protection Act 2017 is an amendment that dramatically overhauls the existing Environment Protection Act 1970. The updates went into effect on July 1st, 2021. At this point, businesses involved in potentially hazardous activities should have the proper environmental management systems in place.

Previous laws have attempted to reduce the impact of harmful materials. For example, the government banned the use of asbestos decades ago. Asbestos was used in one in three Australian buildings before the ban. Unfortunately, modern industries continue to use and produce potentially harmful materials and by-products. The new laws are designed to help reduce the impact of environmental hazards, such as: Air pollution; Industrial waste; Radiation; Contaminated land; Chemical hazards.

To help minimise the effects of these hazards, the EPA introduced the Environment Protection Amendment Act 2018. The act granted the EPA new powers, including the ability of an environmental regulator to penalise businesses that fail to comply with the new laws. You may face fines and/or jail time for violating the laws.

At the heart of the new environmental protection legislation is the General Environmental Duty (GED). The GED is comparable to the duty of employers under the Occupational Health & Safety Act. Employers must provide and maintain a reasonably safe work environment. As with the OHS Act, the environment protection laws require businesses to assess risks and develop specific risk management plans. You need to identify potential environmental risks and then implement steps to minimise those risks.

Who needs to comply with the new EPA laws?

Any business that engages in hazardous activities needs to identify and mitigate potential risks. Businesses in the following industries are more likely to need to pay close attention to the new laws: • • •

Agriculture Infrastructure Energy & petroleum industries

• • •

Construction Manufacturing Waste and recycling

The GED requires all businesses in Victoria to understand and minimise risks from pollution and waste. You need to take reasonable, proactive steps and employ adequate environmental management practices. Your obligations increase with the size of your operations. For example, a small business may need to undergo a basic compliance inspection. However, a medium or large business may need to follow specific industry guidance and can expect more detailed inspections.

How to comply with the Environment Protection Amendment Act No matter the size of your business, you should still take steps to reduce your impact on the environment. Here are the typical steps involved in complying with the EPA laws: 1.

2.

3.

4.

Arrange an environmental audit Create an environmental management system Track and report your environmental impact Review all applicable government requirements

Licenses/permits are also needed for certain operations.

For example, if a business activity may affect an area of national significance.

1. Arrange an environmental audit The first step in complying with the EPA laws is to schedule an environmental audit. An EPA officer can assess your business and subsequent audits provide a way to monitor your progress. For example, you can use your initial audit to set the benchmark for measuring improvements and setbacks.

2. Create an environmental management system After assessing your environmental impact, you should develop a detailed environmental management system (EMS).

Management systems provide clear instructions for you and your employees to follow for minimising potential hazards.

The EMS should identify all areas of your business operations that may harm the environment. It should also include operational and emergency procedures for dealing with potential hazards.

3. Track and report your environmental impact Continue to track and report your environmental impact.

Depending on your industry and type of operations, you may need to report energy usage, greenhouse gas emissions, natural resource management monitoring, and more. Reporting is typically voluntary but may be mandatory for certain industries.

4. Review all applicable government requirements Along with Victoria’s new environment protection laws, you need to comply with all applicable government requirements.

This includes national, state, and local laws and industry standards. As a business owner, it is your responsibility to understand which laws apply to you.

Environmental protection is a priority for the government. The latest Victorian environmental laws aim to reduce the impact of pollution or waste. If your business engages in activities that may pose a threat to humans or the environment, take the time to implement the necessary risk management systems.

Explore Victorian occupational health & safety (OHS) courses available through ohs.com.au. You may also contact Alertforce for more information about EPA compliance.

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 brendan@alertforce.com.au alertforce.com.au

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AMTIL INSIDE

Similarities between business and golf I spoke recently to a group of young(ish) business students and thought it might be interesting for you to share the message I gave our next generation of businesspeople. Let me start by saying that, as a baby boomer, and having recently been told that Gen Z can tell in the first 15 seconds whether they are going to pay any attention to a presentation or not, I was a little apprehensive.

So, seeing as I get on the golf course with my two 30-something sons, I thought I would use the analogy of golf in my presentation as a way of bridging the generation gap. These graduates have just spent three or four years training, practising and learning their craft, on the range so to speak, getting ready to join the tour. Hopefully they had some fun along the way but have been disciplined enough to ensure the training has been beneficial and will stand them in good stead for what they want to achieve in the future. One of the first challenges is to decide where you want to make your mark. Deciding what industry or job sector you want to work in is a bit like deciding what tour to play on. It will depend on your skills and interests, but more importantly what you have passion for.

Now they are ready to stand on the first tee and ready to mix it with the big boys. So what is the first step? As any golfer will tell you, it’s important to get the first drive down the middle.

This is a nervous time: wanting to make a good impression, feeling anxious about your capabilities, and trying to control your excitement. Keeping a positive attitude and faith in your ability (trust your swing) are key messages to remember. Now we have hopefully got down the first fairway, we need to look ahead. There is a target that has been set, usually by somebody else, and your challenge is to get to that target in the most effective way. This is where you need to be thinking all the time. More often than not there are hazards in the way and sometimes the target can be tricky to get to. Being innovative in your thinking and positive in your efforts can make the outcome easier to achieve. It is important to remember that it is never going to be smooth sailing all the way. You are going to go in the rough at times, maybe even hit it out of bounds. How you recover from adversity and learn from your mistakes so that you don’t make them again is an important lesson. And remember, spitting the dummy is not an option.

How do we score our efforts? Like golf, success in business is not a one-off special effort, but a combination of many holes and rounds over many different courses. When you make a bogey, learn from what you did wrong. Remember that par is what you are expected to do and keeps you at the same level as the majority of your competitors. Birdies are special.

They show everybody you are capable of performing at a level better than average. The overall outcome is to have more birdies than bogies if you want to share in the winnings.

The next stage in the analogy refers to your caddy. This person is here to help you. He can mentor and assist you to get where you are going. He probably stands to benefit as well if you achieve what you want to, so use him to his fullest ability. Even if you think you know better, it doesn’t hurt to get his opinion. Experience and knowledge are more often just as important as attitude and skill. Success awaits with the X factor. A lot of your colleagues are going to be able to perform as well as you do. Being the Tiger Woods of the professional world requires something special. Determining what your X factor is and being the best at it will be an area of continuous improvement as others catch up. Staying on top of the game is a big challenge that not everybody can do.

By far the biggest lesson for you to take into your business future is that the journey is so much more enjoyable if you have fun and get along with your playing partners. Enjoying the workplace and getting on with people (even bridging the generation gap) is essential to success in business, and golf! Play well.

Shane Infanti, CEO AMTIL

AMT JUN 2022

AMTIL HEADING INSIDE

Make the Future 2022: AMRF Manufacturing Technology Conference There are events within events at Australian Manufacturing Week (AMW) being held on 7-10 June, Sydney ICC, Darling Harbour.

There are collaborations between companies and sectors of different industries. There are also co-located conferences, with all kinds of chances to spot business opportunities.

Tuesday 7 June, 8.30am-6.30pm Schedule Program for Plastics and Medical Applications – SPEANZ-2072 SPEANZ-2072 is hosted by the Australia-New Zealand Section of the Society of Plastics Engineers in collaboration with the BioMelbourne Network, the Medical Technology Association of Australia, the Plastics Industry Manufacturers of Australia. It is a one-day event, taking place on Level Three of the ICC Sydney, just upstairs from AMW’s trade show floor. Attending the Conference will also provide you with entry to the Exhibition between 12.00 pm and 2.00 pm (lunch at your own cost at the Exhibition).

Registration is essential

Tuesday 7 June 2022, 4.00-5.00pm

Wednesday 8 June AWRF Manufacturing Technology Conference On the second day of AMW, AMTIL is hosting the AMRF Manufacturing Technology Conference in E5.2 and E5.3 of the Sydney ICC at Darling Harbour. Hosted by the Advanced Manufacturing Research Facility (AMRF), this one-day conference will deepen your knowledge of technologies being used in manufacturing today.

Free to attend. Booking is essential

Wednesday 8 June 2022, 3.00-4.00pm AMW Women in Manufacturing Networking Function In the afternoon, AMTIL is hosting the AMW Women in Manufacturing Networking Function from 3.00pm to 4.00pm. This gathering and networking event will be happening at the AMTIL Stand and it will be sponsored by Integra Systems.

Free to attend. Booking is essential

AMW Exhibitor and Visitor Happy Hour At the end of the first full day of walking the aisles and stands at the Australian Manufacturing Week, AMTIL is pleased to advise there will be a chance to relax. We present the AMW Exhibitor and Visitor Happy Hour, sponsored by Autodesk. This networking opportunity is a chance for a more relaxed and informal catchup with fellow attendees, away from the bustle of the day. This is a great chance to follow up with those you saw earlier in the day and synchronise dairies for the week. It will be located at the AMTIL Stand, on the AMW Exhibition floor.

Thursday 9 June 2022 Manufacturing LAB Industry Breakfast: 8.30-10.00am Future-proof your business to reap the rewards tomorrow. Join the Manufacturing LAB at Australian Manufacturing Week. On Thursday 9 June, 8:30am to 10:00am, on Level 3 at the ICC in Darling Harbour Sydney, meet us for breakfast. Speakers include Matthew Kelly, the Head of Manufacturing and Wholesale at St.George Bank; Director at Coleman Greig, Rebecca Hegarty; and Mark Calvetti, Director at William Buck.

Free to attend. Registration is essential

Free to attend. Registration is essential

1382V4AMTIL

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

AMT JUN 2022

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AMTIL INSIDE

A cracker of a day!

AMTIL members, guests and a serve of glorious sunshine descended upon the Riversdale Golf Club in Melbourne on 8 April for our AMTIL Golf Day 2022.

Teams out on the fairways made the most of the sunshine and fresh air. After the last of the teams finished up at the 18th hole, all in attendance enjoyed an amazing lunch and networking drinks, and the prizes were handed out. Congratulations to Jon Larosa, Randy Derozario, Jeremy Raniti and Robbie Bannindi in Team One, who won the event’s main prize with a score of 63.

The winners of Nearest The Pins were Peter Ford on the 1st, Gary Lazard on the 3rd, Michael Adams on the 14th and Brigitte Stavar on the 17th. The Longest Drive was shot by Todd Hodge on the 6th and the Straightest Drive was hit by Gerard Burmeister on the 18th.

AMTIL would like to thank the event’s sponsors: William Buck; Headland Machinery; Metal Industries Insurance Brokers; BRM Patent Attorneys; Harry the Hirer; Dimac Tooling; and Australian Precision Technologies (APT). amtil.com.au/events

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

CONSEP PTY LTD

ONEKLOUDX PTY LTD

ROOTECH PTY LTD

59 Newton Road WETHERILL PARK, NSW 2164

96 Bedford Road HEATHMONT, VIC 3135

28/324 Settlement Road THOMASTOWN, VIC 3074

consep.com.au

onekloudx.com.au

rootech.com.au

LEADING EDGE ENERGY

1A/96 Buckingham Street SURRY HILLS, NSW 2010 leadingedgeenergy.com.au

REAP THE BENEFITS OF AMTIL MEMBERSHIP Contact us to learn more www.amtil.com.au

AMT JUN 2022

AMTIL FOOTY TIPPING 2022 ON WE GO!

At the time of writing, the Mighty Dees were yet to lose a game in season '22, stretching their unbeaten run and winning their past 16 games – whereas, both West Coast and North Melbourne are struggling to be competitive.

WA's 'disconnect' from the Eastern states during the height of the pandemic now sees them a tad vulnerable with the Eagles struggling for players to put out on the field. Dustin Martin's return to the Tiggies see them slowly build to the force of recent years and have the flag firmly set in their sights.

Leon Cameron has decided he won't be pushed out at the end of the season so pulled the trigger to allow for Alistar Clarkson to be the prime candidate to look after one of the AFL's darlings – could he coach both the Giants and the Suns at the same time? We have a logjam at the top of the tipping table separated only by margin – who's going to blink first? Till next time…

Sanchez ROUND 9 1 murf56 2 Nick Sear 3 Paul Techni 4 Saint Schmick 5 Raff - (Parish Eng) 6 Kings-man 7 blsmithy 8 Shane Infanti 9 PRPLegends 10 LemmyIsGod!

59 (171) 58 (185) 58 (209) 58 (221) 58 (224) 58 (234) 57 (214) 57 (234) 57 (243) 57 (252)

AMTIL INSIDE

Maximise Your Membership Maximise Your Membership events will be held in New South Wales, Queensland, South Australia, Western Australia and Victoria.

The following events will offer an opportunity to learn about AMTIL’s latest activities and initiatives, as well as to make connections with colleagues from across the industry.

Western Australia

Event details are as follows:

Wednesday 27 July; 6.00pm-9.00pm Santini Bar & Grill 133 Murray Street (#level 1) Perth WA 6000

New South Wales

Victoria

Tuesday 19 July; 6.00pm-9.00pm Verandah Bar and Restaurant 60 Castlereagh Street Sydney NSW 2000

Wednesday 3 August; 6.00pm-9.00pm The Boatbuilders Yard 23 South Wharf Promenade Melbourne VIC 3006

Queensland

All of these events are free to AMTIL members, with a $45 admission fee for non-members. Finger food and drinks will be served at all events.

Wednesday 20 July; 6.00pm-9.00pm Hyatt Regency Brisbane 72 Queen Street Brisbane QLD 4000

South Australia Tuesday 26 July; 6.00pm-9.00pm 2WK Bar 20 Peel Street Adelaide SA 5000

0PEN II0T

To book your place at any of AMTIL’s upcoming events, please visit the Events page on the AMTIL website. For more information, please email events@amtil. com.au amtil.com.au/events

AUTOMATE

Why choose Open IIoT? We practice what we preach! Each of our members are internationally recognised experts in Smart Manufacturing.

Learn more by scanning the QR code

1800 465 348 www.romheld.com.au

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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.health. gov.au/health-topics/novel-coronavirus-2019-ncov. For more events, please visit www.amtil.com.au INTERNATIONAL METEF Italy, Bologna 9-11 June 2022

MANUFACTURING SURABAYA Indonesia, Surabaya 13-16 July 2022

ALUMINIUM EXHIBITION Germany, Dusseldorf 27-29 September 2022

www.metef.com

www.manufacturingsurabaya.com

www.aluminium-exhibition.com

FABTECH CANADA Canada, Toronto 14-16 June 2022

ENGINEERING ASIA Pakistan, Karachi 22-24 July 2022

https://canada.fabtechexpo.com

www.engineeringasia.net

SAUDI FASTENER & MACHINE TOOLS EXPO Saudi Arabia, Riyadh 2-5 October 2022

MMTS Canada, Montreal 14-16 June 2022

EXPOMAC Brazil, Curitiba 16-19 August 2022

www.mmts.ca

www.expomac.com.br

IMTEX India, Bangalore 16-21 June 2022

MMMM India, New Delhi 25-27 August 2022

www.imtex.in

www.mmmm-expo.com

TUBE Germany, Dusseldorf 20-24 June 2022

TECH INDIA India, New Delhi 25-27 August 2022

www.tube.de

www.techindiaexpo.com

LASYS Germany, Stuttgart 21-23 June 2022

TECHNI-SHOW Netherlands, Utrecht 30 August - 2 September 2022

www.messe-stuttgart.de/lasys

www.technishow.nl

M-TECH Japan, Tokyo 22-24 June 2022

IMTS USA, Chicago 12-17 September 2022

www.japan-mfg.jp

https://www.imts.com

MANUFACTURING EXPO Thailand, Bangkok 22-25 June 2022

PHARMA ASIA Pakistan, Karachi Expo Center 13-15 September 2022

www.assemblytechexpo.com

www.pharmaasia.com.pk

INTERPLAS THAILAND Thailand, Bangkok 22–25 June 2022

INTERMACH Brazil, Joinville 13-16 September 2022

www.interplasthailand.com

www.intermach.com.br

METALTECH Malaysia, Kuala Lumpur 22-25 June 2022

SMART FACTORY South Korea, Busan 21-23 September 2022

www.metaltech.com.my

www.smartfactorykorea.com/busan

SMART FACTORY South Korea, Seoul 24 June 2022

KOREA METAL WEEK South Korea, Goyang 21-23 September 2022

www.smartfactorykorea.com

www.korea-metal.com

ALUMINIUM CHINA China, Shanghai 6-8 July 2022

MAKTEK EURASIA Turkey, Istanbul 26 September-1 October 2022

www.aluminiumchina.com

www.maktekfuari.com/en

MTA VIETNAM Vietnam, Ho Chi Minh City 6-9 July 2022

STAINLESS STEEL WORLD The Netherlands, Maastricht 27-29 September 2022

www.mtavietnam.com

www.stainless-steel-world-event.com

MICRONORA France, Besancon 27-30 September 2022 www.micronora.com

AMT JUN 2022

www.fabxsaudi.com/saudi-fastners

MOTEK Germany, Stuttgart 4-7 October 2022 www.motek-messe.de

WELDING BRNO Czech Republic, Brno 4-7 October 2022 www.bvv.cz/welding

ANKIROS Turkey, Istanbul 6-8 October 2022 www.ankiros.com

BI-MU Italy, Milan 12-15 October 2022 www.bimu.it

IMT Taiwan 19-21 October 2022 www.imttaiwan.com

EUROBLECH 2022 Germany, Hanover 25-28 October 2022 www.euroblech.com

EUROBLECH Germany, Hanover 25-28 October 2022 www.euroblech.com

ADVANCED MANUFACTURING USA, Minneapolis 2-3 November 2022 www.advancedmanufacturingminneapolis. com/en

FABTECH EXPO USA, Atlanta 8-10 November 2022 www.fabtechexpo.com

ADM Canada, Montreal 9-10 November 2022 www.admmontreal.com/en

TUBE INDIA India, Mumbai 23-25 November 2022 www.tube-india.com

INDUSTRY CALENDAR HEADING LOCAL NO-DIG DOWN UNDER SYDNEY, ICC 14-17 JUNE 2022 The southern hemisphere’s only large scale conference/exhibition dedicated to trenchless technology. Includes training courses on trenchless installation for the accurate installation of new utilities, services, casings, or other underground facilities. Plus a summary of the proven benefits compared to a traditional trenched approach.

WORKPLACE HEALTH & SAFETY SYDNEY SHOWGROUNDS 20-21 SEPTEMBER 2022 Showcases the latest health and safety products and resources and encompasses a free program of events and opportunities to meet new suppliers, update knowledge, join discussions, and forge connections. www.whsshow.com.au

FOODTECH GOLD COAST CONVENTION & EXHIBITION CENTRE 7-8 JULY 2022 Advancements in food and beverage manufacturing, plus a new conference stream and exclusive networking events.

WA MINING PERTH CONVENTION & EXHIBITION CENTRE 10-12 OCTOBER 2022 Integrates the innovation and research ecosystem while addressing the social and environmental standards driving a more sustainably conscious industry. Showcasing the technical and digital innovation across the entire mining value chain.

www.foodtechqld.com.au

www.waminingexpo.com.au

CEMAT MELBOURNE, MCEC 19-21 JULY 2022 Trade fair for materials handling, intralogistics and supply chain management.

WASTE EXPO MELBOURNE, MECC 26-27 OCTOBER 2022 Co-located with All-Energy Australia, offers waste management, sustainability, clean energy and energy management information.

www.nodigdownunder.com

www.cemat.com.au

www.wasteexpoaustralia.com.au

AUSTRALASIAN WASTE & RECYCLING SYDNEY, ICC 24-25 AUGUST 2022 Showcases innovative products and sustainable solutions to collect, process and recycle waste more smartly.

AUSTRALIAN MANUFACTURING WEEK 7-10 JUNE 2022 SYDNEY ICC AMW is the ONE event that showcases the latest innovations, technologies and equipment in the advanced manufacturing sector. Explore new opportunities, meet and network with industry leaders and technology experts, all under ONE roof at ONE show.

www.awre.com.au

MEGATRANS2022 MELBOURNE, MCEC 24-26 AUGUST 2022 Exhibition for the freight and logistics industry. Co-located with Australian Bulk Handling Expo. Showcasing the latest in AI, robotics, automated racking, telematics and route optimisation, warehouse automation, intelligent fleet systems.

www.australianmanufacturingweek. com.au

www.megatrans.com.au

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MACHINERY FORUM (NSW) Pty Ltd 33 Brodie Street, Rydalmere NSW 2116 Ref. Mr. Heino Windhorst T. +61 (02) 9638960 0 E. heino@mafosyd.c om.au

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AUSTRALIA’S NO. 1 ADVANCED MANUFACTURING MAGAZINE

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AMT JUN 2022

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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 49

AN ALLY IS CONVINCED

WW2: Laurence has finally changed the US perception that offering Lend Lease war materiel to Australia would be a waste. Next stop is Canada!

I

was studying the latest American techniques and sending back detailed reports of everything I thought could be useful to our own munitions programme in Australia. I also became a kind a travelling public relations officer for Australia. During the lunch-hour breaks at a number of the plants I visited, I was asked to talk to the employees about Australia.

In that way, thousands of American war workers, and the top executives, who usually stayed to listen, heard about the staggering production job Australia was doing with comparatively little labour - by American standards - and not very much equipment. My constant theme -"We'll do all we can to help ourselves and your fighting men"- won their friendship and help immediately.

As an example of a good day, let us take the note I made of a visit to Bridgeport, Connecticut: Arrived from New York by car with police escort at 9.30 am; visited Bridgeport Brass; Vought Sikorsky Aircraft; Auto Ordnance; Remington Small Arms; gave a lunch talk to 600 at General Electric; off back to New York at 4 p.m." That day I walked at least five miles through factories and learnt a lot.

I always made sure of giving the Americans tangible evidence of Australia's capacity to help. One particular triumph, which did much to dispel their doubts about our industrial capability, was the arrival by air of a shipment of urgently­needed optics for gunsights which I had had made to American specifications. I was at Frankford Arsenal when they arrived, and I experienced the great thrill of hearing the US Army ordnance inspector deliver his report. The Australian sights could not be faulted. They were assembled into American gun-sights and sent off very quickly to Alaska to help guard America's back door.

The pay-off for this kind of help wasn't long in coming. Americans were at last realizing the truth of our claims that, although our population was small, our skills and organisation were equal to the best in the world. Their reluctance to give us equipment vanished once we proved it would not be wasted. One of the most valuable concessions was their offer to let us have a large quantity of machine-tools which had been ordered for France before the German invasion and was now in store, scattered over the US. These machinetools were all in metric measurement, but

1940 – 1942: A man operating equipment while manufacturing optical glass in Prof Hartung's Optical Munitions Lab, University of Melbourne

I grabbed all I could get hold of and had them shipped to Australia. They did a lot of valuable work for us.

I believe I held the record for an overseas diplomat or visitor. I officially called on more than 500 factories making munitions in the USA. How nice it was for me, too, that two old GM colleagues were in Washington: Jim Mooney as a naval captain and Graeme Howard as a colonel in ordnance.

I then headed north to Canada to take a close look at the Canadians' twenty-five­ pounder production set-up, which was just getting started. Another General Motors man, Harry Carmichael, managing director of GM Canada, had taken up a munitions job almost parallel to mine.

As I have pointed out earlier, the Canadians were in a much more fortunate position than we in Australia: they were filling largevolume munitions orders for the British as well as for themselves; they never had our problem of having to make a little of everything. Their six-pounder productiontarget, for example, was something in excess of 4,000 and they were already making 100 a week. Our Australian requirement was for about 400, but our tooling-up programme to get our small order filled was just as complex as the Canadians'.

In Canada, I was able to give a lot of useful advice based on our experience of getting into production with makeshift tools. It helped, too, that, being an engineer, I could speak to the Canada technical men in a common language.

The Governor-General, the Earl of Athlone, questioned me at length during a lunch about Australia's war work.

In Australia, with our limited range of machine-tools, we had devised many techniques to get the maximum production from each unit. Some of the modifications we made had almost doubled the normal production rates of certain machine-tools.

We had done much detailed research into cutting-speeds, feeds, the angle of tools and how the cutting-edges should be ground so they would cut more metal in less time.

One of our most important discoveries was the use of a technique we called the "negative rake-angle" on milling-machine cutters - a discovery that had proved its worth by increasing production. I was able to tell the Canadians about this, supporting my demonstration with production figures we had achieved. The Canadians - and the Americans and British too - further developed the technique and made it standard machine-shop practice.

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

AMT JUN 2022

To be continued…

The future is smart.

Let’s create your dream factory with world-renowned smart technology and software.

Come and see our technology at Austech, chat to our experts and see how we support our customers with the largest technical support team across Australia and New Zealand.

There will even be a Lego model of a factory from Stoddart. Enjoy a beer or two and let’s create together.

See us at stands MT25 and MT08.

headland.com.au

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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