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CONTENTS
Volume 24 Number 01 February/March 2024 ISSN 1832-6080
FEATURES
AEROSPACE & DEFENCE Titomic takes off in Falcon Raymax M4 Zygo Engineering
32 36 46
RENEWABLE ENERGY & CLEAN TECH NVIDIA solar race Avarni Clean Tech Monash Innovation Labs
50 54 56
ONE ON ONE Heidi Hannonen, Kemppi
58
ADDITIVE MANUFACTURING Metal powders Manpower: Microwave 3D printing Dimensionics
60 62 66
INDUSTRY 4.0 Mathworks: Top 3 AI trends RMIT on graphene BusinessHub on CODECOM
68 70 72
MATERIALS HANDLING Supashock PackServ GETAC
78 80 81
MOTORS & DRIVES Heat Exchanger Data science toolbox Navigating the deceleration
82 83 84
STATE SPOTLIGHT: TASMANIA Ignite Digi
86
CUTTING TOOLS Walter Sutton Tool advice Guhring Mold Series
88 90 92
COMPANY PROFILE PWR in QLD
94
FORMING & FABRICATION Mechio: Datron CNC MITS Alloy ASA Cheras
96 97 98
COMPRESSORS & AIR TECHNOLOGY Kaeser Compressors Oxair
105 107
REGULARS
From the Editor From the CEO From the Ministry From the Industry From the Union Government News Industry News Voicebox Tech News Product News AMTIL Forums AMTIL Inside Industry Calendar Manufacturing History – A look back in time
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8 10 12 14 16 18 20 24 28 30 108 112 116 118
32
Cover image credit: SpaceX
TITOMIC TAKES OFF Titomic technology aids University of Melbourne and the Italian Space Agency deliver Australia’s first scientific satellite in decades.
56 MONASH INNOVATION LABS Companies find formula for success at Monash Innovation Labs.
58 ONE ON ONE Kemppi Oy VP of Markets, Heidi Hannonen
86 IGNITE DIGI Tasmanian cinematographer describes how he reinvented his business with OKUMA CNC machines.
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008
FROM THE EDITOR PAUL HELLARD
The physical economics of steel making Reading physics and engineering texts can be enlightening. Pouring over politically skewed economic forecasts passing as facts, can be confronting. The physics of our politics is now encroaching on our futures. I do a fair amount of reading in this job, putting this magazine together. There is always something new to learn, and even some old stuff I missed at university. I’m no expert, but I love the fun of physics. The cold hard facts of metallurgy. The real physics of metalic tolerances, engineering and cutting metals, machining the various forms from the sheets, plates and billets. I dive into technical reports, industry studies, scientific papers and thought-pieces, to collect the right kind of manufacturing, business and technology editorial you might like to read at the other end. Never a dull day. It’s just the kind of guy I am. I’m great at parties. ‘Econobabble’ is that noise you hear when lobbyists, politicians and commentators use incomprehensible economic babble to dress up their self-interest as the national interest, to make the absurd seem inevitable or the inequitable seem fair. Econobabble is also the title of the latest updated book from Richard Denniss, the Chief Economist at the Australia Institute. The book exposes the circular arguments, contradictions and lack of evidence used in economic and political discourse in Australia. Well worth a read. Denniss also talks about job losses. Every job loss is tragic, but almost everyone who has lost their job knows there’s usually something out there for them shortly afterward. Hear me out. Every whaler out there has lost their job. Asbestos miners have lost theirs. Steam-powered ships destroyed jobs in sail making and the digital media industry spelled the end of the road for film process workers and their labs. I worked in film for fifteen years, so I know. And one day, my writing/editing job may well be done by some sentient AI processor. But I’m amazed at the concern by some of the loss of jobs in the coal mining industry. According to the Australian Bureau of Statistics, an average of around 330,000 people get new jobs every single month. That’s more than six times the number employed in the coal mining industry in Australia. In 2020-21, the Queensland government earned more from speeding fines and car registrations than it did from the coal mining industry, and these figures are from the ATO. The world is changing faster now than it ever has before. Society, economics, climate and the world of work are all changing just as fast. It is so exciting to delve into the many facets of Australian manufacturing and the changes going on in front of us. Surely, I thought, it would be cheaper to avoid the effects of the climate crisis and to change our energy systems right now by stopping digging up coal, than to just let it happen and then try to 'adapt'. But then, as I’ve also just read, the export of Australian coal to Asia for smelting into metals isn’t going to stop anytime soon. Environment Minister Tanya Plibersek has now signed off on a fifty (50)-year extension to the permit for the Gregory Crinum coal mine, 60kms northeast of Emerald in Central Queensland. The Gregory Crinum mine will now produce metallurgical coal used in steelmaking until 2073. At first I thought this was Econobabble. The International Energy Agency also released a statement: ‘Steel production will remain coal-based in the medium term. Other promising technological approaches, such as hydrogen-based steelmaking, are not yet available on the scale and at the cost required and are not expected in the coming years.’ Of the 1.9Gt(Gigatonnes) of steel produced in the world, 1.4Gt is produced in Asia—1Gt in China alone. China produces 90% of its crude steel via the blast furnace method. A transition to green steel will have to be centred in Asia. The bottom line is that the world needs Asia to prioritise the energy transition over green steel. It’s pointless for Australia to try to accelerate steel decarbonisation by denying coal to Asian producers. They will procure lower quality, higher emissions metallurgical coal from elsewhere. Or dig up their own. So what else can one say? Whatever job you may have, find the fun and do it well. If not, make your move, because there’s no time to lose. Perhaps I should read more factual physics papers, find the fun and go to more parties.
Editor Paul Hellard phellard@amtil.com.au Contributors Dr Cameron Chai Michael David Mitchell Tijana Trifunovich Paul Hellard Sales Manager Nicholas Raftopoulos nraftopoulos@amtil.com.au Publications Co-ordinator Caroline Robinson publications@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 under ISO140001 Environmental Certification using FSC® Mix certified paper sourced using sustainable tree farming practices. 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 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 $190.00 (ex GST) per annum. Contact AMTIL on 03 9800 3666 for further information. 1797AMTFEB/MAR2024
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010
FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL
Getting ready for the transitioning to retirement stage Having worked for over 40 years and now being a ‘Pappa’ to five grandchildren and a sixth on the way, it is time to start looking at what the next stage of life offers. So I thought I would google what that might mean! Transitioning to retirement and taking the time to ‘smell the roses’ is a pivotal phase in one's life that holds immense significance. In the hustle and bustle of a career-oriented, goal-driven life, many individuals often overlook the importance of slowing down and appreciating the simpler, finer aspects of existence. This transition is not merely a change in daily routine; it is a profound shift that allows individuals to rediscover themselves, cultivate new perspectives, and embrace the beauty of life in a more holistic manner. The first and foremost reason why transitioning to retirement is crucial lies in the opportunity it provides for self-reflection and rediscovery. Throughout a career, people often become deeply entrenched in their professional identities, defining themselves by their job titles and responsibilities. Retirement allows them to break free from these constraints and explore the facets of their personality that may have been overshadowed by the demands of their careers. This period of introspection enables individuals to reconnect with long-forgotten passions, hobbies, and interests, fostering a renewed sense of purpose and fulfillment. Moreover, the transition to retirement is an ideal time to strengthen personal relationships and create lasting memories with loved ones. The demanding nature of many careers often leaves little room for quality time with family and friends. Retirement presents an opportunity to bridge the gaps, rekindle connections, and invest time in nurturing relationships. Shared experiences, whether through travel, family gatherings or leisurely pursuits, contribute to the fabric of one's life, creating a tapestry of cherished moments that endure beyond the professional realm. Embracing retirement also promotes mental and emotional wellbeing. The constant pressure and stress associated with a career can take a toll on an individual's mental health. Transitioning to retirement allows for a release from these burdens, offering a chance to decompress and focus on one's mental and emotional health. Engaging in activities that bring joy, relaxation, and a sense
AMT FEB/MAR 2024
of accomplishment can significantly contribute to overall well-being. Whether it's reading, painting, gardening, or simply enjoying the outdoors, the retirement phase provides the time and space for these rejuvenating pursuits. Furthermore, retirement offers the gift of time – a commodity often scarce during the working years. With an abundance of time at their disposal, individuals can pursue lifelong dreams and aspirations that may have been deferred. Whether it's learning a new skill, starting a small business, or engaging in community service, retirement provides the latitude to explore uncharted territories and make a meaningful impact. This newfound freedom allows individuals to set their own pace, creating a more balanced and fulfilling lifestyle. The importance of smelling the roses during retirement is encapsulated in the philosophy of mindfulness and appreciation for the present moment. Throughout a career, individuals may be so focused on future goals and deadlines that they neglect to savour the beauty of the present. Retirement serves as a reminder to slow down, be present, and appreciate the small joys that life has to offer. Whether it's a sunrise, a leisurely walk in nature, or a quiet moment of reflection, these simple pleasures take on new significance during the retirement years. Transitioning to retirement and taking the time to ‘smell the roses’ is not merely a luxury but a fundamental aspect of a fulfilling and wellrounded life. It offers the chance for self-discovery, strengthened relationships, improved mental well-being, the pursuit of lifelong dreams, and a deep appreciation for the present moment. As individuals step into this new chapter, they have the opportunity to craft a retirement that aligns with their values, passions, and aspirations – a chapter that is not defined by the absence of work but by the presence of a rich and meaningful life. So in my case, creating a bucket list of holiday destinations around my love of family, friends, golf and the simple pleasures will formulate a plan for the next twenty years, I hope.
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FROM THE MINISTRY THE HON Ed Husic MP – Minister for Industry and Science
Investment mandate The Albanese Government’s plans for greater economic complexity rely on maintaining Australia’s excellent science-based research sector. Our innovative ideas have boosted productivity, enhanced our communities, and contributed to knowledge globally – and we’re committed to ensuring that continues. But we also want to encourage Australian firms to translate more of our R&D into new products and services. The good news is that Aussie companies increasingly recognise the best way to improve productivity and lock in future growth is to maintain a strong focus on technological innovation. They also understand that developing or adopting novel products and services is easier and quicker when they connect with universities, research institutes, and government agencies. However, the Government recognises that innovation diffusion is a complex process. One manifestation of this is that small and medium enterprises (SMEs) trail their larger cousins in innovating and bringing new products and processes to market. Although large businesses employ more people overall in Australia, SMEs dominate the economic landscape. In fact, they make up more than 99% of all businesses in Australia. If Australia’s position in advanced manufacturing is to be boosted over the coming decade, then innovation take-up needs to occur broadly across businesses of all sizes. Which is why I asked the Office of Industry Innovation and Science Australia (IISA) (within my department) to analyse how more businesses can be encouraged to pursue better innovation and commercialisation outcomes. The IISA report is notable for its focus on demand-side innovation incentives. The Australian Government’s supply-side or ‘technology-push’ strategies and investments have helped create a solid innovation and startup ecosystem – one that has produced global brands like Canva, WiseTech Global, and Atlassian. It is important, however, that we complement these with ‘demand-pull’ policies that encourage SMEs to scale up and commercialise new technology. A particular focus of the IISA report was businesses that currently do not perceive the need to innovate and deliver novel products or services – or that lack the risk appetite, capacity, or capability to do so. For these enterprises, increasing aggregate market demand for products or services that have commercial or societal impact is likely to spur innovation and commercialisation. The report proposes a range of actions to achieve this – and to remove or lower other barriers to a more efficient innovation process. The IISA’s key findings and recommendations will ensure a more uniform and consistent approach by industry to innovation. IISA will work with me and my department to implement these important actions to strengthen business productivity in growing markets. In the meantime, we continue to progress other policies and program initiatives designed to grow Australia’s industrial capability. The cornerstone of our industry transformation strategy, the National Reconstruction Fund Corporation, officially commenced in September, with the Board meeting for the first time. In November, I signed off on the NRFC’s investment mandate with Finance Minister Katy Gallagher. This mandate will require the NRFC to operate on a commercially self-sufficient basis and to deliver a positive rate of return to taxpayers. The Corporation will provide finance in the form of equity, loans, or guarantees to crowd in private investment to enable bigger firms operating in sectors where Australia has natural and competitive strengths to expand and scaleup.
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These sectors that the NRFC will prioritise include renewables and low emission technologies; medical science; transport; valueadd in agriculture, forestry and fisheries; value-add in resources; defence capabilities and enabling technologies. The NRFC’s Board is independent of the government and will make decisions in the national economic interest. At the end of December, the NRFC had had about 200 approaches from businesses seeking investment information. I encourage people who want to learn more about the fund to visit the nrf.gov.au website. In the same week I signed off on the NRFC’s investment mandate, our new Industry Growth Program opened its doors for business for the first time. This $392m initiative will help startups and SMEs navigate the so-called ‘valley of death’ – the often difficult period when a new product of process is in development and not yet capable of generate revenue. Eligible startups and SMEs will be able to apply for grant funding ranging from $50,000 to $5m from early this year (2024). Besides providing matched grant funding to eligible business, the program will also offer specialist services for SMEs seeking investment, market testing, and networking advice. By enabling small businesses to scale up, the IGP will grow the pool of Australian businesses able to apply for NRFC funding. In 2021-22, SMEs contributed $951bn to the economy, equivalent to around 54% of the nation’s GDP. Australia’s 2.5 million SMEs — which include self-employed entrepreneurs — also provide more than two jobs each on average. By encouraging innovation investment – and stimulating increased local manufacture content in those seven NRFC focus areas – we can allow our SMEs to grow and capitalise on their expertise and vision. This will expand the sector, leading to growth and increased employment, and a more dynamic economy. industry.gov.au
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014
FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group
Time for a rethink Rethinking the future of Australian defence industry policy. Australia stands at a critical strategic juncture. We are navigating the complexities of the Australian defence landscape, threats of a major conflict, the challenge of shifting and volatile geopolitics and the urgent task of equipping and sustaining our Australian Defence Force to be able to fight and win. The Indo-Pacific presents us with significant strategic challenges, and the very real risk of a major conflict. The evolving defence environment, as highlighted in a range of recent defence policy statements, underscores the urgency for strategic re-evaluation. The 2023 Defence Strategic Review declared that our current defence structure is ‘not fit for purpose’, signalling a return to fundamentals and a first-principles approach. That was a sobering conclusion. According to the review, the end of a prolonged warning time for a major attack now “necessitates an urgent call to action, including higher levels of military preparedness and accelerated capability development”. We no longer, if we ever had, have the luxury of time to prepare our defence. Time is not on our side. It is not our friend. We think this is recognised. The AUKUS trilateral security partnership hit another major milestone last December when legislation to enable the AUKUS agreement passed the US House of Representatives. This is a major achievement. It was not easy to get this done. We need to recognise this effort and thank those who negotiated our way through the complexities of the House. The legislation enables the sale of a minimum of three Virginiaclass submarines to Australia, eases export controls, and allows Australian defence contractors to undergo training in the United States. The AUKUS partnership further propels us into a new era, demanding a substantial boost in capability, infrastructure, workforce and industrial capacity to support nuclear-powered submarines. AUKUS Pillar 2 technologies require rapid adaptation, innovation, and acquisition at an unprecedented pace. In times of potential conflict, a robust industrial sector becomes increasingly critical, ensuring the swift mobilisation of resources and the smooth operation and support of defence capabilities. In this context, at a very important time for Defence and the Australian defence industry, Ai Group has joined with the Strategic and Defence Studies Centre at the Australian National University to launch a major new report: Defence Industry in National Defence: Rethinking the future of Australian defence industry policy. The Australian Government has adopted the concept of ‘National Defence’ as a new approach to Australia’s defence planning and strategy. As our Report notes, while many reforms will be required to implement this concept, building and maintaining Australia’s defence industry capability is one of the most important. The Defence Strategic Review calls for building enhanced sovereign defence industrial capacity in key areas, but it is largely silent on what kind of defence industry this requires, or how these requirements can be met. Our report focusses on these key questions. Industry must be a fundamental element of National Defence, deeply embedded in that concept and the underpinning defence planning and strategy. We have no option and no alternative. To inform the role of industry as a fundamental part of National Defence, the Report draws on observations from five peer countries: Canada, France, Israel, Sweden and the United Kingdom. The case studies identify how other governments think about the role of industry in defence, and how industry capabilities are built to meet government requirements.
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A key recommendation of the Report is that the Australian defence industry should be considered a capability in its own right, and an important underpinning of National Defence. Rather than being seen as a resource that can be captured separately in a stand-alone policy, industry should be considered a capability that supports the force-in-being, but whose strategic value also lies in the ability to expand and rapidly scale to meet operational needs in times of conflict. Secondly, Defence industry should be embedded within and managed as part of Australia’s broader national industry structure and policy. Since 2022, a suite of new industry policies has been announced by the Commonwealth Government, including the $15bn National Reconstruction fund, which correctly and pleasingly identifies Defence as one of its priorities. However, our defence industry should not be considered as ‘just another sector to be targeted by industry policy’. Previous major conflicts have shown that integration with broader civilian industry is required if production at scale is to be achieved. In a time of conflict, or looming or potential conflict, that is what we want and need. Scale. Scale is essential if we are to be able to quickly develop the capability we need to meet the challenges we face. Embedding Defence industry in this way into Australia’s broader civilian industry capability is crucial. This is even more crucial as we move further into the age of digitalisation where speed and the ability to manage complexity are paramount – think big data analytics, cloud computing, advanced robotics and, of course, artificial intelligence. If we are to compete and win, we must develop, train and empower industry and its workforce in the skills of the now and the future. In the world we live in, we have no alternative. We believe this report is a crucial point in the decision-making process on how we defend and protect ourselves. It contains important recommendations in relation to: •
strategic prioritisation of critical defence industries, with the ability to scale these areas through co-ordination of programs; • the development of export markets and building international partnerships; • Government use of the full range of policy levers to shape defence outcomes and strategic partnering arrangements; and finally • appointment of a Defence industry capability manager – a defence industry czar if you will – to define the capability and capacity of the industry the Government needs to develop. This role must be held by a person who knows industry and defence and who recognises the need for speed to get the two to work together now and into the future as our strategic environment invariably evolves. In summary, the Report seeks to initiate a national conversation on reshaping Australia's defence industry policy in this time of strategic uncertainty. There could be no matter of greater importance than equipping the men and women of the ADF with the best capabilities, and we need a powerful Australian defence industrial base to support just that. The Ai Group / ANU Report is available at the following link: aigroup.com.au/news/reports/2023/defence-industry-innational-defence/ aigroup.com.au
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016
FROM THE UNION DAVE HENRY – Acting National President Australian Manufacturing Workers Union
Christmas present Same job, same pay laws make our industry’s workplaces more secure. Workers received an early Christmas present when Parliament passed the first part of the Closing Loopholes Bill last December.
pockets of workers to prop up its profits, which came in at an eyewatering US$12.9bn last year.
Given the overblown scare campaign mounted in the lead up to it, there was no guarantee we were going to see same job, same pay laws passed by the end of the year. It was a timely and welcomed development as workers continue to struggle in a cost-of-living crisis. Same job, same pay laws provide an important safety net for workers who have faced increasing job insecurity and moves to consistently drive down wages and conditions for more than a decade.
What has been lost amidst a debate framed in these terms is the net benefits to industry of these new laws, particularly for employers who want to do right by their workers.
Manufacturing workers have experienced firsthand the corrosive effects of exploitative labour-hire practices and shonky employment arrangements, used to undercut wages, conditions, and the ability of workers to bargain effectively in their workplaces. These new laws, which will be phased in over the course of the coming year, will work towards stopping companies from underpaying workers through the use of labour-hire providers and criminalise intentional wage theft, creating a more level playing field for those employers doing the right thing. They also introduce a new criminal offence of industrial manslaughter and improve protections against workplace discrimination for workers subjected to family and domestic violence. ‘Same job, same pay’ was a union catchcry when I was on the tools. Then, just like now, there was no justification for a worker doing the same job on the same site, on the same roster, and under the same supervision to receive a lower rate of pay. It has always been about ensuring workers get a fair go. Companies like BHP spent millions of dollars telling us how much they don’t want these laws. Yet, when the mining giant complained that same job, same pay laws would cost it more than $1.3bn, it was effectively admitting just how much it had taken out of the
AMT FEB/MAR 2024
These laws will shape business decisions, including the nature of our work and the kind of jobs we are creating. Removing the ability of dodgy labour-hire providers to offer a lower wages bill, we will see more directly employed, secure and better paid jobs. Just recently, Downer, a major rail manufacturer in NSW, terminated its on-site agreement with a labour-hire subsidiary it had owned and operated in order to undercut wages. And we know that when employers show they value their workers and workers feel secure and are able to establish roots in the local community, this has a positive knock-on effect via improved workforce retention and productivity, and the realisation of greater returns from investment in capital and personnel. Closing the loopholes that allow for wage theft and exploitation sends a clear signal that this kind of business model is done. The cost of doing business is to pay workers properly. After years of insecure and underpaid work, manufacturing workers will be looking forward to the improvements this will bring in their working lives. We’re going to see a lot of positives come out of these changes, including the security that comes from permanent, direct employment. That kind of job security makes it easier for workers to get a loan or find a place to rent and call home. It also makes it easier to speak up at work and ensure that our workplaces are safer for everyone. Same job, same pay is a win for both workers and industry. amwu.org.au
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GOVERNMENT NEWS
RSM report Government contracts needed for manufacturing sector to compete on global level. Australian advanced manufacturing can only compete globally with a quantum increase in funding and government contracts, and the National Reconstruction Fund (NRF) alone may not be enough to achieve this, according to a report by national professional services firm RSM Australia. RSM’s Innovate, Transform & Thrive: Securing Manufacturing Industry has four recommendations:
Australia’s
•
The level of funding and number of government contracts for advanced manufacturing must increase; • The NRF must direct funding to critical industries where Australia has a competitive advantage and for meaningful impact provide substantially larger amounts to targeted companies; • Consider implementation of Australia-first supply chain requirements for major projects and mandates for majorityowned Australia companies to support local manufacturers; • Reinstatement of the instant asset tax write-off to provide greater incentive to purchase capital equipment and machinery. This would encourage manufacturers to modernise, which could support decarbonisation, productivity and advanced manufacturing processes. RSM Australia’s national leader manufacturing services, Jessica Olivier, said the backdrop to parliamentary hearings into Developing Advanced Manufacturing in Australia is a broader debate about the best way to fund and support the manufacturing sector, and who within the sector such funding should target. “More government investment into manufacturing must be made if we are to truly embrace local manufacturing capability and boost the number of Australian-made goods,” Ms Olivier said. “Australia needs to model the US which is investing heavily in local manufacturing and pushing green technologies to grow its manufacturing capability. “More clean-energy manufacturing facilities have been announced in the last year in the US than in the previous seven years. This translates to well paid jobs and a massive boost to climate change initiatives that can reshape a nation.”
Back winners, don’t spread investment too thinly While NRF funding detail is still unknown it should be significant for manufacturing, especially in its target sectors of critical technologies, renewables and advanced manufacturing. “A note of caution is that NRF funds pale in comparison to US and EU allocations for manufacturing, even considering size differences,” she said. “It’s notable the US “Bidenomics” flagship initiative, the Inflation Reduction Act focusing on climate, clean energy and manufacturing, is a $US740b investment, contrasted against the NRF’s $15bn budget. Olivier called on the NRF board to be bold, now that its very experienced board has been announced. “The finer details of their first tranche of funding will reveal a lot about whether Australia can take up the challenge to be a world player in advanced manufacturing. Given the intention to unlock funding for strategic projects in Australia’s interest, I’m hopeful the NRF board will accept moderately higher risks than their commercial and private counterparts, in exchange for broader economic benefits that other funders would not normally consider,” she said. She agreed with the Business Council of Australia’s suggested strategy for the Federal Government to pick and back compelling ‘winners’ (rather than giving many companies relatively smaller
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$1-2m tranches). This strategy was reiterated by Peter Gilmour, CEO of Gold Coast business Gilmour Space at the Advanced Manufacturing hearing in July. Olivier said Gilmour spoke passionately about the need for funding to be ambitious and for the government to try to ‘pick winners’ such as space manufacturing rather than spreading funding too thinly. He also emphasised the need for government support via contracts. “I’d support more government contracts, as this would improve the sector’s competitiveness and capability - but grant funding and other government incentives still play an important role,” Olivier said.
Decade of transition for manufacturing She said food and beverage, machinery and equipment, defence and resources and increasingly advanced manufacturing are transforming Australia’s manufacturing industry. Post-Covid, manufacturing businesses globally have innovated at unprecedented speed to stay relevant. This has made government support for R&D more crucial than ever for innovation, Olivier said, in light of a dip in the level of innovation across the Australian economy. “GDP percentage spending on innovation in Australia has dropped from more than 2% to around 1.8% – an anaemic level that gives lie to Australia’s much talked about ‘world leadership’ in areas of technology. The US has passed legislation outlining 3% spending on R&D, and nations such as Israel and Sweden spend more than 4%,” Olivier said. The RSM report also highlighted the need to continue international agreements to embed Australian manufacturing within global supply chains. “Some trading partners, including the US and EU, support their local manufacturers first, creating an uneven playing field. The Federal Government should consider Australia-first supply chain requirements for its major projects, along with mandates for majority-owned Australian companies to support local business,” she said. Olivier said the other major initiative that was important for Australia to compete with other OECD countries was tax reform. “Targeted government investment and incentives such as reinstating the instant asset write-off, raising investment in specific advanced manufacturing niches, continued R&D benefits and overall tax reform are needed for Australia to thrive in the developing net zero global economy,” she said. “The previously proposed Patent Box regime was also a very attractive proposition for large Australian manufacturers, which sadly seems to have been abandoned by the current government. Developing and implementing green energy technologies at scale to capitalise on our natural resources and existing skills in mining is also crucial in the next decade for manufacturing.” rsm.global/australia/
GOVERNMENT NEWS
Closing Loopholes Government ‘Closing Loopholes’ Bill clarifies labour hire proposals for manufacturers and engineering projects. Australian Resources & Energy Employer Association (AREEA) welcomes amendments to the Government’s “Closing Loopholes” Bill introduced to Parliament today, confirming service contractors will be exempt from labour hire proposals. Just recently, AREEA signed off on amendments negotiated with Workplace Relations Minister Tony Burke that would prevent the Fair Work Commission from making a “Regulated Labour Hire Arrangement Order” (RLHA Order) where the performance of work is for a service rather than labour hire. While some of this goes into the reeds of workforce labour conditions and amendments to work rules, under those amendments, representing substantial concessions from the Government: New subsection 1A means the consideration of whether performance of work is for provision of a service rather than supply of labour is now a jurisdictional threshold issue for the FWC. As a result, the “contractor test” sits outside the broader considerations of whether it is “fair and reasonable” to make an order, and instead is a standalone objective issue. Subsection 1A removes the overwhelming burden of proof that previously sat with service contractors. It is now incumbent on the FWC to be satisfied that an arrangement is not for a service before it can proceed with an order. The term “wholly or principally for provision of a service” has been amended to simply “for provision of a service”, meaning the FWC will form a view on balance of probabilities rather than requiring to be convinced work is for a service. To inform its view the FWC must have regard to a simple five-point multifactor test that focuses only on the facts of the relationship between the employer and its employees, and how the work is performed. The highly problematic sixth factor that sat in the previous test, which would have allowed the FWC to consider the workforce practices of the client/host utilising the service, has been removed entirely. The effect of these changes is noted in the Explanatory Memorandum to the amendments: This amendment would provide that … the FWC must not make a regulated labour hire arrangement order unless it is satisfied that the work performed by employees of an employer is not or will not be for the provision of a service, rather than the supply of labour. AREEA chief executive Steve Knott AM said the amendments reflected a carve-out for service contractors in all cases where the service being provided was not traditional labour hire. “AREEA’s multifactor test provides more certainty than a definition of labour hire, and gives service contractors five clear criteria to rely upon to demonstrate their service is not labour hire,” Knott said. “It was important the negotiated carve-out directed the FWC to consider the reality of the arrangement having regard only to the criteria in the multifactor test and not other arguments unions may run including on the workforce arrangements within the client’s business, or other practices in the industry. “Under these changes, if an application is made against them, service contractors will not have to litigate out of an order. Rather, they will simply have to file a submission to the FWC to assist it in informing its view, as per other functions of the IR system.” Notwithstanding AREEA’s success in negotiating a clear service contractor exemption, amendments tabled today revealed other concerning developments in relation to the labour hire provisions.
This includes an apparent expansion of the FWC’s jurisdiction to consider joint venture and “common enterprises”, as well as to effectively make “multi-employer” orders capturing a number of employers supplying labour to a host business via one application. “The service contractor exemption will apply equally to these new processes, but AREEA’s firm position is applications should be considered carefully by the FWC on a case-by-case or employerby-employer basis,” Knott said. “Service contractors should not be roped into proceedings that may involve traditional labour hire companies or attempts to cover all employers operating at one site under a common order. “AREEA’s approach to consult with members and represent their views directly with the Government will continue, including over these new concerns.” areea.com.au
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Quantum Optical An upgraded optical ground station will be established at the Australian National University’s Mount Stromlo Observatory in the ACT to support future NASA crewed missions to the moon under the Artemis program, and onwards to Mars. The ANU Quantum Optical Ground Station is a telescope that will support high-speed advanced communications with satellites from low-Earth orbit to the Moon and other deep space laser communication. It will also support future research on advanced communications technologies, providing satellite networks with quantum security and global connectivity. With support from the Australian Space Agency’s (ASA) ‘Moon to Mars’ initiative, the station is being upgraded with the latest optical technology that will enable communication between the station and future NASA-crewed missions beyond low-Earth orbit. The station received major funding from the ACT Government’s Priority Investment Program with additional support from the Australian Space Agency, CSIRO and TESAT. ACT Chief Minister Andrew Barr labelled the ground station as a key national asset that positions Australia and the Indo-Pacific region to collaborate and compete on the global stage. “Canberra has the capabilities to support space industry success and to take advantage of the enormous investment being made globally in space, through our growing knowledge economy,” Barr said. “The ANU Quantum Optical Ground Station is another of the ACT’s strategic space sector co-investments that will enable competitive advantage for Australia’s space industry, attract talent from researchers, academics and industry to the ACT not only to help our economy continue to diversify but to equip industry with vital infrastructure to innovate and grow.
“The ACT Government is proud to have supported this ambitious project through our Priority Investment Program.” Associate Professor from the ANU’s College of Science Francis Bennet said the ground station was the preeminent technology of its kind in Australia. “Using lasers, the ground station will allow us to communicate with satellites and crews hurtling through space, supporting major crewed space missions and future space exploration,” he said. “We have built systems that are cutting edge in their capability, and upgrading them to be compatible with NASA missions that will help permanent operations on the Moon, and improve astronauts’ ability to connect back with Earth and allow high-definition video from the Moon and Mars.” Director of the ANU Institute for Space Professor Anna Moore said the optical ground station was a stellar example of how ANU and Australian research was making major contributions to the future of space technology and exploration. “It’s really exciting to see this new technology that will play a pivotal role in major future space missions come online,” Professor Moore said. “With this technology, we will also be able to better access unused data and information about the universe.” “We are thrilled that this station is now built and excited about the pivotal role it will play in our exploration and understanding of space. We look forward to working with our project partners on this nation-leading technology for many years to come.” anu.edu.au
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INDUSTRY NEWS
Osborne Naval Shipyard Australian hull steel for Australian SSN-AUKUS Nuclear-Powered submarines. Australian-made steel will be used in the construction of Australia’s conventionallyarmed nuclear-powered submarines built at Osborne Naval Shipyard, South Australia, subject to a comprehensive qualification process. The Australian Submarine Agency has entered into a contract with Australian steel manufacturer, Bisalloy Steels, for the qualification of Australian steel for use on Australia’s future SSN-AUKUS submarines. “The qualification of Australian steel is an important step in the Australian Government’s strategy for acquiring stateof-the-art conventionally armed nuclearpowered submarines,” said Australia’s Minister for Defence Industry, the Hon Pat Conroy MP. “The strength and quality of Australian steel will keep Australian submariners safe in the SSN-AUKUS nuclear-powered submarines for decades to come, just as it does today on our Collins Class submarines. Crucially, this contract will support jobs in an industry which is not only of strategic importance but also a source of innovation and employment, and part of the Australian fabric.” “The $15m contract will put Australian products at the forefront of our submarine construction,” added Minister Conroy. The comprehensive qualification process, involving more than 4,500 tests, is expected to be completed in the first half of 2025. “We are committed to supporting Australian industry support the AUKUS trilateral supply chain.” Bisalloy Steels will perform the advanced heat treatment process on the raw plate steel to produce high grade submarine pressure hull steel that meets or exceeds both
the UK and US standards. The raw plate steel will be supplied by another Australian company, BlueScope. The qualification of the steel to both the UK and US standards will increase the resilience of the AUKUS trilateral supply chain. Not only will the steel produced under this contract be used for qualification purposes, it will also be used to develop the necessary welding procedures, and used in early production demonstration activities occurring ahead of the commencement of construction of Australia’s first SSN-AUKUS submarine later this decade. The AUKUS partnership presents one of the biggest uplifts in Australia’s industrial and defence capability in our history. The signing of this contract is a clear demonstration of the progress being made on, and the Albanese Government’s commitment to the construction of conventionally armed nuclear-powered submarines in Australia and support for future Australian jobs. minister.defence.gov.au
Titomic and Starke Titomic has entered a strategic manufacturing partnership agreement with Stärke Advanced Manufacturing Group. The collaboration brings together Titomic, a leading manufacturing technology company, and Stärke, a global advanced manufacturer headquartered in South Australia. Stärke, comprising a network of vertically integrated advanced manufacturing companies, is renowned for assisting diverse industries in producing complex, high-performance components.
moulding solutions, we will deliver innovation to clients in sectors like defence, aerospace and automotive, offering a range of competitive manufacturing capabilities.”
With clients including DSTG, Babcock, Boeing, and Thales, Stärke is known for delivering robust and reliable solutions. The partnership’s primary objective is to harness the strengths of both Titomic and Stärke in advanced manufacturing technology.
He said the partnership will also look to provide solutions to clients in high-performance sectors such as defence, aerospace and automotive. The announcement of the new collaboration comes less than a week after Titomic reported it had recorded its inaugural sales to the mining industry and into the US.
Leveraging Stärke’s industry connections and expertise, the collaboration aims to provide innovative solutions to clients in highperformance sectors such as defence, aerospace, and automotive. “This venture promotes knowledge exchange between Titomic and Stärke, allowing us to blend our strengths and explore new applications,” TTT Managing Director Herbert Koeck said. “We are thrilled about our partnership with Stärke, a global leader in advanced manufacturing and a partner which shares our commitment to manufacturing innovation,” Koeck said. “This collaboration is set to accelerate Titomic’s growth, thanks to Stärke’s deep industry expertise and network. This venture promotes knowledge exchange between Titomic and Stärke, allowing us to blend our strengths and explore new applications.” “By combining Titomic’s advanced manufacturing tech with Stärke’s advanced manufacturing and renowned tooling and
“This partnership positions us to meet the ever-evolving needs of our clients efficiently and effectively, staying at the forefront of innovation in the manufacturing industry.”
The company is celebrating the sale of two D523 low-pressure cold spray systems – one in Kalgoorlie, Western Australia and the second in Texas – with a combined value of $198,829. Koeck said the sales represented a significant milestone for Titomic and marked a pivotal moment in the company’s expansion into new markets. “The successful sale of our D523 systems in WA and Texas marks a significant stride in our strategic plan to enhance our footprint in essential industries.” “As we move forward, we are excited to continue championing the growth and efficiency of industries, particularly in mining, through our innovative and transformative manufacturing technologies.” Stärke Co-Founder & Group CEO Al Jawhari also stated, “Titomic’s revolutionary cold spray technology will offer our clients an impressively efficient turnkey solution.” titomic.com
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Quantum quandry A major industry review has found that quantum technologies represent a massive opportunity for Australia, but strong global competition and a scarcity of talent will hamper growth in the sector. Quantum technologies represent a massive opportunity, but strong global competition and a scarcity of talent will hamper growth in the sector in Australia, a major industry review has found. Australia’s nascent quantum sector sees the technology as a massive economic opportunity with the potential to be gamechanging for a variety of industries. However, industry players say strong international competition, a scarcity of talent, a lack of domestic investment firepower and industry capability will likely hamper Australia’s ability to truly commercialise quantum applications onshore. The National Quantum Industry and Workforce Development Review, published today by Sydney Quantum Academy, is based on a year-long survey of Australia’s nascent quantum industry. Relying on in-depth interviews with key organisations as well as qualitative and quantitative research, it represents of the first overviews of an emerging local sector projected to be worth $2.2bn and employ almost 9,000 Australians by 2030. Sydney Quantum Academy is a joint venture between University of Sydney, UNSW Sydney, Macquarie University and the University of Technology Sydney, and supported by the State Government of New South Wales. “This gives us some useful insights into the national industry and its expectations,” Prof Peter Turner, CEO of the Sydney Quantum Academy (SQA), a partnership between four Sydney universities and backed by the NSW Government. “It confirms some of our internal thinking, particularly on the education front.”
Wide range of industries surveyed It surveyed both start-ups developing quantum technologies as well as potential users across various industries, including aerospace, banking and insurance, chemicals and energy, health and life sciences, logistics and information technology. It also sought input from industry associations, local offshoots of international companies, as well as Federal and State Government instrumentalities. Respondents considered Australia to have strong levels of research expertise and nucleus of respected global thought leaders, as well as universities with high quality talent and accomplished education programs, particularly in PhD and Master’s programs.
Quantum computing the lead technology Quantum computing was identified as the main quantum technology under development, and the one of most interest to potential users. This was led by computing hardware and high-level software (eg. algorithms and applications), followed by low-level software (control, error correction and fault tolerance). Almost onethird of local quantum companies said they also supply expertise in quantum communications, cryptography or sensing; while quantum simulation, imaging and metrology was at lower levels. A wide range of industries said they are exploring quantum technologies. And almost half of Australian quantum technology developers said they supply to clients in the innovation sector, followed by information technology; then banking, finance and insurance; with quantum technology for defence in the top five. Potential users cited quantum computing as the type of quantum technology they are most likely to use: 78% said they will have a use case for quantum technologies in their business in the next five years, and that it would likely occupy two-thirds of their organisation’s focus on average. Only 22% of potential users said no quantum technology is likely to have a use case in their organisation in the next five years.
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More PhDs needed, but also more business nous While both technology developers and potential users see a strong need for ‘quantum specialists’ (scientists with PhDs in physics, chemistry, mathematics or computer science), a growing need was identified for ‘strategists’: business executives with a sophisticated understanding of quantum technologies to help develop business priorities and opportunities. Another growing need was for ‘technology translators’: graduates with a background science, engineering or software development who can take quantum technologies and turn them into products or solutions. Both quantum technology suppliers and potential users said there’s a clear need for more ‘commercial’ skills among quantum graduates, such as design thinking, scenario planning, financial forecasting and risk assessment. For the industry to mature, potential users said that more individuals in business need to see uses for quantum solutions and understand the basics of when and how they can be used.
Hard science skills in demand Demand for quantum skills – such as physics, chemistry, mathematics and engineering – will continue to be in high among quantum technology suppliers. In software, there was a marked demand for skills in the Artificial Intelligence (AI), Machine Learning (ML) and Algorithm Development and Software Development, including programming. But there is also expected to be a marked priority for non-technical fields, such as Business Development, Product Development and Project Management. For potential users, the focus is primarily on classical software, with AI/ML/Algorithm Development and Systems Architecture the priorities. The second biggest priority is non-technical, eg. Business Development, Product Development and Business Analysis. Much less interest in hard quantum skills, except where they can apply to Device Modelling/Simulation or Quantum Algorithm Development.
Future industries The report found that about one-third of the industry operating in Australia have less than 50 employees, while just under 50% have 1,000 or more employees. For organisations with global offices, just over 50% have 1,000 or more employees, versus 25% with less than 50 employees. Future industries that suppliers intend to provide quantum technologies were led by government and agriculture primarily; followed by transport, telecommunications, pharmaceuticals and medical or life sciences; with energy, resources, utilities, chemicals and business services as among the least focus. sydneyquantum.org
INDUSTRY NEWS
CSIRO mines closure CSIRO report reveals pathways to sustainable mine closures and economic growth in Australia. Australia has a unique billion-dollar opportunity to create a new industry to support mine closures and transitions, generating employment opportunities for regional and Indigenous communities, according to a new report developed by the national science agency, CSIRO. New insights drawn from mining industry databases and CSIRO analysis project an annual expenditure exceeding $4bn on mine closure and rehabilitation activities, as around 240 Australian mines approach closure by 2040. These closures generate a growing demand for innovative solutions and technologies capable of leading mines towards closure, while addressing the associated diverse environmental, social, and economic challenges. The report ‘Enabling Mine Closure and Transitions: Opportunities for Australian Industry’ was delivered for the Cooperative Research Centre for Transformations in Mining Economies (CRC TiME). It explores opportunities for Australian businesses to provide solutions to the challenges posed by mine closures, such as equipment, technology, and services. Dominic Banfield, Senior Manager in CSIRO Futures and lead author of the report, emphasised the continued critical role of mining in Australia’s economy, contributing to jobs and essential minerals for the country’s energy transition and net-zero emissions goals by 2050. “With thousands of active and inactive mines in Australia, the demand for mine closure solutions will only increase as we seek
to ensure positive closures and to transition regions to successful post-mining futures,” Mr Banfield said. The report identified opportunities across four categories of mine closure solutions: •
Engagement and partnership: Solutions that enable effective engagement, co-design, and mutually beneficial partnerships to improve social performance and reduce risks. • Waste reduction and recovery: Solutions enabling costeffective reduction, reuse, and recycling of mine waste to minimise closure liabilities. • Mine rehabilitation: Solutions improving the performance and cost-effectiveness of mine rehabilitation activities. • Land use transitions: Solutions addressing challenges in establishing post-closure land uses to generate lasting economic, social, or environmental value. Dr. Guy Boggs, Chief Executive Officer of CRC TiME, underscored the additional social, economic, and environmental value stemming from a mine closure solutions industry. “The report's comprehensive mapping highlights opportunities in engagement and partnership, waste reduction and recovery, mine rehabilitation, and land use transitions, showcasing the diverse spectrum of possibilities,” Dr Boggs said. “Looking ahead, we believe Australia can harness its domestic mine challenge to emerge as a global leader in cutting-edge mine closure solutions.” csiro.au
Precision Engineering Centre Mawson Lakes showcases its $10m precision optics treasure chest. A $10m manufacturing treasure chest has been unveiled at the University of South Australia with the official opening of the Precision Engineering Centre, showcasing new advanced optics capabilities that will transform a range of industries. The centre – housing lab-on-a-chip technology, micro and nano-machining equipment, advanced sensing and state-of-theart precision optics capabilities and expertise – is the only one of its kind in the Southern Hemisphere, placing Australia at the forefront of advanced manufacturing. The result of a decade-long collaboration between the SA Node of the Australian National Fabrication Facility (ANFF-SA) and the Research Engineering (RE) team at the Defence Science and Technology Group (DSTG), the centre is literally at the cutting edge of defence manufacturing. Among its recent creations is the largest diamond-turned mirror in Australia, made with a multi-axis, ultra-precision machining system, and some of the tiniest sensors which are helping to secure the future of South Australia’s advanced manufacturing sector. The pioneering precision engineering facility is transforming a range of sectors of strategic national importance including defence, health and medical fields, manufacturing, mining, recycling and clean energy, water security, space, and agriculture. UniSA Deputy Vice Chancellor: Research and Enterprise, Professor Marnie Hughes-Warrington AO, says that UniSA is proud to
help advance Australia’s defence manufacturing sovereignty through DSTG’s Capital Refresh Program which is providing researchers with ultra high-end fabrication and test equipment. “The dynamic 10-year partnership between ANFF-SA and DSTG’s Research Engineering team has consistently demonstrated innovative solutions to mitigate risks associated with new technology,” Prof HughesWarrington says. “The collaboration extends well beyond any physical infrastructure. It encompasses top-tier technical expertise and the cultivation of emerging talent, with a mutual desire to be trailblazers.” DSTG RE Program Leader Ben Barona says the collaboration with ANFF-SA is positioning the State as a global leader in innovative manufacturing. “Combining ANFF-SA's expertise and capabilities with DSTG's science and technology applications, we've developed a truly integrated fabrication and testing capability with the Precision Engineering Centre. This paves the way for novel technologies and significant advancements in space optics and complex rapid prototyping,” he says. “ANFF-SA's industry collaborations have also been pivotal, contributing to a significant boost in research capability and fostering an expanding local skills base.” The Centre, which is supported by UniSA and State and Federal Governments, was officially opened at UniSA’s Mawson Lakes campus in December. anff-sa.com dst.defence.gov.au
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Who's leading in sustainable manufacturing? Who's leading in sustainable manufacturing? Analyst commentary by Alex West, Senior Principal Analyst, Omdia. Sustainability topics have continued to rise to near the top of the agenda for many manufacturing CEOs. More and more we are seeing their commitments published along with their investment in delivering environmentally sustainable business. But how well are companies doing, what else can be done, and who’s setting the example? Following SPS 2023 earlier this month, the annual gathering of the manufacturing industry, Alex West, Senior Principal Analyst in Omdia’s Manufacturing Technology practice takes a closer look at sustainable manufacturing in his latest analyst commentary. According to a recent Omdia survey 30% of manufacturers describe themselves as having implemented an environmental strategy with a long-term road map, and this is estimated to increase to 42% over the next 12 months. Companies are allocating additional budget to support these such projects. Target setting is also on the up. In the first six months of 2023, the number of manufacturers having committed to Science Based Targets (SBTis) for emissions reduction increased by 40%. However, whilst the focus is fixed and intentions are intensifying, the reality of the size of the challenge is only becoming more apparent. Decarbonization of the manufacturing sector is proving more challenging than many expected. According to Omdia more than 40% of companies are slightly or significantly behind target when it comes to reductions in greenhouse gas emissions. The delay is even more significant in transitioning to renewable energy, with 47% not expecting to meet the targets that have been set. Over the last year the proportion of companies falling behind has only increased. The focus on the availability of near limitless renewable energy has been misinterpreted to reflect availability by some. And with challenges in not just the intermittency of the energy source, but also the limitations around infrastructure readiness and integration capacity, companies cannot simply rely on decarbonizing their energy source and must look internally at how to improve their usage of energy. A combination of existing and new technologies will be central to facilitating these improvements, with industrial automation vendors
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playing a key role in offering solutions across hardware, software and services they can provide. With industrial electric motors consuming over seven quadrillion KWH of electricity each year vendors can support customers with both more efficient motors (see the ongoing trend higher efficiency IE4 and IE5 motors), as well as motors drives specified for the optimum energy efficiency. Proper operation and monitoring of hardware from pumps to bearings through condition monitoring solutions is also important in ensuring maximum efficiency. Beyond this the range of solutions, including energy management and emissions monitoring systems, as well as analytics tools to optimize process control, improve waste management, coordinate across a vendor ecosystem an consider and balance the needs for sustainable operations with business profitability. The leading industrial automation vendors are not only offering such solutions commercially, but also have unique access to trials and apply it to their own business in order to address their own environmental footprint. But how do they compare? Omdia recently completed an analysis of the environmental footprint of the top 50 industrial solutions vendors here (registration required). From this data, a subset of the ten largest industrial automation providers were analyzed. Results were mixed, some companies had limited reporting, whilst there was also significant variance in results across companies for some ESG metrics. The biggest variations across companies were in the metrics of water intensity (the amount of water user per $million), renewable energy as a proportion of total energy, and owned emissions (Scope 1+2), whilst the difference in waste intensity and energy consumption intensity. One should bear in mind that all of these companies are different, and for some industrial automation is one division of many in the company. Leaders in the headline statistics of energy intensity, owned emissions and renewable energy (as a proportion of total energy) were Rockwell Automation, Siemens, and Schneider Electric respectively, with these companies also scoring significantly better than their peers in aggregate as well. omdia.com
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Infor on AI A look at how AI and automation is set to drive the e-commerce revolution, by Matthew Addley, Industry Strategist – Manufacturing, Infor.
E-commerce sales in Australia have soared over the past few years. It is estimated that retail sales in Australia could amount to $602bn, with 19% of retail attributed to e-commerce by 2027. Lockdowns and the subsequent rise in online shopping has clearly accelerated this technology shift. Manufacturers are leveraging automation to scale quickly and eliminate supply chain bottlenecks to meet growing consumer demand. From drones to robotic process automation (RPM), technology is pushing manufacturers to challenge conventional ways of doing business. This is a far cry from legacy global manufacturing business models that were centred around physical factories in countries where labour costs were cheap. It made sense when global supply chains were efficient and cost effective. Today, with vessel shortages and soaring shipping costs, companies have recognised the benefit of moving manufacturing closer to customers – and are reimagining how their factories operate. Australian manufacturers in particular are increasingly relying on automation to transform manually driven warehouses and distribution centres into more automated ones. End-to-end manufacturing automation solutions, along with warehouse mobility, traceability, and tools for tracking labour and time – have emerged as disruptive new technologies. Automation is designed to give companies the visibility and insight to understand true costs, improve cycle times, and respond to customer expectations for on-time delivery. This helps streamline production, improve the pace of inventory operations, and keep labour costs in control. We have especially seen this in fashion e-commerce, which has adopted automation to drive transparency across the value chain and improve sustainability. Modern ERP solutions provide manufacturers with new capabilities to manage evolving business models and improve end-to-end visibility, ultimately reducing the product development time by nearly half. Furthermore, the advent of modular robotics, whether RPA or physical robots, are revolutionising supply chains by reducing costs and improving efficiency. The Australian Manufacturing Week in Melbourne earlier this year showcased some of the latest innovations to digitise the manufacturing process. It was interesting to witness the uptake in the deployment of advanced technologies among Australian manufacturers. Robots are obviously especially useful when transitioning from complex low volume to high volume tasks. Equally, using people to supplement automation
is critical. A blended approach to automation that integrates the best of human skill and intelligence with the efficiency of AI and technology is the future. We have seen chatbots being used very effectively to resolve consumer issues. But even though chatbots can be programmed to respond to most customer queries, manufacturers can only rely on a limited amount of predictive analysis. This is where a blended approach is most effective. It is about recognising the intelligence and agility that robots offer and integrating that with what people bring to the table. Additive manufacturing and 3D printing represent the next frontier in automation. Both improve operational flexibility and agility, while generating value not only from a local production perspective, but also from an aftermarket perspective where instead of having hundreds of units all around the world, manufacturers can produce on demand and according to a specification. This means service depots are more self-fulfilling than they were in the past. As more manufacturers embrace automation, sustainable practices, and the nearshoring of facilities, we are witnessing smart factories becoming increasingly common. For instance, Infor partnered with Deloitte to open The Smart Factory @ Wichita on the Innovation Campus of Wichita State University to help manufacturers explore use cases for innovative technologies and to transform their facilities into smart factories. The best part about advanced automation capabilities like smart factories is that it can help manufacturers overcome supply chain disruptions. Automating tedious and repetitive processes also means that employees can be re-deployed to more complex tasks that require critical thinking. Digital transformation will be critical for Australian businesses set to scale in the medium term as consumer spending and energy exports pick up pace. To accelerate their operations, build resilience and enhance their workforce capabilities, manufacturers will have to invest in future-proof technology that offers unprecedented visibility into the supply chain. Meanwhile, customers expecting faster delivery times, easy returns processing and personalised marketing as they move away from brick-and-mortar stores, are also likely to keep manufacturers on their toes. infor.com/en-au/manufacturing-industries
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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY
Navigating diversity and retention challenges Hunter Executive Search Consultants leads the way in heavy industries. In the exciting world of heavy industries encompassing Manufacturing, Engineering, Construction, Infrastructure, Mining & Resources, Energy, Oil & Gas, Defence, Government/Not-for-Profit, Environmental and more, Executive roles are vital. The successful recruitment and retention of these leaders play a pivotal role in an organisation's growth and stability. Hunter Executive Search Consultants, a prominent Australian recruitment firm, has recently conducted a survey among registered executives, shedding light on the diversity and retention challenges faced in these sectors. "In the dynamic landscape of heavy industries, executive roles are vital for organisational growth and stability. With 78% supporting equal career growth and a call for improvement due to the 33% facing gender bias, our expertise in attracting and retaining top executive talent is more valuable than ever in navigating these complexities,” said Jayde Stokes, a Regional Manager at Hunter. “I am passionate about building diversity across heavy industries, particularly within the executive space as that’s where change starts.”
Key survey findings: Executive tenure: Out of 377 responses from executives in heavy industries, 35% have been in their current roles for one to three years. This highlights the significance of executive retention. A large proportion of these executives are relatively new in their positions, underscoring the importance of efficient executive search processes to ensure long-term commitment to their roles. New appointments: The survey revealed that 17% of executives had been in their roles for less than six months. This indicates the constant need for effective recruitment processes to manage the influx of new leaders driving change within these sectors. Long-term commitment: Only 4% of executives reported being in their roles for more than ten years. This suggests that executive turnover is notably high in heavy industries, emphasising the critical nature of making the right executive placements. Gender diversity: The survey unveiled a substantial gender gap, with 18% of executives identifying as female. This statistic, though promising, underscores the need for greater efforts to promote gender diversity within traditionally male-dominated sectors. Job mobility: An eye-opening 73% of surveyed executives are considering changing roles in the next 12 months. This signals a need for organisations to create the right culture for executives, as well as offering competitive salary and benefits, work-life balance, professional development opportunities, a positive company culture, and meaningful relationships with colleagues and superiors. Equal opportunity: An encouraging 78% of respondents believe that their current employers provide equal opportunities for career growth and advancement regardless of gender. This is a testament to the evolving attitudes towards gender equality in heavy industries. Gender bias and discrimination: However, 33% of respondents have personally experienced or witnessed instances of gender bias or discrimination at the executive level. This statistic indicates that more work is needed to foster inclusive environments in these industries. Hunter Executive Search Consultants' commitment to facilitating executive placements and their remarkable success rate with retained search assignments positions them as frontrunners in the field. In light of the survey findings, their expertise in identifying, attracting, and retaining top executive talent becomes even more
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valuable, as organisations grapple with these complex challenges. In summary, the heavy industries rely on skilled, diverse, and committed executives to navigate the evolving landscape. The survey by Hunter Executive Search Consultants highlights the firm's dedication to addressing these needs. Their impressive statistics in terms of executive retention, diverse placements, and successful search assignments demonstrate their unwavering commitment to making a positive impact on the leadership of heavy industries. Hunter Executive Search Consultants is an Australian-owned executive search firm that identifies, assess and secures top-tier talent. Acting as the catalyst for business transformations through crafting management and executive leadership teams, we help businesses and individuals drive growth and innovation in the workforce. Our services redefine the executive search experience and connect visionary organisations with exceptional off-market talent. With an unwavering commitment to excellence, we specialise in retained executive search services, delivering a blend of discretion and precision at every stage of the talent search journey. With success in executive search, board appointments and whitecollar placements, we work in industries such as energy, engineering, industrial and manufacturing, mining and resources, defence, building and construction, demolition, finance, environment and water, government and not-for-profit and private equity firms. Our national team of expert consultants and researchers treat each search uniquely, based on the specific requirements and expectations and help us deliver tailored results, connecting clients to candidates who fit seamlessly into their business. We not only help business and individuals to employment solutions – we help people find human connection. Hunter Executive Search Consultants is part of the IntoWork Group. hunterexecutive.com.au
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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY
Harnessing automation Leveraging technology for a resilient manufacturing future. Here’s the view from Chris Smith, a senior manager in Partner Sales, APAC, M-Files. The manufacturing industry has navigated an array of challenges in the past few years, from supply disruptions to workforce shortages. Even as the sector posts robust growth, with a 17.8% rise in industry division earnings in 2021-2022, it highlights the critical need for resilience and innovation. Manufacturers must now consider digital transformation. It’s not just about using new technologies, but also about improving processes, increasing efficiency, and leveraging data. This includes the integration of knowledge work automation for routine tasks and a complete overhaul of how organisational data is managed.
Choosing the right tools for maximum efficiency With external pressures mounting, many manufacturers are turning to technology as a solution. While the inclination to invest is commendable, it’s essential that decision-makers engage in detailed due diligence to ensure they’re selecting the right tools. By prioritising technologies that demonstrate a quick return on investment (ROI), manufacturing executives can deliver immediate benefits to business operations. This shows stakeholders the value of investments in technology and paves the way for more resources to be allocated for future technology focused endeavours. Updating document handling processes to enable greater automation can significantly enhance how manufacturers manage various pieces of information, including customer details, quotes, and orders. This enhancement lets staff quickly access current information, freeing them up to concentrate on tasks that directly contribute to the company’s value, rather than just managing paperwork.
Automation also enhances the consistency and accuracy of work. Automated workflows serve as a daily guide, distributing tasks and sending reminders to maintain high levels of transparency. Artificial intelligence (AI) further augments this automation by updating metadata that categorises files, initiates workflows, and sets document access permissions. The advantage is that users don’t have to apply AI or metadata to their documents manually; platforms equipped with metadata capabilities manage this automatically.
Knowledge work automation systems that harness metadata driven architectures are invaluable to manufacturers, offering multiple benefits, including:
Advanced technologies offer manufacturers the insights and agility to navigate unforeseen challenges. Through technical insights, they can pre-emptively identify potential disruptions and adapt quickly.
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For example, organisations can leverage technology to optimise production lines by analysing various data points. The findings can pinpoint ideal shift lengths, peak times when production should be scaled up, or how resources can be used most effectively.
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a centralised hub, ensuring all data is readily accessible; seamlessly integrating with existing applications and storage solutions; a straightforward setup and maintenance so users don’t have to manually categorise documents or worry about misplacing versions; information within these systems is methodically arranged, safeguarded, and categorised using innovative metadata tags that readily identify the nature and relevance of each document.
Harnessing automation to improve business agility Most technological solutions are designed not to replace human workers but to enhance their capabilities and simplify their tasks. There’s currently a significant staffing challenge in Australian organisations, and the manufacturing sector is also feeling this pinch. According to Ai Group’s Australian CEO survey, 90% of companies expect to be affected by staffing shortages in 2023. Employees must have tools at their disposal that help maintain production levels despite reduced people power. Manufacturers can alleviate some of this pressure on their workforce by automating certain processes. This defines clear roles and responsibilities and ensures that the production moves seamlessly from one phase to the next. Automation is even more valuable for businesses adopting a hybrid work model, letting employees approve documents remotely and access necessary data even when offline.
Leveraging technology to oversee supply chain communications empowers manufacturers to stay ahead of potential disruptions, ensuring timely deliveries and proactive solutions. Knowledge work automation platforms with in-built workflows offer a structured and easily accessible record of all interactions, facilitating easy assessment of performance throughout the production phases. For any technological innovation to integrate seamlessly into a company, comprehensive training and effective change management are vital. All employees must receive thorough instruction on using these new tools, grasping not only their functionalities but also how they promote collaboration, efficiency, and overall support in their roles.
Embrace the tools of the future Changes brought about by technology can enrich a business’s culture. Transparent communication from senior leaders ensures that employees grasp the significance of these new tools, understanding their role in achieving the company’s objectives. The expansion of the manufacturing sector relies on organisations adopting novel and effective methods to enhance efficiency and raise production levels. Businesses can better navigate future challenges and improve daily operations by pinpointing and integrating the appropriate technology. m-files.com
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TECH NEWS
Australia: CSIRO’s research vessel (RV) Investigator has set off on the longest voyage in its 10-year history to the Southern Ocean and sea-ice edge The aim of the 60-day voyage is to improve our ability to anticipate the impacts of future climate change. The science teams on board, led by the Australian Antarctic Program Partnership (AAPP) and Australia’s national science agency, CSIRO, will search for climate clues between the deep ocean, up to six kilometres below the water surface, to low-lying clouds, two kilometres above in the atmosphere. Co-Chief Scientist Dr Steve Rintoul, of CSIRO and AAPP, said the Southern Ocean takes up vast amounts of heat and carbon dioxide and acts as a handbrake on climate change, which means it has a profound influence on climate patterns in Australia and the rest of the globe. “To anticipate how climate and sea level will change in the future, we need to understand how the Southern Ocean works and how sensitive it is to change,” Dr Rintoul said. “What’s amazing about the Southern Ocean is that everything is interconnected – we can’t hope to understand how the region influences climate unless we measure each piece and how it fits with the other parts of the system.” The voyage, known as MISO (for ‘Multidisciplinary Investigations of the Southern Ocean’), will explore how links between physics, biogeochemistry, plankton, aerosols, and clouds influence the Earth’s climate. Changes in the Southern Ocean would have profound implications, influencing the rate of climate change, the productivity of the Antarctic ecosystem, and the future of the Antarctic Ice Sheet. Changes in the Antarctic Ice Sheet, in turn, would affect the rate of sea level rise.
Recently published research has shown the “overturning circulation” of Antarctic waters driving global ocean currents may be slowing down, affecting the redistribution of heat, carbon and nutrients across the globe. Co-Chief Scientist Dr Annie Foppert from the Australian Antarctic Program Partnership at the University of Tasmania said the meltwater from the Antarctic Ice sheet is reducing the amount of dense water sinking to the deep ocean around Antarctica, slowing ocean currents that control climate. “Data collected on the MISO voyage will be compared to earlier measurements to track how the Southern Ocean is changing and what it means for climate and sea level rise,” Dr Foppert said. “To track these changes in the deep ocean, we will deploy a dozen deep-diving robots. These new floats, able to collect measurements down to six kilometres below the sea surface, will allow us to track how the ocean is changing for the next five years by profiling the full depth of the ocean. “Observing the deep ocean so regularly and over such large swaths was impossible before this new technology.” The Southern Ocean takes up more of the heat and carbon added by human activities than any other latitude band on the earth. “A key question is whether the Southern Ocean will continue to remove large amounts of our heat and carbon from the atmosphere, or will
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the Southern Ocean ‘sink’ become less effective as the climate warms,” Dr Foppert said. “The Southern Ocean has essentially acted as a ‘climate shock absorber’ until now, but we need to probe the ocean depths to see if this will change in the future.” Scientists onboard RV Investigator from the University of Tasmania and the Bureau of Meteorology will also study gases and particles released by tiny marine organisms called phytoplankton, grown in special aquariums mounted on the ship’s deck. Gases and particles (or aerosols) released by the phytoplankton will be analysed to see how effectively they act as ‘seeds’ for new clouds. Dr Marc Mallet, of the University of Tasmania, said understanding cloud formation in the southern hemisphere was a blind spot for climate science and model projections. “This voyage will test the hypothesis that aerosols released by phytoplankton ’seed’ clouds and explain the unique properties of the Southern Ocean atmosphere,” Dr Mallet said. University of Tasmania
Hong Kong: E-COATING is an eco-friendly solution that solves two problems in one Air-conditioning accounts for almost a third (31%) of total electricity consumption in the developed world. In addition, over 470,000 glass bottles end up in landfills every day. E-COATING, invented by Hoi Fung Ronaldo Chan and Can Jovial Xiao, is created from recycled waste glass and can be applied to exterior roofs and walls to reflect the sun’s rays thereby reducing the heat absorption of buildings. This reduces the amount of electricity consumed on cooling solutions like air-conditioning and mitigates the associated greenhouse gas emissions. “We invented E-COATING with a desire to help tackle the serious environmental problems our planet is facing," Ronaldo and Jovial said. "The prize money will allow us to further our research and development goals and start a company to take our invention to the next level.” “Ronaldo and Jovial have come up with a clever way to turn waste into something much more valuable. E-COATING uses recycled glass to create a coating to put on exterior walls. This reflects the sun’s rays, and therefore saves a substantial proportion of the electricity needed to cool the building. It is a dual solution that is good for the environment and saves money,” Sir James Dyson, Founder and Chief Engineer at Dyson. The Sustainability Award will support the team’s plans to advance E-COATING’s adhesion and ease of application. They will also investigate new E-COATING formulas for indoor use. scimex.org
Poland: The Life Chariot wins Humanitarian Award As Piotr Tłuszcz watched the conflict unfold in Ukraine, young inventor observed the challenges of medical evacuations across challenging terrain. This inspired him to design The Life Chariot, a MEDEVAC off-road ambulance that can attach to any hookequipped vehicle. The vehicle’s low weight and suspension makes it safer for a casualty to travel in than the boot of a car. The Life Chariot increases the evacuation capabilities of rescue teams by adding room for one injured person on a stretcher and two more seats for medics or the lightly wounded. The initial two builds have been given to the Ukrainian Medical Military Unit and
TECH HEADING NEWS
Australia: New Photonic chip fits together like Lego A new semiconductor architecture developed at the University of Sydney Nano Institute that integrates traditional electronics with photonic, or light, components could have application in advanced radar, satellites, wireless networks and 6G telecommunications - and provide a pathway for a local semiconductor industry. Researchers at the University of Sydney Nano Institute have invented a compact silicon semiconductor chip that integrates electronics with photonic, or light, components. The new technology significantly expands radio-frequency (RF) bandwidth and the ability to accurately control information flowing through the unit.
the Polish Voluntary Medic Unit of Damian Duda “W Miedzyczasie” Foundation, having been tested in terrains such as mountain trails, forests, caves and mines. The Life Chariot can be towed by anything – allowing medics to do their life-saving work with the resources they have at hand. Piotr is continuing to implement upgrades to The Life Chariot based on feedback received from medics working on the front line. He is also working on adapting the vehicle for mountain rescue purposes. scimex.org
Australia: High-power fibre lasers pioneering technology Optical scientists in Australia and the US have created a high-power Star Wars style-laser, boosting their use in defence and for remote sensing applications. Researchers from the University of South Australia (UniSA), the University of Adelaide (UoA) and Yale University have demonstrated the potential use of multimode optical fibre to scale up power in fibre lasers by three-to-nine times but without deteriorating the beam quality so that it can focus on distant targets. Co-first author Dr Linh Nguyen, a researcher at UniSA’s Future Industries Institute, says the new approach will allow the industry
Expanded bandwidth means more information can flow through the chip and the inclusion of photonics allows for advanced filter controls, creating a versatile new semiconductor device. Researchers expect the chip will have application in advanced radar, satellite systems, wireless networks and the roll-out of 6G and 7G telecommunications and also open the door to advanced sovereign manufacturing. It could also assist in the creation of high-tech value-add factories at places like Western Sydney’s Aerotropolis precinct. The chip is built using an emerging technology in silicon photonics that allows integration of diverse systems on semiconductors less than five millimetres wide. Pro-Vice-Chancellor (Research) Professor Ben Eggleton, who guides the research team, likened it to fitting together Lego building blocks, where new materials are integrated through advanced packaging of components, using electronic ‘chiplets’. Nature Communications
Scotland: Self-eating rocket could helping minimise space junk New developments for a ‘self-eating’ rocket engine capable of flight beyond the Earth’s atmosphere could clear up the global orbital paths and help the UK take a bigger bite of the space industry.
to continue squeezing out extremely high power from fibre lasers, make them more useful for the defence industry, and for remote sensing applications and gravitational wave detection. “High-power fibre lasers are vital in manufacturing and defence, and becoming more so with the proliferation of cheap, unmanned aerial vehicles (drones) in modern battlefields,” Dr Nguyen says. “A swarm of cheap drones can quickly drain the missile resource, leaving military assets and vehicles with depleted firing power for more combat-critical missions. High-power fibre lasers, with their extremely low-cost-per-shot and speed of light action, are the only feasible defence solution in the long run. This is known as asymmetric advantage: a cheaper approach can defeat a more expensive, high-tech system by playing the large number.” In delivering an asymmetric advantage this advanced capability has the potential to provide a strong deterrent effect, aligning well with the objectives of the Defence Strategic Review and AUKUS Pillar 2 objectives. Nature Communications
University of Glasgow engineers have built and fired the first unsupported ‘autophage’ rocket engine which consumes parts of its own body for fuel. The design of the autophage engine - the name comes from the Latin word for ‘self-eating’ - has several potential advantages over conventional rocket designs. The engine works by using waste heat from combustion to sequentially melt its own plastic fuselage as it fires. The molten plastic is fed into the engine’s combustion chamber as additional fuel to burn alongside its regular liquid propellants. This means that an autophage vehicle would require less propellant in onboard tanks, and the mass freed up could be allocated to payload instead. The consumption of the fuselage could also help avoid adding to the problem of space debris – discarded waste that orbits the Earth and could hamper future missions. Overall, the greater efficiency could help autophage rockets take a greater payload into space compared to a conventional rocket of the same mass. They could, for example, take tiny ‘nanosatellites’ into space directly without having to share space on more expensive conventionally-fuelled rockets. The concept of a self-eating rocket engine was first proposed and patented in 1938. However, no autophage engine designs were fired in a controlled manner until a research partnership between the University of Glasgow and Dnipro National University in Ukraine achieved this milestone in 2018. University of Glasgow
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PRODUCT NEWS
HollowStream 1/8 NPT hollow cone liquid nozzle for cooling and washing. EXAIR’s new 1/8 NPT HollowStream liquid atomising spray nozzle is the latest addition to EXAIR’s line of Liquid Atomising Nozzles. Providing a hollow cone spray pattern, the HollowStream features a tangential flow design, is vaneless with wide open internal features to resist clogging. It produces a uniform distribution in a ring pattern with medium to large droplets to solve cooling, cleaning, foam breaking, rinsing and dust suppression applications for industry. With HollowStream nozzles, the liquid is supplied into the body of the nozzle creating a swirling action within a vortex chamber. This vortex produces the spray pattern when the machined nozzle breaks the liquid surface tension as it exits the orifice and into a controlled spray angle. The open, right-angle design is compact and serves well in applications involving liquids that are thicker or containing particulate and operates at up to 250psi liquid pressure. Available from Compressed Air Australia, the stainless steel construction of liquid atomising nozzles adds to their durability and corrosion resistance. HollowStream nozzles are CE compliant and available in a variety of flow rates. They complement EXAIR’s large line of 1/8, 1/4 and 1/2 NPT Air Atomizing and No Drip Air Atomizing Spray nozzles. Models come with their five year Built-to-Last Warranty. caasafety.com.au
DAC-360T Accurpress Australia unlocks new UX Design and Control systems in the DAC-360T. Unlocking shear comfort with precision control. The DAC-360T control system by Delem (by KEBA Group), integrated into the Accurpress machinery at Azzco Engineering, brings shear comfort to the fingertips of operators. This versatile shear control solution offers an extensive range of functionalities, including multiple back gauge axes, cutting angle, stroke length, and gap control. The state-of-the-art electronics ensure precise adjustments based on material properties and thickness.
Supporting the Back Gauge The DAC-360T doesn't just control the back gauge; it calculates the optimal settings for cutting angle and gap, improving productivity by optimising stroke length based on the required cutting length. With support for servo control, 2-speed AC control, and inverter control, this control system provides robust options for back
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gauge control, including two-side or singleside positioning.
UX Design The user-friendly touch screen navigation on the LCD screen simplifies numerical programming, guiding operators through all #programming functionalities for efficient and precise shearing. Operatorfriendly features, facilitated by clear icons and numerical programming on the bright LCD screen, instil confidence and boost #productivity. The DAC-360T, like
the machines it controls, is robust and reliable, ensuring a strong performance. Leveraging new technologies, this state-ofthe-art control system achieves the highest accuracies, elevating functionalities and user-friendliness to new levels in the realm of shear control. With features like back/front gauge control, cutting angle and gap control, stroke length limitation, and force control, the DAC-360T series offers a comprehensive solution for shearing applications. azzco.com.au
PRODUCT NEWS
Anybus CompactCom HMS Networks releases Raspberry Pi Adapter Board – further simplifying the integration of the Anybus CompactCom. HMS Networks has launched the Raspberry Pi adapter board, providing industrial device manufacturers with a simplified method to test and evaluate the Anybus CompactCom, a ready-made communication interface that connects devices to any industrial network. While previous adapter boards were designed for testing Anybus CompactCom modules with STM32 or NXP (formerly Freescale) microcontroller platforms, this new adapter board is specifically tailored for use with the Raspberry Pi. The new adapter board provides compatibility with the widely popular Raspberry Pi. Easy installation and usage for assemblyline coding sequences in manufacturing scenarios, with full compatibility with the free-to-download Anybus Host Application Example Code (HAEC). “The Raspberry Pi is incredibly popular, with over 45 million units in use around the world. Many of our customers already own a Raspberry Pi and are familiar with it,” Andreas Stillborg, Anybus Embedded Product Manager at HMS Networks stated. “Therefore, we were keen to develop an adapter board that enables our customers to easily use the Raspberry Pi to test and evaluate Anybus CompactCom.” The Raspberry Pi adapter board is fully compatible with the free-to-download Anybus Host Application Example Code (HAEC). This code includes a reference port designed for the Raspberry Pi, which customers can use with the adapter board and an Anybus CompactCom module to quickly start their embedded development project.
“We’re excited about this new adapter board, as it will allow our customers to quickly get set up and familiarize themselves with our Anybus CompactCom offering,” concluded Andreas Stillborg. The first Anybus module was developed in 1994. The number of fieldbuses increased rapidly and the Anybus embedded concept made it possible for device manufacturers to connect their devices to any industrial network in an easy way. Over the last decade, the evolution of industrial networks has continued and many industrial Ethernet protocols with high performance have been introduced. With full fieldbus and industrial Ethernet con-nectivity, IT-features and solutions for functional safety and security, the Anybus embedded technology has always been in the forefront, now also covering wireless technologies. Today, more than seven million Anybus products are used in factories globally. The multinetwork connectivity offered by the Anybus embedded concept is still the key benefit for the user. HMS Networks offers a starter kit that provides everything needed to comprehensively test and evaluate the capabilities of the Anybus CompactCom. The starter kit enables you to perform indepth assessments of communication speed, latency, and try out different network combinations before starting manufacturing production.
3D METAL PRINTING
3D Metal Large Format Printing is a game-changing solution. It surpasses castings, forgings and other traditional manufacturing processes by cutting production time and delivers new and replacement parts and tooling so fast, that it is reshaping industrial production.
Within the HMS Starter Kit case, you’ll find all the essential boards, adapters, and cables required for evaluating Anybus CompactCom. But of course, please note that the actual Anybus CompactCom module or brick needs to be ordered separately. hms.se anybus.com
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AEROSPACE & DEFENCE
Australian spaceshot Titomic technology aids University of Melbourne and the Italian Space Agency deliver Australia’s first scientific satellite in decades. Australia has marked its historic return to space exploration by successfully launching into orbit its first scientific satellite in over two decades.
on one side. This design maximises thermal efficiency, enabling the satellite to host heat-sensitive instruments that are typically reserved for larger satellites.
The SpIRIT nanosatellite, a landmark project, emerged from a collaboration between the University of Melbourne and the Italian Space Agency, with a consortium of pioneering Australian SME partners and support from the Australian Space Agency. Titomic, an innovative additive manufacturing company based in Melbourne, was instrumental in this historic achievement with its groundbreaking thermal radiator design, a critical component of the satellite.
“Titomic has had a longstanding relationship with University of Melbourne which dates back quite a few years,” said Ben Andrews, Titomic’s Global Marketing Manager, “and we’ve been researching radiation shielding and heat radiators for a range of clients within this space [pun intended], also automotive, and defence sectors, so the technology application or parallel applications have been in development for 18-24 months.”
The SpIRIT (Space Industry – Responsive – Intelligent – Thermal) nano-satellite is an Australia-Italy mission supported in Australia by the Australian Space Agency’s International Space Investment – Expand Capability scheme. “The team utilised Titomic’s state-of-the-art TKF 1000 additive manufacturing unit to develop high-efficiency radiator panels that are crucial for the satellite’s operation,” said Herbert Koeck, Managing Director of Titomic.
The radiator’s unique bird-shaped spray pattern – generated by a sophisticated computer algorithm – allows the SpIRIT to efficiently reject heat, enhancing its thermal performance ratio. “That pattern was optimised by SpIRIT,” said Khin Thar, one of Titomic’s Manufacturing Engineers. “They analysed which areas of the satellite emits the most heat on their simulation flights using AI. So they have optimised that data and come up with that shape. The University of Melbourne then handed it over to us to do the thermal management coating.”
“SpIRIT’s journey into space is not just a technological triumph. It’s also a significant step in scientific discovery,” Koeck added. SpIRIT is designed to fly in low Earth orbit for two years in a Sunsynchronous polar orbit, where the satellite travels from north to south over the poles and is tuned so it always faces the sun at a similar angle. After the launch, the team will spend about four months testing and commissioning the nanosatellite in the extreme conditions of space before scientific operations can begin. The nanosatellite will then transition to a full operational phase to investigate the mysteries of the cosmos through international scientific cooperation, and to measure the long-term performance of Australian-made space technology. SpIRIT aims to grow Australian space industry capabilities through the development of an innovative nano-satellite which will break new ground in high-performance autonomous operations, communications, propulsion and thermal management. SpIRIT will also be the first made-in-Australia spacecraft to host a foreign space agency’s scientific instrument as its main payload, showcasing the competitiveness of Australia’s space industry, and growing international cooperation in astronomy and space science with the Italian Space Agency. The SpIRIT design is based on a standard format (6U CubeSat) with ~11.5kg mass and linear dimensions of approximately 30×20×10cm when stowed in the launch dispenser, which will stretch to almost one meter once in orbit due to deployable structures. Titomic’s contribution features a bespoke bi-metallic radiator design, cold-sprayed in pure copper and coated with mirror tape
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Titomic's bespoke bimetallic radiator
“There's not really many other technologies that can combine copper onto aluminium,” continued Andrews. “We can build the heat exchanges directly onto the satellite body without having to re-engineer the body itself to incorporate a separate system.” “When one metal powder feedstock is accelerated to supersonic speeds, the metal particles plastically deform, and they lock together to make a mechanical bond. The parts don't exceed hundred degrees centigrade. So there's no risk of oxidation that you might see in some other large scale 3D printing processes like wire arc additive manufacturing.” The TKF1000 3D printer is very small and compact compared to other printers. It's very easy to use,” according to Khin Thar. “The very best thing about this TKF1000 is its dual powder feeder.
AEROSPACE & DEFENCE
Image credit: SpaceX
You have the option of putting two powders through this, not for this application and there are several applications where we do that. You can also do blended materials in a cold spray, you can optimise one side of the material.” AMT magazine spoke with Professor Michele Trenti, Director of the Melbourne Space Lab and SpIRIT’s Principal Investigator more about the Italian Space Agency’s space instrument on SpIRIT. “The HERMES instrument on board SpIRIT aims to detect gamma and x-ray flashes emitted by massive rotating stars collapsing into black holes or by collisions between very compact stars made almost completely of pure neutrons,” explained Trenti. “Based on a novel compact design of just 1U (cube of 10cm in each side), the instrument achieves high sensitivity between 3keV and 2MeV (x to gamma rays) and combines a Silicon Drift Detector (SDD) and scintillator crystals, with an optical light filter to prevent noise from sunlight. The x-rays are detected directly as they interact with the SDD, while the gamma rays interact with the crystals and produce optical light that is captured by the SDD. The instrument has a field of view of about half the sky, and the position of the transient burst is localised in the sky by cross-correlating photon arrival time using a constellation of nanosatellites. SpIRIT is one of the seven elements of the HERMES Scientific Pathfinder constellation, and the first to have reached orbit.”
University of Melbourne The University of Melbourne developed four payloads and subsystems on SpIRIT: an Instrument Control Unit (called Payload Management System - PMS in short), a payload thermal management system (TheMIS), an edge computing and multicamera system (Loris) and a low-latency communication system (Mercury). Loris is based on an NVIDIA Jetson Nano GPU, with University of Melbourne proprietary thermal management solutions suitable for efficient use in space. The GPU is controlling a multi-camera system, including a selfie stick camera that will be deployed with the solar panels and has the ability to process images on board with AI algorithms. The Mercury subsystem includes both a redundant GPS system for precision position and timing acquisition to support HERMES, and an Iridium duplex user terminal for low latency telecommanding of the spacecraft and prompt transmission of event detections from HERMES. The satellite’s primary mission while in space is to search for gamma rays – the elusive phenomenon created when stars collide or die. To achieve that, SpIRIT is equipped with solar panels, thermal radiators, cameras, guidance systems, an electric propulsion thruster, and computers. After completing its two-year mission, SpIRIT will return to Earth and burn up on re-entry, concluding a historic chapter in Australia’s space exploration history. Titomic’s involvement in this project not only showcases its expertise in advanced manufacturing technologies; it also positions the company as a key player in the burgeoning space industry. This successful launch paves the way for future collaborations and innovations in space technology. titomic.com unimelb.edu.au
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AEROSPACE & DEFENCE
Optimus space pit-stop partnership Space Machines Company and Orbit Fab join forces to advance in-orbit roadside assistance. Space Machines Company, the leading Australian in-space servicing organisation, and U.S.-based Orbit Fab, the leading global provider of on-orbit refuelling services, have entered into a partnership combining their expertise to advance in-space servicing capabilities and establish a sustainable space ecosystem. These integrated technologies will enhance space sustainability through reduced debris and extended satellite lifespans. The partnership brings together two industry leaders from opposite sides of the globe and is defined by the joining of innovative technologies, most notably the installation of Orbit Fab’s space fiducial alignment markers on Space Machine Company’s Orbital Servicing Vehicle, Optimus. These markers will act like QR Codes in space, allowing Space Machines Company to work collaboratively with an approaching vehicle by using the markers to provide valuable position and orientation data, ensuring safe and reliable on-orbit operations. Optimus will provide on-orbit, transportation and other in-space services following its launch on the SpaceX Transporter-10 in early 2024. The success and sustainability of Optimus’ launch will be supported by the attachment of the two ‘fiducial’ markers developed by Orbit Fab. These fiducials, which are designed to support the safe and effective navigation and approach of Optimus, will demonstrate Orbit Fab's ability to achieve safe navigation for the refuelling of spacecraft in-orbit. This partnership will reach a significant milestone in 2024, with both companies scheduled to launch missions on board SpaceX Transporter rideshares. The mission of Space Machines Company and Orbit Fab is geared towards conducting a range of rendezvous and proximity operations maneuvers to validate and test the technologies of both companies. The cooperation between Space Machines Company, Orbit Fab, and SpaceX also represents a practical example of successful international collaboration. Orbit Fab and Space Machines Company join forces to not only combine expertise and foster strategic national capabilities for both Australia and the U.S. but to champion their shared goals of driving improved space sustainability through reduced debris and an on-orbit circular economy. By partnering to undertake a suite of safe, secure, and sustainable proximity operations, Orbit Fab and
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Space Machines Company will play a pivotal role in defining this developing commercial technology to unlock on-orbit refuelling, servicing, repair, and de-orbit innovation for the global space sector. “This collaboration represents a significant milestone in the advancement of in-space servicing technologies,” said Rajat Kulshrestha, Space Machines Company co-founder and CEO. “It is the first purely commercial partnership of its kind and will serve as a pioneering example of in-space validation of these groundbreaking technologies. By leveraging our respective strengths and expertise, Space Machines Company and Orbit Fab are setting a new standard for international collaboration in the space industry.” “Orbit Fab was founded to eliminate the single-use spacecraft paradigm through in-space refuelling. Our collaborative work with Space Machines Company demonstrates cooperative docking alignment markers that support safe, sustainable space operations,” said Daniel Faber, Orbit Fab CEO. “We provide these spacecraft fiducials to support cooperative refuelling in space, but they can also support any satellite servicing activities. By simply including a low-footprint fiducial market, any company can make its assets serviceable just as Space Machines Company has done.” Space Machines Company (SMC) is an Australian company delivering on-orbit servicing and protection of critical space infrastructure through its Orbital Servicing Network. SMC supports mobility, inspection, deorbiting, repair, life extension, and protection capability to satellite customers when and where they need it. Orbit Fab is the leading provider of in-space refueling services delivering propellants that allow for extended missions and fuel the growth of the in-space economy, enabling dynamic space operations and offering access to significant cost-savings and revenue opportunities. Over the past decade, rockets have become reusable. Orbit Fab is making satellites reusable. The company, based in Lafayette, Colorado, with offices in the UK, and has developed the Rapidly Attachable Fluid Transfer Interface (RAFTI) as well as spacecraft fiducial markers, which are being integrated aboard a growing number of government and commercial spacecraft to enable refuelling in GEO and LEO orbits. Orbit Fab has signed the first government and commercial fuel delivery agreements in GEO. spacemachines.co orbitfab.com
AEROSPACE & DEFENCE
Australia’s sovereign defence capability Sovereign Australian Prime Alliance (SAPA) and Australian Industry & Defence Network (AIDN) join forces to provide recommendations for Defence as Australia faces our most challenging outlook since the Second World War. A new report sets a path to building genuine sovereign defence capability for Australia, recommending the Department of Defence cultivate Australian defence prime contractors and create a new $1bn fund to acquire capabilities and services from medium and small Australian companies for defence purposes.
Underscoring the geo-political context is Australia’s increasingly important role in the Indo-Pacific, our AUKUS partnership, and concerns expressed by the Albanese and former Morrison governments through the Defence Strategic Review and Defence Strategic Update, respectively.
The report, Developing Australia’s Defence Industrial Base, details eight recommendations to the Department of Defence and Australian Government to grow Australia’s defence industrial base, in the interests of strengthening Australia’s deterrence capabilities, improving our self-reliance, and becoming an active contributor to our AUKUS alliance.
It also proposes a deeper working partnership between Australian companies, government ministers and the Defence organisation, driven by the urgency of our strategic environment and focused on results that strengthen Australia’s military deterrence capability and national security.
The paper argues, achieving these objectives will de-risk the nation as we face our most challenging strategic outlook since World War II. The eight recommendations in the report are for the Australian Government to: •
declare the intent to establish Australian defence industry primes; • establish a Government Defence Industry Steering Council; • produce a new definition of ‘industrial sovereignty’; • revise the Commonwealth Procurement Rules to recognise economic security and industrial sovereignty as ‘value for money’; • change Defence core processes and structures to enable and grow direct partnerships with Australian companies; • create a new $1bn budget line to fund sovereign capabilities and services from medium and small Australian companies for defence purposes; • make AUKUS Pillar Two – Advancing the Capabilities of the U.S., UK, and Australia – deliver now, by setting industry to work; and • replace the fruitless search for the perfect lists of ‘Strategic Capabilities Priorities’ and detailed industry plans with practical priorities. The report examines Australia’s strategic challenges in the context of increasingly expansionist, policies of the People’s Republic of China and the growing grey-zone warfare tactics being perpetrated against Australia and our allies.
The paper asserts its recommendations will see Australia shore up its defences by building a stronger industrial base centred on stronger manufacturing capabilities, a multi-pronged approach to reducing supply chain risk – including greater stockpiles of key resources – and building a stronger sovereign defence industry underpinned by Australian primes. The paper argues this would lower Australia’s current overdependence on multinational primes which may be required to support their home nations during a major conflict, potentially at Australia’s expense. The report looks at examples of how comparable countries, with lower GDP and – in many case – smaller defence budgets, have built highly capable defence industries when faced with strategic threats and uncertainty. These include Israel, South Korea, Sweden, and Turkey, all of which have become defence export powerhouses. “Even our most trusted security partners will be stretched in the event of a regional war. So, Australia must have more independent capacity to defend ourselves and to be a strong partner with our allies,” said Rob Nioa, CEO of NIOA, a member of SAPA and one of the paper’s co-sponsors. Nioa underscored how Australian industry is ready to step up to support Defence and the Government meet the current challenge. “Give us the tools and we will finish the job. In this case the tools are the conditions that will allow strong Australian owned and run defence prime companies to emerge and thrive.” The research was commissioned by the Australian Industry Defence Network (AIDN) and the Sovereign Australian Prime Alliance (SAPA). aidn.org.au
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From above and beyond Hyperspectral drones and satellites to redefine mine waste monitoring and re-mining say Friederike M. Koerting from Norsk Elektro Optikk, and Ekaterina Savinova, Steven Micklethwaite from UQ and the Sustainable Minerals Institute. Mining is a fundamental human activity, crucial for the homes we live in, the power we rely on, our transportation, the medical equipment we use to sustain lives and so much more. While mining is often associated with its negative impacts on the environment and communities, the green shift associated with necessary raw materials for the energy transition has brought the importance of mining back to our general attention. The International Energy Agency (IEA) estimated an increased demand of 40% for copper, 60-70% for nickel and cobalt and 90% for lithium. Mining covers around 60,000 square km of the Earth’s surface and activities reshape landscapes into open pits, associated infrastructure, processing plans, evaporation ponds and tailings, and mine waste storage facilities. To the general public, mining is often perceived via headlines pointing out the scale of surface disruption or catastrophic failures that cause harm to the environment or surrounding communities. Tailings storage facilities (TSFs) with material in the form of a slurry can pose high environmental risks, owing to ground and surface water contamination from Acid Mine Drainage (AMD) and other geo-hazards. Breaches and failures of TSFs can lead to catastrophic events such as mudflows, with the potential to cause fatalities and destruction of property or even damage to entire local townships (e.g., Brumadinho dam disaster in Brazil 2019, initially estimated socio-economic and -environmental reparations at nearly $12bn). The global tailings review emphasises the scale of potential risk, estimating 8500 active, inactive and closed TSFs with a total of 217km3 of tailings and a growth rate of 12.3km3 every year (Visual Capitalist, 2021). Furthermore, AMD is a significant environmental hazard associated with mine waste. For Australia alone, AMD management is estimated to cost approximately $150m for operating mines and over $500m for abandoned mine sites. The Canadian environmental liability cost is estimated at around $2-5bn by the Canadian Mine Environment Neutral Drainage Program. Northern American cost of AMD remediation at abandoned mine sites totals around US$10bn (Naidu et al., 2019). Satellite technology has enabled mining to enhance exploration, monitor pit and TSF stability, support the closure and rehabilitation
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of mine sites, and manage AMD. With the advent of drones and light-weight remote sensing technology both satellite and drone platforms offer improved efficiency, accuracy, especially when combined. Now, hyperspectral cameras are mounted onto drones to enable surface mineral mapping capabilities that were unimaginable before. These technologies combined are set to play an increasingly important role as mining operations upscale; ensuring timely and accurate information for responsible decision making around sustainable mining practices and efficient extraction of raw materials. Traditional monitoring of mining areas relies heavily on groundbased surveys and periodic manual inspections. These methods, though valuable, are time-consuming, expensive, and often limited in scope. In recent years, Earth observation satellites equipped with high-resolution cameras have offered unparalleled perspectives from space. These satellites can capture images and quantitative data about mine sites, terrain, vegetation, and water bodies, among other aspects. Drones complement satellite technology by offering much more detailed information at low costs, and can be used repeatedly to detect changes. Because drones can fly closer to the ground, they capture high-resolution images and data with exceptional accuracy (<1cm resolution in some cases). By integrating satellite and drone technologies one can combine the wide coverage of satellites with the detailed insights from drones. The European Union-funded “Multi-scale, Multi-sensor Mapping and dynamic Monitoring for sustainable extraction and safe closure in Mining environments”, or M4Mining for short, is working towards just such a solution (m4mining.eu). M4Mining is deploying hyper- and multispectral data in mining environments, utilising both hyperspectral drone platforms and hyper- and multispectral satellite data. Hyperspectral imaging is a technique used to capture and analyse a broad range of wavelengths across the electromagnetic spectrum. Unlike standard imaging cameras that capture data in a few discrete bands (e.g., red, green, blue in the visible spectral wavelength range, RGB), or of broad, discrete bands (multispectral in the visible to near to shortwave infrared (VNIR-SWIR)) hyperspectral imaging captures a large number of
AEROSPACE & DEFENCE
overlapping, narrow, contiguous bands across the electromagnetic spectrum (VNIR, SWIR, thermal infrared), providing detailed, highly resolved spectral information for each pixel in an image. M4mining is currently developing a hyperspectral drone system for mining at one of the project’s partner sites in Europe (HySpex, Norway), and the associated navigation, real-time processing, analysis and visualisation software in a pan-European and Australian consortium. The drones will be deployed in active mining environments as well as in legacy mine sites including tailings and waste facilities. M4Mining is striving to develop a robust, easy-to-use system, with edge computing and the ability to deliver near-real-time results. The key objective of m4mining is to develop and demonstrate a costeffective method for regular mapping, monitoring, and geo-hazard prediction, as well as management of mining operations, including stockpiles and TSFs over time. The M4Mining partners from HySpex and the University of Queensland just completed the first field survey in North-Western Queensland at the Mary Kathleen legacy mine site. Forty minutes east of Mount Isa city lies the former Uranium and Rare Earth Element (U-REE) mine. This open pit operation was active from 1956 to 1982 and rehabilitated in 1985. Over the years of operation, mining the valuable ore also left about 7.1Mt of fine-grained tailings. Although the original rehabilitation procedures have been partly successful in reducing the dispersion of U and related elements into the surrounding environment, decades after rehabilitation, a physical and chemical mobilization of trace elements is occurring. The Sustainable Minerals Institute, the Geological Survey Queensland and HySpex visited the open pit and adjacent tailings and evaporation pond in September 2023 to collect baseline hyperspectral drone images of the area and samples for laboratory analysis. These are being used to aid the interpretation of the drone and satellite data, and to inform M4Mining how we may develop a more versatile, integrated drone platform that allows hyperspectral data collection from different angles. A week after the field survey a workshop at the University of Queensland in Brisbane, invited different stakeholders within mining and environmental agencies to a workshop, showing preliminary results of the survey, including a mineral map of the Eastern walls of the openpit and showcasing the hyperspectral drone in action. While public discussions often centre on the distant 'future' concerning the transition to a clean economy, the current pace is incompatible with the timelines required to meet our 2050 commitments. Decarbonization is going to necessitate a holistic approach to solve this crisis, including responsible mineral extraction. Emerging technologies like hyperspectral drones and satellites will help expedite metal production from current mines, manage environmental health and assess the re-mining potential of legacy sites. Looking ahead, ongoing technological advancements will likely enhance the capabilities of both satellites and drones. Improved sensors, increased resolution, and more sophisticated analysis techniques will further refine monitoring processes. Additionally, the automation of data processing and the utilization of real-time analytics will streamline decisionmaking and foster more sustainable mining practices. The fusion of these technologies opens up new horizons, promising a future where we can harness Earth's resources while safeguarding the environment for generations to come. This survey was funded by the AuScope EarthDrone project and M4Mining. M4Mining is funded by the European Union's Horizon Europe programme under Grant Agreement ID 101091462 and the Swiss State Secretariat for Education, Research and Innovation (SERI). The workshop was supported by Raymax Applications, Suppliers of laser systems and HySpex systems in Australia and New Zealand. raymax.com.au hyspex.com m4mining.eu
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ELO2 Australia’s ELO2 consortium unveils first Moon rover, a milestone for Australia’s first lunar rover mission. The ELO2 consortium, leading the way in autonomous robotic technology, has unveiled a prototype of what could become Australia’s first lunar rover. The consortium is working on the project under the Australian Space Agency’s Moon to Mars Trailblazer program which aims to land the rover on the Moon as part of a future NASA Artemis mission as early as 2026. The first glimpse of the rover showcases the unique technology and design elements built into this specialised rover. On the Moon’s surface, it will be tasked with transporting lunar regolith (Moon soil) to a NASA-run facility for the extraction of oxygen. The initial prototype focuses on testing chassis and suspension subsystems and features an early design of a collection device and special wheels that will enable the rover to cross the Moon’s challenging terrain. The rover prototype's unveiling marks an essential step in this process, focusing initially on testing chassis and suspension subsystems while paving the way for iterative enhancements and expanded functionalities throughout Stage One of the Trailblazer program. This prototype and the following iterations are a practice in derisking critical technologies, validating requirements, and ensuring their seamless integration – crucial for the success of Australia’s national flagship mission. Prototyping such as this is an important step in testing designs for continuous improvement; something that is essential in the space industry. Beyond transporting regolith, the rover will autonomously navigate the lunar environment, locate and collect regolith, and is an essential element to enable NASA’s in-situ resource utilisation facility to operate. There, oxygen will be extracted from the regolith, which can be used for Artemis astronauts to breathe and for spacecraft fuel – essential elements for a sustained human presence on the Moon. "Our consortium's unveiling of the lunar rover prototype is a testament to Australia's commitment to space exploration,” says Joseph Kenrick, ELO2 Technical Director with Lunar Outpost Oceania. “Through the Trailblazer program, ELO2 is spearheading efforts to de-risk critical technologies while striving to deliver a successful and impactful mission for Australia. This unveiling marks the beginning of an exciting journey and invites every Australian to
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be part of our nation's cosmic endeavours.” The public unveiling of this early rover prototype aims not only to showcase progress but also to engage the Australian public. ELO2 seeks to make space more accessible by actively involving citizens in space exploration and hopes that the display of this prototype will encourage comments, feedback and ideas. Part of the rover design process is involving the Australian public through participation in a range of initiatives, such as the Big Dipper and Little Dipper Challenges which invite people of all ages to present ideas for one element of the rover – the regolith collection device or scoop, for the chance to win prizes and badges. This unveiling, along with the wider Moon to Mars Initiative led by the Australian Space Agency, underscores the reality of Australia's unique capabilities, STEM engagement and innovative spirit that places the country in a prime position to contribute to missions on the Moon and beyond. “ELO2 is designing and developing world-leading technology, capitalising on Australia’s strengths, and leveraging Trailblazer funding to develop dual-use critical technologies able to support technology development for AUKUS Pillar II. This initiative extends beyond advancing our space industry; it encompasses critical applications in climate change monitoring, critical mineral sourcing for Earth’s green transition, and remote operations in healthcare. This integrated approach not only benefits our space endeavours but also contributes significantly to vital industries on Earth,” stated Ben Sorensen, Director of Innovation and Commercialization at EPE." The ELO2 consortium is a collaborative venture which has combined the strength of Australia’s leading industry partners and research institutions towards the goal of creating Australia’s first lunar rover. This initial prototype is an early step in this advanced design process, which involves continuous enhancement of the rover's capabilities throughout Stage One of the Trailblazer program. As the mission progresses, the consortium aims to engage the public, offering insights into the advancements, challenges and discoveries on the path toward Australia's lunar exploration milestone. elo2.au
AEROSPACE & DEFENCE
Photonic chips Advanced Navigation has been awarded a grant by the Australian Department of Defence to advance the nation’s sovereign manufacturing capability for photonic chips. Currently, Australia does not have commercial manufacturing capability for photonic chips. Advanced Navigation is the first and only company to produce this technology in the country. The company plans to manufacture 45,000 photonic chips per year. Advanced Navigation CEO and co-founder, Xavier Orr, said, “The technological breakthroughs enabled by photonic chips offer new opportunities for defence and commercial applications requiring always available, ultra-high accuracy, orientation and navigation, including subsea, marine, robotics, aerospace and space. Advanced Navigation is honoured to be a major driver of this capability, and empower technologies to safeguard national security in a time defined by technological warfare and geopolitical uncertainty.” As part of the Sovereign Industrial Capability Priority grant, the Department of Defence has awarded Advanced Navigation $306,631. The award, one of several received by Advanced Navigation, further underscores and validates the earned trust between the Department and Advanced Navigation’s capability to deliver innovative solutions addressing the sector's most critical and emerging needs.
Advanced Navigation’s Boreas D90 inertial navigation system
Navigating new frontiers with photonics Advanced Navigation uses photonic chips in its fibre-optic gyroscopes (FOG) inertial navigation systems (INS). These systems are recognised by global defence forces as a critical capability for Assured Positioning, Navigation and Timing (A-PNT) across navy, army and air force to enable autonomous capability, accurate positioning and high value asset tracking.Advanced Navigation is one of only four companies in the world to manufacture strategicgrade FOG components, and the only in the world to develop a completely digital FOG (DFOG). While FOG offers highly accurate position and navigation data, Advanced Navigation’s patented DFOG combines closed-loop FOG with digital modulation techniques and a revolutionary photonic chip to offer higher performance, delivering a 40% reduction in size, weight, power and cost over comparable products, as seen in its Boreas range. Specifically, the Boreas X90 will be utilised by Australian satellite manufacturer Space Machines onboard its Orbital Servicing Vehicle, scheduled to be launched off the SpaceX Falcon 9 rocket in early 2024. The technology will be critical for the vehicle’s navigation and docking in orbit.
Achieving manufacturing scale with automation and vertical integration Advanced Navigation has adopted a vertical integration framework, encompassing various stages of the photonics and DFOG INS system development, from design to quality testing to automated manufacturing. This streamlines processes, improves quality control, and ensures agility in adapting to evolving threats. In the context of A-PNT, precision and reliability are non-negotiable. Utilising machine learning, Advanced Navigation’s automated manufacturing process delivers components that function in the most challenging conditions, from subsea to space. Specifically, advanced quality control mechanisms, such as realtime monitoring and machine vision, can detect defects at the early stage of production. This ensures only components meeting the highest standards are integrated into the navigation system, enhancing overall reliability, quality and longevity.
Advanced Navigation’s Boreas D90 inertial navigation system.
Advanced Navigation's mission is to be the catalyst of the autonomy revolution. Powered by a deep curiosity to apply ground-breaking technologies to uncover and explore new frontiers, the company is ultimately extending human capabilities to build a more resilient and sustainable future, with safer outcomes. Advanced Navigation was founded in Sydney, Australia in 2012 by engineers Xavier Orr and Chris Shaw to commercialise university research on AI-based inertial navigation. Since 2012, the company has experienced great success and has progressed into several deep and new technology fields. This includes underwater acoustics, GNSS antennas and receivers, radio frequency systems, inertial sensors, robotics, and quantum-enhanced inertial navigation. Advanced Navigation is a supplier to some of the biggest companies in the world, including Airbus, Boeing, Google, Apple, and General Motors. Advanced Navigation is headquartered in Sydney, Australia with multiple research facilities throughout the country and offices around the world. Advanced Navigation exports globally while maintaining carbon-neutral operations. advancednavigation.com
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Omni Tanker Australian manufacturer delivers world-leading liquid hydrogen storage project with Lockheed Martin. Two years in the making, Australian composites manufacturer Omni Tanker in collaboration with international aerospace giant Lockheed Martin and the University of New South Wales (UNSW) has developed a world-leading solution for the transport of cryogenic and liquid cargoes of hydrogen and helium, with support from the Advanced Manufacturing Growth Centre (AMGC). The collaborative partnership builds upon Omni Tanker’s expansive composite capabilities developed for use across its industrial transport portfolio. The company currently leads global manufacturing in lightweight, composite road tankers for caustic materials that are used and sold locally and exported to Europe, and North America from its Sydney base. Omni Tanker is an advanced manufacturer using carbon fibre composite materials to produce innovative safe and lightweight tanks with exceptional chemical resistance. Omni Tanker’s patented technology solves the challenges of transport equipment for aggressive corrosive and strong oxidising chemicals, and has been widely recognised by numerous international awards in the transportation and composites industry. The company has established a dominant position for corrosive chemical transport equipment in the Australian market, where it manufactures and exports bulk liquid transport equipment to worldwide locations including North America and Europe. The equipment is available as road tankers, cargo tank motor vehicles, and portable tank containers including ISO and Swap tanks. Pairing Omni Tanker’s capabilities with Lockheed Martin’s extensive aerospace experience led to the development and manufacture of two new tanks including a: - Type 4, fluoropolymer-lined, carbon fibre composite tank, and a - Type 5, liner-less, carbon fibre composite tank. The tanks can store and transport liquid hydrogen, as well as oxygen, hydrogen peroxide, and hydrazine at high pressures under extreme cryogenic temperatures. In testing, the tanks achieved their performance metrics, particularly when materials were exposed to cryogenic temperatures as low as minus 269 degrees Celsius. As a result of the successful project, operational-scale demonstrator versions of the tanks for Lockheed Martin’s LM2100 satellite have now been manufactured at Omni
Tanker's advanced manufacturing facility located in Sydney’s west. “By leveraging Omni Tanker’s capabilities, we have been able to translate our composite road tanker technology to the global space sector – where performance, weight, and cost are of paramount importance”, said Omni Tanker CEO and Founder Dr Daniel Rodgers. “The $1.59m project has taken the company’s worldleading capabilities to new heights.” “Omni Tanker can develop and deliver composite pressure vessels to meet demanding technical requirements quicker and at a lower cost than exotic materials, such as titanium, which are widely used in the space sector.” Rodgers said. Christopher Hess, Lockheed Martin Australia’s Head of Industrial Development said, “The global strategic environment is constantly evolving, and Lockheed Martin is committed to working with industry, through exemplary partners such as Omni Tanker, UNSW, and AMGC, to deliver a world-leading space capability.” “With the assistance of AMGC, Omni Tanker has done what more manufacturers should do: seek ways to leverage their capabilities across adjacent opportunities, in this case moving from road tankers to spacecraft”, said Dr Jens Goennemann, Managing Director of AMGC. “It’s generally not rocket science – except in this case it actually is,” said Goennemann. Together, the project participants identified a new application for Omni Tanker’s patented OmniBIND solution which links an interior thermoplastic tank to a lightweight composite exterior tank. The use of a nanoengineered additive product, developed by a UNSW, prevented matrix cracks usually present at extremely low temperatures in pressure vessels storing liquefied hydrogen. “The collaborative efforts with Omni Tanker and Lockheed Martin Space have been pivotal in transforming this cutting-edge technology into practical commercial applications”, said UNSW’s Scientia Professor Chun Wang. “As a result of extensive nanoengineering efforts, we now have composite structures that can withstand the extreme cold of liquid hydrogen without experiencing microcracking or hydrogen gas leak.” said Professor Wang. The co-funded project worth a total $1.59m, received co-investment from the Advanced Manufacturing Growth Centre to the value of $700,000, while in-kind contributions totalled $194,000. omnitanker.com amgc.org.au
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AEROSPACE & DEFENCE
Long range strike Australia on track for missile manufacturing and increasing long range strike capability. The Albanese Government will ensure Australia starts manufacturing Guided Multiple Launch Rocket System (GMLRS) missiles from 2025, following the signing of a $37.4m contract between Defence and Lockheed Martin Australia. The contract will enable an initial batch of GMLRS missiles to be manufactured in Australia, which is an important first step towards establishing domestic missile manufacturing on a larger scale. It will facilitate the transfer of technical data from the United States, establish processes for engineering certification, and begin to build the technical skills of an Australian workforce. The Australian Government will also acquire Precision Strike Missiles (PrSM). Both PrSM, which can engage targets out to 500km, and GMLRS can be fired from HIMARS launchers. These activities are part of the $4.1bn investment, announced in response to the Defence Strategic Review, which will enable Defence to acquire more long-range strike systems and manufacture longerrange munitions in Australia. The Albanese Government continues to deliver on its commitment to establish domestic missile manufacturing while also accelerating the acquisition of long-range strike capability, strengthening the Australian Defence Force’s ability to defend Australia and its immediate region. “Signing this contract with Lockheed Martin Australia to begin the manufacturing of GMLRS in Australia from 2025 is another example of the Albanese Government delivering key outcomes of the Defence Strategic Review,” said Deputy Prime Minister, the Hon Richard Marles MP. “These are important milestones which will
see Australia gain the technology we need to establish a sovereign industry, providing opportunities for a highly-skilled workforce.” “This important first step towards the establishment of domestic guided weapons manufacturing in Australia will complement the acquisition of long-range precision strike capabilities and strengthen the ADF’s ability to protect Australia and its interests,” added Acting Minister for Defence and Minister for Defence Industry, the Hon Pat Conroy MP. “This work is a clear demonstration of the ongoing collaboration between Australia and the United States on Australia’s Guided Weapons and Explosive Ordnance Enterprise – a key outcome of the Australia-United States Ministerial Consultations in July 2023.” defence.gov.au
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Manufacturing for lift off The metal cutting considerations in the space race. A new record for the number of people in space all at once was set in May 2023, with 20 people simultaneously in orbit. Among the many space missions that have taken place this year, Virgin Galactic’s Galactic 01 marked the first commercial suborbital spaceflight mission for the company, with SpaceX also gearing up for its first commercial spacewalk. From space tourism to rocket innovation, man is diving deeper into the great black. But how much is known about the tools that are engineering space exploration? Here, William Durow, Global Engineering Project Manager for space, defense and aerospace at Sandvik Coromant, reveals the metal cutting considerations for outer space. We have seen several giant leaps for mankind in recent years. The European Space Agency’s JUpiter ICy moons Explorer (JUICE) mission launched in April 2023 and is set to arrive in the Jovian System in 2030. It will then take three-and-a-half years to observe Jupiter’s three moons. Roughly 100 launches are also planned by SpaceX this year, and NASA’s OSIRIS-Rex has recently returned to Earth in September 2023. And that’s just a handful of the recent, current and future projects aiming to help us know more about our galaxy. Ensuring success among the stars takes many considerations. Whether that is thorough mission planning, rigorous simulation, qualified mission managers or effective contingency planning, a successful space trip requires careful planning, preparation and execution. In addition, materials used in space applications must withstand some of the most extreme conditions one could imagine — such as vacuum, radiation, thermal cycling and micrometeoroid impacts.
satellites, scientific instruments and crew, it can carry into space. Lighter tanks allow for a larger portion of the rocket's total weight to be allocated to payload, maximising the mission's capabilities.
Tough materials
Popular materials for these applications include heat resistant super alloys (HRSAs). These materials are advantageous for space due to their exceptional ability to withstand harsh conditions. However, their hardiness also brings machining challenges.
Building anything destined for space involves a range of material considerations to ensure its safety, performance and functionality in extreme conditions. Structurally, materials must be able to withstand high pressures and stresses experienced during launch and in-flight. Spacecraft will also experience intense heat during re-entry to the Earth’s atmosphere and so external materials must work to stop the vehicle burning up, while other components, such as rocket nozzles, must also be made from heat resistant materials.
HRSAs are designed to withstand extreme temperatures, mechanical stresses and corrosive environments and are primarily used in applications where conventional materials would fail due to their limitations under extreme conditions. Capable of maintaining their mechanical properties and structural integrity at very high temperatures, often exceeding 1000°C (1832°F), and with excellent creep resistance and good thermal stability, HRSAs are used for components including turbine blades, exhaust nozzles and combustion chambers.
Weight is also a consideration, particularly for elements such as rocket propellant tanks where a lighter tank can better withstand structural stresses and can aid with payload capacity. The more the rocket itself weighs, the less payload, including
But HRSAs do come with their limitations — particularly from a machining standpoint. While the materials are metallurgically composed to retain their properties when exposed to extreme temperatures, this also means the stresses generated when
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machining these materials are high. The unique capability of these nickel based super alloys to perform close to their melting point also gives them generally poor machinability. Another key material used for space components is titanium. A lightweight metal with a density roughly half that of steel, titanium helps to reduce the overall weight of spacecraft, which in turn results in greater fuel efficiency and payload capacity. It’s also highly corrosion resistant and has excellent resistance to atomic oxygen, making titanium ideal for applications in low Earth orbit, where its oxide layer can provide protection against this highly reactive form of oxygen. However, these advantages also make titanium difficult to machine. Cutting tools need to be sharp, maintain their edge line and be incredibly wear resistant to battle the material’s high strength, while its low thermal conductivity compared to metals like steel or stainless steel can lead to heat accumulation during machining, which can result in premature tool wear.
Machining considerations Machining heat-resistant superalloys requires specialised tools and techniques — so what do space engineers need to
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consider? First, they’ll want to think about the material of their cutting tools. While carbide is the predominate material of choice, other materials are also available such as ceramic for roughing and cubic boron nitride (CBN) for finishing of HRSAs and polycrystalline diamond (PCD) for finishing on titanium alloys. Tool coatings and geometry are other important considerations. These materials like to be sheared, so a sharper geometry is typically a better option not to generate heat while machining. Thin tough coatings are preferred. Physical Vapor Deposition (PVD) is generally the first choice for HRSA materials, however, in titanium turning applications an uncoated grade is preferred as a first choice. HRSAs are typically machined at lower cutting speeds (rpm) compared to conventional materials to prevent excessive heat build-up and notch wear. Adjusting feed rates and depths of cut also play a crucial role in maintaining efficient machining. The right cooling strategy is also crucial due to the amount of heat HRSAs and titanium generate during machining. High pressure coolant is often employed to aid in breaking chips and dissipate excess heat. Manufacturers will also want to prioritise tool wear monitoring to predict tool failure and reduce the chance for insert failure, which can potentially damage an expensive component. One method Sandvik Coromant recommends for machining space components is high feed side milling. The technique involves a small radial engagement with the workpiece, which allows increased cutting speeds and feed rates and axial cutting depths with decreased heat and radial forces. To support this method, Sandvik Coromant has developed the CoroMill® Plura HFS high feed side milling range. The range features a series of end mills with unique geometries and grades and is made up of two end mill families. One family is optimised for titanium alloys, the other for nickel alloys.
Unique requirements While titanium and HRSAs are crucial materials in the space race, experts are constantly innovating their own materials too. In a bid to reach new space heights before their competition, most organisations operating in the field also develop their own, unique blend of materials to give themselves an edge. The contents of those materials are often shrouded in secrecy — it could be titanium alloys, ablative materials, carboncarbon composites or something totally different. Apart from the spacecraft engineers themselves, the secrets of its material blend will also be revealed to their machine tools
supplier. In Sandvik Coromant’s case, our expertise in space explorations spreads across the globe and includes several dedicated R&D teams tasked with advising on the best tools and techniques for the job. When a customer approaches Sandvik Coromant, the team will work with them to discover the machining solution for their material requirements. This can involve testing in a secure site, consulting on tool selection and advising on machining methodologies. The stakes are high when developing components destined for outer space. Even the slightest falter in quality can
stop a mission from getting off the ground, so careful attention must be paid to every step of the manufacturing process. That includes the materials selected for each component and how they’re machined. To deliver success among the stars, it is important manufacturers consider a balance between tough materials and the machining challenges they bring. Having access to the right machining knowledge and robust tools is key to making the next great leap. sandvik.coromant.com
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Digital dividends delivered for defence suppliers Australian SMEs are enhancing their prospects of winning supply chain work in the defence sector by beefing up their digital literacy and adopting Industry 4.0 in their operations. By engaging with a broad range of Australian defence manufacturers through its Smart Enough® Factory (SEF) Program, DMTC Limited is empowering participating businesses to achieve important capacity and technology development goals in regard to digitisation, artificial intelligence (AI), robotics, Industry 4.0 and Internet of Things (IoT) – including smart factory ambitions.
“We’re showing companies that while collecting data is important, using low-cost and low-code systems to turn that data into actionable insights and knowledge is really where the magic happens.” In 2023, the ICD Program included activity in Victoria, New South Wales and South Australia harnessing support from both the Department of Defence and the respective state governments.
As the name suggests the SEF Program, the current focus of DMTC’s Industry Capability Development (ICD) efforts, works by supplying businesses with ‘smart enough’ digitisation and sensor solutions that provide line of sight to the company-wide benefits of factory connectivity and optimisation of equipment and supply lines, whether legacy or new equipment.
The newest activity, led by DMTC with support from BAE Systems Australia and Flinders University, is part of BAE’s Connected Supplier Project in South Australia. Six manufacturers took part, accelerating their preparedness to directly contribute to defence industry supply chains. Participants included five South Australian-headquartered businesses as well as Tasmanian manufacturer CBG Systems, supporting CBG’s establishment of a new facility in South Australia.
Benefiting around 70 participating businesses to date, the SEF Program shows that data-driven approaches are one of the keys to spurring productivity improvements in modern manufacturing, in addition to opening doors to defence supply chain opportunities. “With an aim to boost digital literacy and associated capabilities, this Program demonstrates that data-driven advances can enhance business processes and manufacturing productivity, leading to efficiencies and to potentially significant cost savings,” DMTC Program Leader Charlotte Morris said.
“Working with DMTC, Flinders University and BAE Systems has allowed us to better grasp and open the door to the 4th industrial revolution and allow a clear digitisation pathway for our core manufacturing capability in South Australia,” Chris Brown, CBG Systems’ Business Development Manager, said. Too often, perceived barriers around cost and complexity, along with the pressure to maintain business-as-usual operations, result in companies being reluctant or slow to embrace Industry
DMTC Intern Morgan Brown examines machine performance via a digital dashboard with Parish Engineering’s Production Manager, Joshua Roos.
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The SEF program has been successfully deployed across Australia, in both metropolitan and regional areas. The technology can be applied in a broad range of ways to deliver digital uplift benefits for participating businesses.
4.0 technologies. Small businesses, particularly in the defence sector, face a convergence of challenges that can be summarised by the four Ds – disruption, decarbonisation, digitalisation, and diversification. Central to each of these challenges is the need to collect data and objectively demonstrate performance. The push for decarbonisation and Net-Zero targets across manufacturing supply chains is an emerging and significant challenge for companies at all levels of supply chains to both quantify, and then to progressively reduce, their emissions footprint. While there are a number of valid reasons why small businesses might be reluctant or slow to embrace Industry 4.0, exploiting digitalisation provides a key to unlocking productivity gains, achieving better integration of systems and collecting meaningful data across an SME’s business operations. The global push to decarbonise manufacturing supply chains presents an emerging and significant challenge for companies at all levels of supply chains to both quantify, and then progressively reduce their emission footprint. The industrial context and insights into issues such as Net-Zero reporting that is provided by DMTC’s direct engagement with Defence primes is a key part of the Program and reinforces its value and impact. Through the smart application of simple, cost-effective technology, companies like Moorabbin-based family business Parish Engineering are realising points of difference and competitive advantage in bidding for work in the supply chains of prime contractors. Parish was involved in one of the first SEF cohorts and has used the digital dashboards to benchmark and enhance cycle times and machine utilisation, and to take their expertise in precision machining to another level. Beyond the initial scope of their SEF project, the company has taken further steps to position themselves to target defence supply chain opportunities, and to implement Industry 4.0 more broadly across the company’s operations. The benefit of DMTC’s ICD programs, including the Smart Enough® Factory, extends to companies that are emerging as ‘defence specialists’. Better known for their indelible footprint in the motorsport and automotive industries, Queensland-based company PWR Advanced Cooling Technology has applied learnings from DMTC’s ICD programs to bolster both the digital connectivity of their Australian-based operations, and their credentials as a defence supplier.
Smart connections DMTC’s SEF Program roll-out is complemented by a Community of Practice that provides networking and ongoing support. The SEF Community of Practice enables companies to share their
Industry 4.0 insights and learnings for the benefit of all, as well as opening doors to collaboration opportunities. This opportunity has already been realised in a partnership between Victorian companies Parish Engineering, Redline Engineering and R&I Instrument & Gear.
Inspiring interns In addition to the direct dividend for businesses, the SEF Program is also actively contributing to the development of human capital, and helping to bridge the divide between students’ university studies and careers in defence or related technology sectors. A number of third or fourth-year undergraduate interns engaged to support the SEF Program have gone on to secure continuing employment with their host company, or employment in a similar role with another company. Many of the interns acknowledge that the defence sector had not been an active consideration in terms of career opportunities until their involvement in DMTC’s program. Contributions from interns are becoming an increasingly important part of the SEF Program delivery model, and highlight the benefits that investment in carefully-targeted workforce development can realise for Australia’s future sovereign capability ambitions. Sam McNaughton, General Manager for SEF delivery partner Defence Industry Advisory Services, is convinced of the mutual benefit for both companies and interns. “Industry often lacks the digitisation experience and capacity to deliver continuous improvement projects, in addition to meeting business-as-usual operational demands, so an intern can be a tremendous asset to an SME. Just as importantly, exposing interns to real-world business problems is critical to prepare them for a role in industry once they graduate.”
Poised to deliver Experts engaged by DMTC provide hands-on support, oversight of the interns and evidence-based feedback through workshops and during the implementation phase as well as in post-activity reviews, highlighting improvement opportunities and potential next steps for each company. This collaborative team includes DMTC personnel, industry partners and researchers from The University of Queensland and RMIT. Recognising critical and yet oftenoverlooked issues around appropriate cyber security controls for operating technology (OT), discrete briefings and training in cyber security are also provided. The support from these delivery partners positions each company to embrace the digitalisation of their manufacturing processes, as well as developing their defence-readiness and lifting cyber maturity and digital literacy standards. dmtc.com.au
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Women in Engineering Embracing diversity and encouraging passion to optimise outcomes. An article about welcoming women into engineering, by Neil Curtis, DVP Marketing at the Zygo Corporation. In this article, I take some time to discuss the topic of women in engineering with some successful women that have and are excelling in engineering related roles: Jennifer Helberg, Division Vice President (DVP), Business Unit Manager, at Zygo; Karen Nyberg an engineer, retired astronaut, and Zygo brand ambassador who, in 2008, became the 50th woman to travel to space as a Mission Specialist on Space Shuttle Discovery, STS-124; and Sara Moein and Lisa Zhang, Optical Systems Engineer and Application Engineer respectively at Zygo. The topic of women in engineering is of paramount importance today because diversifying the engineering field ensures a broader range of perspectives, fostering innovation and better solutions to complex challenges. Historically under-represented, women bring unique experiences and ideas that enrich the discipline. Additionally, promoting gender equity in engineering not only corrects longstanding systemic biases but also expands the talent pool, optimising the potential for breakthroughs in the field. As our world becomes more interconnected and reliant on technological advances, it’s imperative that the engineers shaping our future reflect the diverse populations they serve. While maternal roles and responsibilities can influence career choices and progression for some women, attributing women’s underrepresentation in engineering or senior roles primarily to maternal duties oversimplifies a complex issue. Many women without childrearing responsibilities still face barriers, including systemic biases, stereotypes, and a lack of mentorship or opportunities. Additionally, societal expectations often place a disproportionate burden of household and caregiving tasks on women, irrespective of their professional aspirations. While motherhood can be a factor, it's only one of many intertwining elements that contribute to the broader challenge of gender disparity in the workplace in general. Historically and currently, women’s under-representation in engineering can be attributed to a confluence of societal, cultural, and institutional factors. Deep-rooted stereotypes have often pigeonholed women into certain roles, deeming technical fields as ‘masculine’ and discouraging women from pursuing such careers. Educational systems and workplaces, at times, have perpetuated these biases, either subtly or overtly, through limited access to resources, opportunities, or mentorship for women. Additionally, the lack of visible female role models in the field and challenges in balancing work-life dynamics can deter women from entering or persisting in engineering. As a result, these systemic barriers have historically side-lined a significant portion of potential talent.
Gender diversity Let’s look at why attracting women into engineering roles and gender diversity in engineering teams is so important. Gender diversity introduces a variety of perspectives, experiences, and creative approaches to problem-solving, enriching the brainstorming process. Engineering, at its core, is about designing solutions, and a diverse team can offer a broad spectrum of ideas, leading to more innovative and comprehensive solutions. By combining the experiences of all genders, engineering teams can tap into a richer pool of creativity and insights, which often results in out-of-the-box thinking and enhanced product designs. Engineering products and solutions are used by a diverse global population. When engineering teams reflect the demographics of the end users, it ensures that the designed solutions cater to a wider audience’s needs and are more universally adaptable. For instance, safety equipment designed only by men might not
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account for women’s specific requirements, leading to potential usability or safety concerns. Gender diversity ensures that products and systems are more inclusive and effective for all users. In addition, a diverse team often leads to improved group dynamics and collaboration. Studies have shown that companies with gender-diverse teams often outperform their counterparts in terms of productivity, profitability, and employee satisfaction. The mix of masculine and feminine approaches can lead to better decisionmaking and overall team synergy. A balanced team, where all voices are valued, fosters a positive working environment and boosts morale. By actively promoting gender diversity, engineering firms can access a wider talent pool. Limiting opportunities based on gender means missing out on a significant portion of potential top-tier talent. In the global marketplace, where competition is fierce, having the best minds — regardless of gender — is crucial for success. Additionally, companies that prioritise diversity are often seen as more progressive, making them more attractive to potential employees and partners, and further enhancing their talent draw and competitive edge.
Gender diversity in engineering and leadership roles When it comes to women in engineering and leadership positions, we need to nail down tangibly why it is so important. Jennifer Helberg puts things quite succinctly. “One of the keys to attracting women to engineering roles is for them to identify themselves as having a place in that environment, and so being able to see women in influential positions is fundamental.” Karen Nyberg picks up this topic. “Many women and girls have mentioned that I am an inspiration to them, someone from a small town succeeding in being an astronaut which is something very few women have done. But what is unfortunate is that I started my journey as an astronaut 30 years ago, and not that much seems to have changed. In mechanical engineering, university undergraduates today are still 90% men. Role models need to be in place to break this bias, and to help women shine when they eventually enter the engineering workforce.” A conversation with Sara Moein, Optical Systems Engineer at Zygo shows how she struggled with and overcame such bias. “When I started my doctorate degree in optical engineering in the US, I was very aware of the fact that I was in a male dominated discipline, and that the ratio of female to male classmates and professors was still very low. From the standpoint of a female engineer, this meant that I had very few female role models around me to look up to, and that people made assumptions about my professional path and choices based on my gender. To overcome these challenges, I reached out to the very few female classmates and professors and made a small community in which we could freely discuss the challenges and learn from each other’s experiences. I also became member of professional societies and reached out to them to use their resources, such as invited talks and online workshops, to educate myself and my classmates and professors (male and female) about these issues and how to face them.” Hellberg elaborates, “Beyond the under-representation and need to overcome workplace challenges mentioned by Sara, what I see is that in many instances, women are not being impeded from entering high powered engineering jobs or leadership positions, but rather they are self-selecting out as they consider the sacrifices and balancing them with traditional family roles. Men make the same sacrifices, but I feel that on a level, we really do begin to boil this
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Karen Nyberg, an engineer, retired astronaut, and Zygo brand ambassador.
whole subject down to genetic wiring and nurture versus nature. People and indeed company policy have entrenched positions when it comes to gender specific family roles.” When talking about this topic, it seems to me that Hellberg nails it. Fundamentally, if companies want to attract more women, and truly embrace gender diversity, they have to understand the dynamic of family life which is so important to all, and be more understanding and welcoming to people (male or female) who want a family. Sara Moein identifies other areas where companies can level the playing field. “Companies can encourage young women to pursue roles in engineering by providing them with opportunities to advance their professional career. This could include facilitating hiring more qualified female engineers and scientists, providing equal pay and opportunities for professional growth, and encouraging women to take leadership positions. I believe that putting a spotlight on female engineers and scientists is one of the key components in letting others know that the engineering field is evolving and moving towards a more diverse and welcoming field.” The upside of having true gender diversity is too great to not try and even the playing field on such matters. Nyberg again adds an insightful and clear expression of why. “It’s all about diversity of thought and diversity of background. Forget about there’s a man, and there’s a woman. If teams are diverse, they pool different experiences and bring together different aptitudes, and this makes a HUGE difference to outcomes.” Hellberg agrees, “One of the things in business that is important is risk management. Stereotypically women are more risk averse than men, it is in their DNA. Too often, however, I think we feel we have to bang the drum for equality by saying there are no differences between men and women, but the reality is that there are, and we need to embrace and leverage these differences. When it comes to risk, a balance of risk aversion and risk tolerance, for example, is healthy.”
Encouraging interest and passion At the root of everything when it comes to helping people make positive career choices is to recognise a passion and encourage
that passion. Engineering is such a huge field, and some engineering roles may on the face of it seems to be male dominated. But the key is to approach this from a different angle. Nyberg picks up this point. “Addressing the under-representation of women in engineering roles requires a nuanced approach beyond just encouraging more women to pursue engineering. Recognising and tapping into an individual’s innate passions can be a game-changer. If we can illustrate to women how engineering can be a tool to realise their passions, whether it's in environmental conservation, healthcare, art, or any other field, it becomes a means to an end they care deeply about. By connecting the dots between what a woman is genuinely passionate about and how engineering can be the pathway to achieve that, we shift the narrative. It becomes less about fitting into a male-dominated field and more about harnessing engineering as a powerful enabler to fulfil personal and professional aspirations.” Once ignited, and once involved in a career in engineering, the motivations are the same for men and women. There is a wonder about science which informs so much in our everyday lives. This is beautifully encapsulated by Lisa Zhang, Application Engineer at Zygo. “When you work in the engineering industry, you will be exposed to many creative inventions and discoveries and have a chance to understand many production processes. Sometimes this can give you a deeper understanding of things you see in life and can be a spur for sparking a woman’s interest in things as well as a man’s. Taking the appearance of some brand-new car lights as an example, they are brighter and cooler recently, which is because of an improvement in the processing technology of the lights and the moulds. To ensure that the manufacturing of the lights conforms to the design, high-end instruments are needed to do quality control, and many manufacturers use Zygo's optical profilers for this. I am excited that when I look at a new headlight array, I understand why the lights look so great, and that I am part of the reason why.” zygo.com
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Sunlock with Capral Revolutionising the Australian solar rooftop mounting market. When you fly out of Melbourne airport, look for the rooftop installations of iconic brands like Elders recreated in solar panels mounted using systems from Australia's leading commercial solar mounting manufacturer. In the renewable energy landscape, Sunlock is synonymous with innovation and efficiency, with its solar mounting systems gracing the rooftops of Australia's most prominent commercial and government buildings. Sunlock's work with renowned brands, including Ikea, Aldi, McDonald's, Goodmans, Woolworths, Bunnings, and KFC, and its widespread presence on commercial and government rooftops across Australia underscores its market-leading position. Sunlock, as described by general manager Mani Kaparakis, is not just a company but a revolution in the solar industry. “We're fresh, we're innovative, we are very different in how we approach the market and our products and our customers,” said Kaparakis. This ethos of innovation is deeply ingrained in Sunlock's operations, from its unique C-Channel designed for commercial installations to its rapid three-year ascent to becoming Australia's leading commercial solar mounting manufacturer. Sunlock's specialised focus on commercial solar mounting systems is a critical factor in its success. “We only make commercial solar mounting systems for commercial solar,” Kaparakis emphasised. Their exclusive C-Channel design is engineered to withstand the highest loads and is tailored specifically for commercial installations. This efficiency is reflected in the product's quick installation time, making it a favourite among installers and retailers. What also sets Sunlock apart is not just its products but its people and culture. With a small team that knows each customer by name, Sunlock adds a personal touch to the solar industry, making service not just a priority but a defining characteristic. “Culture's very important to us, and all of our employees know all our customers by first name,” Kaparakis emphasised. A partnership with Capral Aluminium is an alliance that has fortified Sunlock's commitment to Australian-made quality and sustainability. “Partnering with Capral has allowed us to manufacture an Australian product,” Kaparakis noted, “Capral delivers the best possible product for us in a speedy timeframe. They understand our business requirements, their service is exceptional, and the fact that we can make our product locally support the Australian market and have an Australian product is very important to us. Sunlock's philosophy, built on embracing change, innovation, and
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sustainability, resonates through its products and partnership with Capral. Kaparakis emphasised the importance of a shared vision as a key strength of the Sunlok Capral partnership: “We wanted someone that would understand our business, share our vision, our passion, and grow with us. And that happened day one, I think Craig came out to see me and I explained to him what we do, how we do it. He got it very quickly. So did the whole team, our relationship has grown significantly and it's just been so exciting over the last couple of years. They understood our direction, our passion, our vision, what we needed out of there from them. And they've basically gone above and beyond to help us get to where we are today.” Capral's introduction of LocAl® Green in 2022, a low-carbon aluminium, has been a game-changer for Sunlock. By exclusively using LocAl® Green to produce its C-Channel solar rails, Sunlock has not only upheld its commitment to quality but has also enhanced the sustainability of its production. The adoption of LocAl® Green means that Sunlock's mounting solutions are not only the most efficient and effective but now the most sustainable. “One thing which stood out for us whilst we were considering the switch to LocAl Green was the fact that we could drastically reduce our carbon emissions without any change to our product quality, performance or specifications,” Kaparakis asserts. By switching to LocAl® Green, Sunlock will reduce its carbon emissions by 3,000 tonnes this year, a bold move that demonstrates the company's leadership. Capral's introduction of LocAl® Green aluminium is transformative across industries, offering strength, durability, and a sustainable edge. With carbon emissions at just eight kilograms per kilogram of aluminium, compared to the global average of 13.9kg CO2e/ kg Al, LocAl® Green represents a significant step forward in reducing the environmental impacts of all aluminium products. In 2023, in the solar industry alone, Australian solar panel installers will use over 16,000 kilometres of aluminium solar rails, equivalent to approximately 12,000 tonnes of aluminium. Sunlock's journey, marked by a relentless pursuit of innovation and quality and its strategic partnership with Capral Aluminium, is an exceptional example of Australian manufacturing excellence. As the solar industry continues to grow, Sunlock's story of innovation, market leadership, and sustainable practices will inspire and shape the future of renewable energy in Australia and beyond. sunlock.com.au capral.com.au
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Designer solar BIPV software new tools to unlock smart solar design Designing buildings with solar cleverly incorporated into the design has just become easier, thanks to software developed at RMIT University. Building-integrated photovoltaics, or BIPV, are building features such as roof tiles, cladding and windows that double as solar panels. Depending on the dwelling, BIPVs can cover a greater area of a building, generating solar energy from different angles. They also look smart and can be customised.
Cable-less Data Collection
Despite the potential of BIPVs, conventional roof-mounted panels continue to account for the lion’s share of new installations in Australia due to the extra complexity in predicting performance and sourcing BIPV technology. Now a team at RMIT has created software to help architects and engineers incorporate, source and cost BIPV in a building’s conceptual design phase. The software, funded by RMIT and the Australian Renewable Energy Agency, is the first of its kind to be designed using Australian data. Project lead Associate Professor Rebecca Yang from RMIT’s Solar Energy Application Group said she hoped the tool, called BIPV Enabler, would help make buildings greener. “This is the perfect solution for building designers and developers looking to select the right solar option to suit their design,” said Yang, the director of the Australian PV Institute and driving the BIPV Alliance. “We’re making integrated-solar a more attractive option to developers, slicing the time it would normally take to research and implement incognito solar devices. This isn’t just for new buildings either. Those looking to retro fit integrated solar into existing buildings will benefit too.” The tool integrates product, regulation, technical, economic and construction data to create 3D models and detailed lifecycle simulations tailored to each building’s planned location. It comes as the construction of Australia’s first office tower to be fully clad in solar panels was announced last year. For architects like Nic Bao, BIPV Enabler is set to help bridge the gap between BIPV technology and architectural design. Bao, a Lecturer in Architecture at RMIT, said having a tool to effortlessly incorporate factors such as climate, building code and materials would make solar-savvy design easier. “There are so many technical factors to consider when integrating BIPV into a design that it hadn’t been a popular choice, which was a missed opportunity,” he said. “Making BIPV design more accessible promotes sustainable development of energy-efficient buildings, while providing opportunities for low-carbon architecture.” BIPV panels can also take the form of wall panels, paths, even one day perhaps window panes. Corrugated panels may have the possibility to capture full solar rays at a range of angles. While building codes may slow the introduction, the ability to power homes and businesses safely and cheaply will ease the process, with data proof set to grease the timeline. The other challenge faced by designers and developers using integrated solar is choosing and sourcing materials. BIPV Enabler helps with both, boasting Australia’s first photovoltaic product database where Australian suppliers can be easily identified. Among the tool’s features are maps, a 3D shape library, solar visualisations, hourly weather data and pricing information for materials and feedin tariffs. “We hope to see more buildings capable of generating solar electricity, while maintaining good design standards – a win for the planet and aesthetics,” Yang said. Yang also said BIPV Enabler also worked with computeraided design programs and could be scaled and customised to incorporate other open-source datasets to suit changing needs. rmit.edu.au
Promotes Smart Factory by Collecting and Managing Measurement Data Advantages of Introducing U-WAVE Higher Efficiency Data can be input by single button operation! Since there is no need for manual input misinput does not occur. Efficiency is greatly improved!
Centralized Data Management Measurement data can be managed centrally! “Visualization of quality” helps prevent the generation of defective products!
Cost Reduction Effect Easily connected to the Digimatic gage* currently in use! A system configuration reducing the initial and running cost is possible. * Some models of U-WAVE-TM/TC are not applicable.
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Up to 99 gages can be connected to 1 receiver M.T.I. Qualos Pty Ltd 55 Northern Road, West Heidelberg VIC 3081 Ph: 03 9450 1900 Fax: 03 9458 3217 sales@mtiqualos.com.au www.mtiqualos.com.au
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Riding the rays UNSW Sydney taps NVIDIA’s Jetson platform for competition victory for Sunswift Racing on energy efficiency. In the world’s largest solar race car event of the year, the University of New South Wales Sunswift Racing team is having its day in the sun. The World Solar Challenge, which first began some 35 years ago, attracts academic participants from across the globe. This year’s event drew nearly 100 competitors. The race runs nearly 1,900 miles over the course of about four days and pits challengers in a battle not for speed but for greatest energy efficiency. UNSW Sydney won the energy efficiency competition and crossed the finish line first, taking the Cruiser Cup with its Sunswift 7 vehicle, which utilizes NVIDIA Jetson Xavier NX for energy optimization. It was also the only competitor to race with 4 people on board and a remote mission control team. “It’s a completely different proposition to say we can use the least amount of energy and arrive in Adelaide before anybody else, but crossing the line first is just about bragging rights,” said Richard Hopkins, project manager at Sunswift and a UNSW professor. Hopkins previously managed Formula 1 race teams in the U.K. Race organisers bill the event, which cuts across the entire Australian continent on public roads — from Darwin in the north to Adelaide in the south — as the “world’s greatest innovation and engineering challenge contributing to a more sustainable mobility future.” It’s also become a launchpad for students pursuing career paths in the electric vehicle industry. Like many of the competitors, UNSW is coming back after a threeyear hiatus from the race due to the COVID-19 pandemic, making this year’s competition highly anticipated. “Every single team member needs to understand what they’re doing and what their role is on the team and perform at the very best during those five-and-a-half days,” said Hopkins. “It is exhausting.”
All in on energy efficiency The race allows participants to start with a fully charged battery and to charge when the vehicles stop for the night at two locations. The remaining energy used, some 90%, comes from the sun and the vehicles’ solar panels. UNSW’s seventh-generation Sunswift 7 runs algorithms to optimize for energy efficiency, essentially shutting down all nonessential computing to maximize battery life.
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The solar electric vehicle relies on NVIDIA Jetson AI to give it an edge across its roughly 100 automotive monitoring and power management systems. It can also factor in whether it should drive faster or slower based on weather forecasts. For instance, the car will urge the driver to go faster if it’s going to rain later in the day when conditions would force the car to slow down. The Sunswift 7 vehicle was designed to mostly drive in a straight line from Darwin to Adelaide, and the object is to use the least amount of power outside of that mission, said Hopkins. “Sunswift 7 late last year was featured in the Guinness Book of World Records for being the fastest electric vehicle for over 1,000 kilometers on a single charge of battery,” he said.
Jetson-based racers for learning The UNSW team created nearly 60 design iterations to improve on the aerodynamics of the vehicle. They used computational fluid dynamics modeling and ran simulations to analyze each version. “We didn’t ever put the car through a physical wind tunnel,” said Hopkins. The technical team has been working on a model to determine what speed the vehicle should be driven at for maximum energy conservation. “They’re working on taking in as many parameters as you can, given it’s really hard to get good driving data,” said Josh Bramley, technology manager at Sunswift Racing. Sunswift 7 is running on the Robot Operating System (ROS) suite of software and relies on its NVIDIA Jetson module to process all the input from the sensors for analytics, which can be monitored by the remote pit crew back on campus at UNSW. Jetson is used for all the control systems on the car, so everything from the accelerator pedal, wheel sensors, solar current sensors and more are processed on it for data to analyze for ways AI might help, said Bramley. The next version of the vehicle is expected to pack more AI, he added. “More than 100 students are getting course credit for the Sunswift Racing team work, and many are interested in pursuing careers in electric vehicles,” said Hopkins. Past World Solar Challenge contestants have gone on to work at Tesla, SpaceX and Zipline. unsw.edu.au
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Sustainable Solutions Alteria Aluminium Systems using responsibly sourced Lower-Carbon Aluminium. In an era where sustainability is paramount, a newcomer to the aluminium batten and cladding market – Alteria Aluminium Systems is responding directly to a growing awareness amongst architects and designers of the need to decarbonise the built environment. With a focus on clever design, reducing carbon emissions and responsible sourcing Alteria has entered the market with sustainability as a top priority. 100% Australian-made, the Alteria range includes Aluminium Battens and Cladding Profiles designed to deliver a beautiful and sustainable solution for both internal and external applications. Aluminium is inherently non-combustible and can be finished in a range of on-trend colours or wood-look finishes to suit the specific requirements of a project. Aluminium is also infinitely recyclable at the end of life, with recent statistics suggesting more than 75% of all Aluminium ever produced is still in use today. Going a step further, Alteria products are produced exclusively from Capral LocAl® Green a primary aluminium option with carbon emissions of 8kg CO2e/1kg Al, significantly lower than the current global averages for primary Aluminium. "A key sustainability driver for Alteria was to ensure we found options to lower carbon emissions,” Natalie Middleton, Alteria Commercial Manager says. "Capral's LocAl Green Aluminium means it only produces 8kgs of carbon emissions per kilogram of aluminium, which offers a substantial reduction in carbon emissions when compared with the current global average for primary aluminium; this means by choosing LocAl Green aluminium, we reduce the embodied energy of our aluminium products.” Introduced in October 2022 the Capral LocAl® Lower Carbon aluminium offer continues to gain momentum among Australian manufacturers. "We are excited to see industry-
leading businesses, like Alteria, take up this option to source their extrusions from our Lower Carbon aluminium product,” says Luke Hawkins, Capral General Manager of Industrial. Capral has been certified against the Aluminium Stewardship Initiative Performance and Chain of Custody standards. This gives customers confidence that the aluminium they use for their products has been responsibly sourced all the way along the aluminium value chain. By using ASI-certified, lower-carbon aluminium sourced locally from Capral Aluminium, Alteria minimises its environmental footprint and supports Australian manufacturing and responsible procurement. This sustainable approach aligns perfectly with Alteria Aluminium Systems ethos, highlighting the organisation's dedication to delivering quality products while prioritising environmental consciousness. alteria.com.au capral.com.au
Circular Plastics Australia Victoria’s biggest PET plastic bottle recycling plant opens for business in Melbourne. A new $50m facility capable of recycling the equivalent of up to one billion 600ml PET plastic drink bottles each year has been opened by the Federal Environment Minister Tanya Plibersek and Victorian Minister for the Environment Steve Dimopoulos. The facility has commenced operations in Melbourne, just in time to take advantage of the state’s Container Deposit Scheme. The Circular Plastics Australia (PET) plant will convert used drink bottles into high-quality food grade resin which will then be used to manufacture new recycled PET bottles and food packaging. The plant will be fully operational and recycling PET bottles collected through the Container Deposit Scheme, and additionally some refuse of the household and office recycling bins in the system. This is the biggest facility in Victoria and the state-of-the-art equipment is capable of producing 2.5 tonnes of the recycled PET resin per hour. Multiple infrared and optical sorters firstly separate out any non-PET material like bottle lids, labels and metals. The PET bottles are then shredded, ground and washed, before the flaked material is then pushed through a two-stage heating and drying process. The washed flake is finally sent through an extrusions and purification process to produce the recycled PET resin, certified to US FDA standards at this word-class facility. When fully online and operational, this plant will be able to produce 20,000 tonnes of recycled PET resin each year. There will be 45 jobs for its 24/7 operations, and will be supported by about 60 fulltime jobs during its construction. A similar sized plant was opened in Albury NSW early last year.
Both sites will create a closed loop solution for plastic beverage bottles where they are made, used, collected and recycled to be given another life. These new facilities enable Australia to recycle and manufacture our PET plastic drink bottles and packaging locally, without the need to import plastic material for new packaging. CPA (PET) leverages the expertise of each partner to deliver a closed loop for PET beverage bottles. Cleanaway collects, sorts and delivers plastic waste to the recycling facilities. Pact operates the recycling facilities and uses the recycled resin to make new food packaging, while Asahi Beverages and Coca-Cola use the recycled resin to make new beverage bottles. Solar panels are incorporated into the design of the facilities to power some of the operations, and water treatment units and rainwater tanks will reuse and recycle as much water on site as possible. Circular Plastics Australia (PET) is a joint venture between Pact Group, Cleanaway Waste Management, Asahi Beverages, and Coca-Cola Europacific Partners (CCEP) and was formed to provide a bottle-to-bottle solution to help accelerate the local plastic circular economy. While competitors in the beverage industry, CCEP and Asahi Beverages have come together for this joint venture to deliver a significant increase in the volume of PET plastics recycled in Australia. By recycling locally, the two plants are helping to create a “closed loop” solution for plastic drink bottles and imported recycled resins. ccep.com pactgroup.com cleanaway.com.au
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Reducing power costs SMC Corporation comes up with five ways to lower your manufacturing plant’s energy costs. In an era where manufacturing and process plants are under increasing pressure from soaring energy bills and ever-tightening CO2 emissions legislation, it begs the question: is there a way to reduce energy consumption – quickly - without compromising efficiency or output? The short answer is yes; but only with the right advice and expertise.
Bill Blyth, Group Manager ANZ, Energy Conservation for SMC Corporation ANZ
Recently, SMC Corporation shared an article on a hot button issue in factories the world over: energy savings. “We have spoken to this topic time and time again, but knowledge and information continues to evolve and with it, comes further insights and advice for our customers,” said Bill Blyth, Group Manager ANZ, Energy Conservation for SMC Corporation ANZ. “In this article, we detail five pertinent ways to ensure energy savings, all of which are relevant to our customers in Australia and New Zealand.”
Five ways to deliver fast and effective energy reductions 1) Relieve the pressure The first way is to reduce the pressure of the compressed air system, where possible. For most industrial plants, typical operating pressure is between 6 and 7 bar. By lowering your pressure to 4 bar, energy consumption reduces by up to 29%. However, expert input is required to avoid compromising performance. “For those seeking a quicker route to improvements, shutoff solenoid valves help prevent air losses, caused by leaks - even when machines are idle. Other solutions include a two-pressure module that switches to a lower pressure during machine idle periods, vastly reducing air leakage, or the new plug and play Air Management System (AMS series) by SMC,” said Blyth. 2) Plug leaks SMC have encountered plants suffering from 20 to 50% leakage rates, driving up energy consumption and bills. The optimal way to identify leaks is by appointing an expert company to undertake an audit, ideally twice a year. “SMC’s main line filter series, the AFF, is the ideal solution,” added Blyth. “It offers an increased air flow capacity due to the lower pressure drop, contributing greatly to one’s energy saving. It also offers a flow capacity of 14.5min (ANR) and pressure drops of 5kPa or less.” Other complementary recommended products include SMC’s range of S couplers (the KK130 series), the TKS double layer tube stripper and the TRB/ TRBU series of double layer tubing. 3) Blowing applications Did you know that air-blow tasks are accountable for more than 40% of your factory air consumption, thus offering a real savings opportunity? Here, sizing your blow nozzles correctly, coupled with a reduction in factory pressure, delivers good results. Further initiatives in this area include better use of regulators to ensure you only use the amount of air necessary. Pulse-blow valves, which switch the air blow on/off very quickly while maintaining the force of the blow, offer another great way to reduce your air consumption, sometimes up to 50%.
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“SMC offers a range of components for efficiency in air blowing applications. These include the KN series of nozzles for blowing, the ever-popular VMG blow gun, the IBG compact type blow gun series, the IBV10-X5 impact blow vlave and the AXTS series of pulse blowing valves.” 4) Efficient vacuum systems If you have machinery using air-generated vacuum pick and place applications, the use of vacuum ejectors with multiple Venturi and air switch-off energy-saving technology reduces air consumption by up to 93%. “SMC is dedicated to enhanced savings through our vacuum ejector range,” commented Blyth. “The ZK2A vaccum ejector series is an energy saving ejector which cuts off air supply once vacuum is reached. The ZL3 series is a multistage ejector is a high-efficiency vacuum generator, operating at around 150%. Finally, the ZKJ vacuum manifold series is designed to reduce air consumption by 90% and is Fieldbuscompatible.” 5) Right components We always say at SMC that energy and cost efficiency is deliverable through many small actions. Choosing components wisely makes a big difference. For example, adding power-saving circuits to your solenoid valves, a speed controller, such as the AS-R series, to your cylinders or using triple inverter technology in your thermo-chillers such as the HRSH inverter type, helps to ease energy bills. “With the right advice and components, energy savings can be quickly and easily achieved,” said Blyth. “SMC’s range is able to deliver on all five energy saving mandates, and our team is ready to help you achieve long-term savings.” smcanz.com
RENEWABLE ENERGY & CLEAN TECH
COP31 in Australia will help Hosting the UN climate talks here will help Australia embrace a clean energy future. Dr Wesley Morgan is a senior researcher with the Climate Council of Australia and a research fellow at the Griffith Asia Institute. Fossil fuel production is in an inevitable decline and states that can embrace lucrative new opportunities in the clean energy economy will thrive. The Albanese government has sought to move in this direction, and hosting the UN climate talks in 2026 would be a first big step. Significant progress was made at COP28 in Dubai last year as the UAE hosted the biggest United Nations climate conference ever held. Australia joined more than 115 countries that have committed to a global target of tripling renewable energy capacity by 2030. Negotiations are now focussed on an agreement to move rapidly away from fossil fuels. Many observers were sceptical that the COP28 hosts could deliver a consensus on shifting away from coal, oil, and gas because the United Arab Emirates is a major oil exporter. This is a problem Australia also faces, having put up its hand to host the UN climate talks in 2026 in partnership with Pacific island countries while remaining a major exporter of coal and gas. Today, Australia exports almost three times as much fossil fuels as the UAE does, with dozens of further coal and gas projects in the approvals pipeline. Yet Australia’s economic interests are changing. Australia has no future as a major fossil fuel exporter. The global energy transition is well underway, and demand for coal, oil, and gas is expected to peak before the end of this decade. As the Minister for Climate and Energy Chris Bowen has told delegates in Dubai: “We must face this fact head on: if we are to keep 1.5C alive, fossil fuels have no ongoing role to play in our energy systems – and I speak as the climate and energy minister of one of the world’s largest fossil fuel exporters.” Mature technologies are readily available to replace fossil fuels in electricity generation and transport. Destination markets for Australian energy and commodities – like Japan, Korea, China, and India – have all committed to achieve net-zero emissions by midcentury and have set interim targets to cut emissions over the next decade. Australia’s challenge is to manage the now inevitable decline of fossil fuel production while embracing lucrative new opportunities in the clean energy economy. Hosting the UN climate talks in 2026 would be a chance to signal Australia’s transition from a past as a fossil fuel heavyweight, to a future as a clean energy powerhouse. Over the next three years the world is set to pass a key inflection point. If Australia hosts COP31 in 2026, it will be in a context where global greenhouse gas emissions will likely be falling. We know this because a growing number of countries have declining trends for fossil fuel CO2 emissions, including the United States, the European Union, the United Kingdom, and Japan. China is currently the world’s biggest fossil carbon emitter, contributing 31% of the global total. But explosive growth in clean energy investments mean China’s emissions are set not only to fall in 2024, but to go into structural decline with renewables installations outpacing energy demand. Behind these trends is surging market demand for clean energy technology – solar, wind, batteries, and electric cars – that is displacing legacy fossil fuel technologies like coal-fired power and
combustion engine vehicles. Based on current market trends, the International Energy Agency now warns of a risk of over-investment in fossil fuel supply. The worldwide shift toward clean energy technologies means we are close to a peak in global greenhouse gas emissions. New analysis from the Global Carbon Project says carbon emissions are nearing their peak. This is echoed by analyses from the International Energy Agency suggesting global CO2 emissions may have already peaked in 2023, and from Climate Analytics which suggests global greenhouse gas emissions will likely start falling in 2024. Having taken their foot off the accelerator of warming, countries will need to slam on the brakes. Once global greenhouse gas emissions peak they will still be accumulating in the atmosphere. Emissions will continue to drive catastrophic warming until we bring them down to as close to zero as possible. The Intergovernmental Panel on Climate Change (IPCC) says we need to roughly halve global emissions before the end of the decade to keep 1.5C within reach. The stakes could not be higher. A major new report says we are now at grave risk of crossing irreversible “tipping points” in the Earth’s climate system, which could precipitate runaway warming. This is a threat of a magnitude never faced before by humanity. The good news is that major powers are doubling down on clean energy technologies, using green industrial policy and targeted government support to redirect investment. In 2022 the United States committed its largest ever climate spend through the Inflation Reduction Act, which allocates $520bn – around a quarter of Australia’s entire GDP – to stimulate investment in renewables and new solar, wind, battery, and electric vehicle manufacturing. Since it came into effect, 270 clean energy projects have been announced across 44 US states, representing $400bn in private investment which could generate 175,000 new jobs. China is also undergoing a boom in clean energy manufacturing and a historic expansion of renewables – especially solar. In 2023, China is installing around 210GW of solar, twice the installed solar capacity of the US and four times what China added in 2020. By 2025, China is expected to be adding 1000GW of solar each year. Around 30% of all vehicles sold in China this year are electric. Australian Treasurer Jim Chalmers has flagged that the 2024 federal budget will include targeted support for green industries such as critical minerals, battery manufacturing, renewable hydrogen, and green metals. If Australia hosts the UN climate talks in 2026 it will be the largest diplomatic summit we have ever hosted. With the international spotlight on us, Australia must be ready to show the world that we are moving rapidly away from coal, oil, and gas, and embracing our clean energy future. Dr Wesley Morgan is a research fellow at the Griffith Asia Institute, and a senior researcher with the Climate Council of Australia. This article is republished with permission from the Australian Institiute of International Affairs. internationalaffairs.org.au
www.raymax.com.au
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EcoCleaning Heat pump with heat exchanger instead of electric heatings saving 169MWh of electricity per year. Energy efficiency and climate protection are key issues in the automotive industry. This does not only concern products but also their manufacture. To exploit the existing potential in the cleaning of engine components, a premium car manufacturer replaced the electric water heating system in its Austrian works with a heat pump. This has resulted in electricity savings of approximately 70% per year in this process step. The energetic optimisation of production lines and machinery for the manufacturing of core engine components like crankshafts and crankcases, cylinder heads and housings for the latest generation of electric drives has been on the agenda of BMW Group's Steyr site for several years. This also includes the cleaning machines for these components. “To reduce energy consumption we have started with Ecoclean to equip the pumps of cleaning machines with variable frequency drives in 2016,” explained Gerhard Fuchs, the person in charge of the processes and energy officer in the Steyr works. In the search for further ways to save energy, consumption measurements showed that the electrical heating systems of the cleaning machines running in three-shift operation caused a high electricity consumption,” said Fuchs. Considerations on how energy could be saved in hot water generation resulted in the use of a heat pump. “I wanted to implement a pilot project to determine the energy savings potential we could achieve by replacing the previous electric heating system with a heat pump. I asked the company whether EcoClean would join us as general contractor. After they agreed, we chose a transfer cleaning machine of the manufacturer.”
Annual energy savings of 169 MWh The solution is exactly tailored to the situation at BMW Steyr: On the roof of the transfer system there is a tank holding 2,000 litres of clean water that is supplied to the cleaning process at 56°C. The required electrical heating system had a power drawal of 39kW. Cooling of the vacuum pumps and control cabinet was effected by a cold water circuit. Cooling water is provided at a supply temperature of 16°C and returns at a temperature of 22°C. This 'warm water' serves as energy source. It is supplied to the heat pump (power draw of 11.2kW) where it is heated to 65°C. The heat transfer to the hot water supply of the cleaning machine is effected by a plate heat exchanger. A new circulating pump (power drawal 1.2kW) delivers the heated process water to the hot water tank of the cleaning machine while a second new circulating pump (also with 1.2kW power drawal) returns the water that has been cooled to 16°C to the cold water circuit. This well-thought out solution reduces the energy consumption from 39kW to 13.6kW. With a defined production time of 5,760 hours per year, this adds up to more than 146MWh. Furthermore, another 23MWh are saved in cold water generation since the cooling water now only needs to be cooled down from a much lower return temperature to the required supply temperature.
Quick modification without interruption of production As the project was to be implemented without interruption of production operations, the modification job was carried out during a two week holiday in the summer of 2022. The heat pump, plate heat exchanger and the two new circulating pumps were installed on the shop floor near the machine, insulated and surrounded with guard fencing. The surface area required for this corresponds to approx. the size of two pallets. In addition, the modification required four new pipes. Two of them connect the clean water tank on the machine to the plate heat exchanger. The two other pipes transport the warm water from the cooling circuit to the heat pump and return it after cooling. “We integrated a display for temperature and flow
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By integrating a heat pump with plate heat exchanger, power savings of 169MWh and savings of 123 tons of CO2 annually.
monitoring,” explained Fuchs. “The company's energy monitoring system includes an energy meter to verify the saved heating power. This monitoring as well as measurements made by the independent engineering office after completion of the project show that 100% of the predicted savings have been achieved.
CO2 footprint and operating cost reduction Due to the saved current of a total of 169MWh, the annual operating costs for cleaning have been reduced by approx. 19,000 Euros. In addition, significantly fewer CO2 emissions are emitted into the environment, in this case the savings amount to approx. 34 tons of CO2. “It has been a good decision to involve Ecoclean as prime contractor for energy-efficient projects. We are very happy with the results and their support, and will continue our cooperation,” concluded Fuchs. ecoclean-group.net
RENEWABLE ENERGY & CLEAN TECH
Green Economy In recent years, many policymakers thought they had found the perfect formula for implementing climate-friendly policies without facing difficult politi massive subsidies. David Amiel reports in this piece, republished with permission from Project Syndicate. Historically, mainstream economists believed the best way to facilitate a green transition was to establish a carbon price through taxation or quotas and then leave the relevant economic decisions to private actors. Unsurprisingly, many economists have criticised the US Inflation Reduction Act as a less efficient method of allocating resources. But they missed important aspects of policies based on green industrial subsidies. Such policies managed to overcome some of the political obstacles that have hindered climate policymaking. They raised hopes that industrial interests, security concerns and environmental priorities could be aligned. They balance voters’ deep concerns about climate change and workers’ demands for reindustrialisation, and even serve some purely economic objectives. From a macroeconomic perspective, when interest rates were at historically low levels, debtfinanced programs could provide economies traumatised by the COVID-19 crisis and the fear of protracted secular stagnation with a much-needed boost in aggregate demand. From a microeconomic perspective, such programs can be expected to accelerate innovation in specific fields. But the limitations of this doctrine are becoming increasingly apparent. First, financial conditions have changed. The green investments France needs to make by 2030 are estimated at 2% of GDP, half of which is expected to come from the public sector. These figures are in line with other estimates for similar countries. Given the rise in interest rates, additional fiscal scrutiny is needed to accommodate these investments. Second, subsidies alone can’t bring our climate targets within reach. The risk lies in potentially increasing the use of clean energy without dramatically reducing the use of fossil fuels. Regrettably, this is the current global trend. Third, from a political standpoint, while green industries are necessary, they don’t immediately create a constituency large enough to counter the public backlash against new restrictions. A revised doctrine is needed. While key aspects of green industrial policies should be maintained and even enhanced, amendments and additions are essential. Crucially, fiscal policy must be reformed. In an age of monetary tightening, public debt related to climate policies should be differentiated. By publicly committing to a long-term strategy to finance and deliver climate investments, governments could more easily influence the investment decisions of private companies and households and facilitate coordination of fiscal and industrial policy across national borders. Annual budgets don’t provide the visibility we need. The French parliament has already passed a bill mandating such a measure. A detailed roadmap is also needed. To reconcile climate objectives, economic sustainability and political support, all policy instruments must be harmonised. To this end, French President Emmanuel Macron’s second term has been marked by the introduction of a new approach: environmental planning. This strategy emerged from recognising the shortcomings of relying too heavily on carbon pricing, especially after the 2019 increase in gasoline and diesel taxes sparked the ‘yellow vest’ protests, driven by people who were dependent on petrol- and diesel-powered vehicles and felt abandoned. While acknowledging that market forces can’t produce alternatives quickly enough to meet social needs, environmental planning also recognises the limitations of relying solely on subsidies. To be sure, there’s still a long way to go to achieve a greener economy. The coming year will serve as a crucial test for many Western countries, with elections in the US, the EU and the UK
occurring amid escalating political tensions over environmental issues. Several factors are crucial to preventing popular opposition to climate policies and encouraging take-up of clean solutions, such as electric vehicles. While the negative impact of policy changes is often explicit, positive outcomes remain implicit. For example, European governments announced that new petrol-and diesel-powered cars will be banned by 2035 but have struggled to provide even an estimated price for electric vehicles. Clearer commitments must be made, given that citizens comparing the current prices of petrol- and diesel-powered cars to electric vehicles are understandably concerned. Moreover, public engagement must play a central role, as the phaseout of fossil-fuel vehicles will require extensive plans for retraining automobile workers and supporting small businesses. Geographic differentiation and renewed urban planning are also needed to reduce long commutes that force people to depend on cheap fuel. Lastly, we must strive for fairness. To counter the populist narrative of elites evading restrictions imposed on the middle class, the super-rich should contribute more than the general public. As a symbolic gesture and proof of concept, the EU could announce ambitious plans for regulating the private-jet industry and hastening its clean-energy transformation. This is just a small part of the broader reinvention we urgently need. By focusing solely on carbon prices and industrial subsidies, policymakers had hoped to sidestep tough political choices. But both approaches have proved inadequate, both socially and economically. Climate policies must move away from the ages of green taxes and subsidies and enter the age of politics. David Amiel is a member of the French National Assembly, is special rapporteur of the budget for environmental policies and a member of the finance committee and the European affairs committee. He coordinated the conception of French President Emmanuel Macron’s campaign platforms in 2017 and 2022 and is a former policy adviser to the President (2017–2019). project-syndicate.org
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Blue sky over Monash Companies find formula for success at Monash Innovation Labs. Businesses looking to turn ‘blue sky' ideas into reality are tapping into on-site expertise, facilities and student talent at Monash Innovation Labs, located at the heart of Monash University’s Clayton campus in Melbourne’s southeastern suburbs.
Enzide Technologies is developing advanced plastics that incorporate bioengineered enzymes to improve their biodegradability in water and in home compost, with the potential to open up a wide range of new applications for biodegradable plastics.
Opened in 2023, the Monash Innovation Labs, formerly the Monash Smart Manufacturing Hub, is designed to support and enable companies across all sectors and at all life-stages to advance their ideas, their products and their processes.
"We’ve taken up an office and wet lab here at Monash Innovation Labs so we can access Monash's state-of-the-art facilities and academic experts to help advance our technology," said Pete Cass, Enzide's Chief Scientist. “We’re also able to access spectrometers, advanced imaging techniques, materials testing and material processing facilities right here. In our lab at Monash we’re creating new protein formulations and testing degradation of the plastic composites in water,” he explained.
A partnership with Monash Innovation Labs allows a company to licence state-of-the-art offices, workshops and/or ‘wet lab’ spaces to design, test and develop new innovations, with full technical support and purpose-built infrastructure.
But staying at Monash rather than relocating as it grows has helped the company unlock the full potential of the university’s top-tier engineering and business expertise and resources, including its commercialisation incubator, The Generator.
International medical technology startup Proton Intelligence is developing the world's first wearable continuous potassium monitoring platform to guide the management of high potassium levels (hyperkalaemia) in people with chronic kidney disease and heart failure. "Our motivations for setting up at Monash Innovation Labs include access to academic experts, the unique research and business ecosystem, and proximity to state-of-the-art infrastructure like Monash Health Nephrology, the Victorian Heart Hospital on the Monash campus, and the Melbourne Centre for Nanofabrication,” said Proton’s Head of Sensor Engineering, Dr Citsabehsan Devendran. "Our company is growing rapidly and we need larger facilities with better equipment like the clean room processors and instrumentation, which we use extensively. We looked at other collaboration spaces, but the mix of offices with labs at Monash is really convenient and the cost is more competitive,” said Dr Devendran.
"Being here at Monash Innovation Labs has been a fantastic fit for ElectraLith,” says CEO Charlie McGill. “It provides us with the use of best-in-class laboratories and access to world-leading facilities and academics. Monash Innovation Labs is integral to our development from a spinout to a world leader in lithium technology.”
“Monash also provides a range of services that are critical to our business including chemical characterisation facilities.” Jupiter Ionics, named for the ammonia-rich atmosphere of the solar system’s largest planet, is developing green technology to produce ammonia using air, water, and renewable energy in a patented
Recognising that innovation doesn’t only depend on physical resources, Monash Innovation Labs also offers access to the talent and thinking of students and researchers in disciplines from engineering and science to business and IT. In January 2024, companies including Jupiter Ionics, Proton Intelligence and Enzide Technologies joined Monash Innovation Labs’ first licensee ElectraLith, which is pioneering clean and efficient technology for direct lithium extraction and refining. ElectraLith traces its origins to groundbreaking research on lithiumselective membranes by chemical engineers at Monash’s Research Hub for Energy-Efficient Separation.
CEO Electralith Charlie McGill (left) with Monash Innovation Labs founder and director Adrian Neild.
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process. Established in 2021, the company is developing an electrochemical cell device that will produce ammonia without releasing carbon dioxide into the environment. “The technology we are developing aims to replace grey ammonia and revolutionise the production of fertiliser for global agriculture as well as creating a sustainable fuel source for marine vessels," said Jupiter Ionics CEO Dr Charlie Day. "With a staff of 18 expanding to 30 by the end of this year, we needed a large wet lab with office space close by, and the idea of working within the ecosystem of the Monash Innovation Labs along with other startups facing similar challenges really appealed to us; it feels like we are part of something bigger than ourselves,” said Dr Day. "Being able to set up lab facilities here will allow us to scale up and get to the next stage, which is critical. We aim to be here for a couple of years to keep developing our technology, until we can demonstrate performance of a larger commercial-scale device."
The Proton team in their laboratory.
A key feature of Monash Innovation Labs is the Smart Manufacturing Lab, which offers additive manufacturing expertise and ‘digital twin’ technology to help businesses design and develop more intelligent manufacturing processes and advanced automation.
Consulting accessed student talent via the Industry Innovation Program (IIP) and were able to turn ‘sketchpad’ ideas into real innovations. “We’re a small firm, but engaging with Monash and the Industry Innovation Program has allowed us to feel like we're playing on a bigger stage,” said Wave director, Rob Catchlove. “With dedicated resources focused on this part of our business, plus access to research expertise, smart Monash students and the resources of the Monash Makerspace, we’ve been able to accelerate development of new products.”
Using digital twin technology and mixed reality tools like augmented reality and virtual reality can allow a business to test the effects and impacts of process changes, trial new production lines or develop training and maintenance routines in a risk-free environment.
Engineering/Science students William Wang and Christopher Scott worked with Wave Consulting on a grey water filtering product with input and supervision from Monash environmental engineering expert Dr Brandon Winfrey.
And the Smart Manufacturing Lab also offers expertise and leadingedge resources in areas like connectivity, collaborative robotics and the integration of AI.
“The IIP students were very engaged, dedicated, responsive and open to feedback as we worked together,” Catchlove explained.
“Monash Innovation Labs also gives us access to great talent and we have taken on two engineering interns, one science intern and an economics intern.”
Importantly, Monash Innovation Labs provides a low-risk way for businesses to access and engage with the next generation of engineers, scientists and technologists through student-based initiatives including the Industry Innovation Program (IIP), Industry Doctoral Program (IDP) and Engineering Co-operative Education Program. Environmental engineering design consultancy Wave Consulting had been established for several years but found themselves with ideas they hadn’t had the time or resources to pursue. Through partnership with Monash Innovation Labs, Wave
“And the program itself is very flexible - we were able to set up the objectives, timelines and tasks to suit our company and product. We’d love to take on more IIP students as our company grows and we look at further product development opportunities. Monash Innovation Labs is addressing wide-ranging industry challenges through hybrid programs involving both research expertise and students,” explained founder and director Professor Adrian Neild. “We’re committed to ensuring direct industry benefit through innovation and by providing a career-ready talent pipeline for the future workforce.” monash.edu/monash-innovation-labs
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Australian Manufacturing Technology magazine had a chance to interview Heidi Hannonen, Vice President, Markets, Kemppi Oy in Finland, on her recent trip out to the open the Kemppi Australia Welding Innovation and Training Hub in Sydney. AMT: Tell me about some of the advancements Kemppi has made in welding equipment technology, and how these innovations improve efficiency and precision? Heidi Hannonen: Kemppi’s advancements have concentrated on three key areas. That’s welding productivity, welding quality and product usability. In all three, the focal point has always been the welder - what will make their day at work better, safer, and more efficient. In terms of efficiency, we have incorporated various technology features such as Weld Assist so that the welder can quickly set up the right parameters on their machine faster to increase productivity. Welders can also weld up to 30% faster using our Double Pulse function on our TIG AC/DC models, which accelerates the travel speed in DC hand welding and mechanised applications. The MicroTack function lets welders complete multiple, repetitive tacking on thin sheet applications quickly and without forgoing quality. In addition to these features which all aid precision, many of our GMAW models also incorporate the latest in ignition technology – Touch Sense Ignition. This delivers precise ignition capability and stable arc control to help minimise spatter and ensure precise, quality welding. To further enhance welding efficiency and precision we have also released a range of software solutions that can be combined with our digital machines. Solutions such as our range of MAX and WISE processes work to increase the welding travel speed and quality of welds, while helping save the welder time and money. AMT: In what ways has digitalisation and data analytics been integrated into Kemppi's welding processes for monitoring and optimisation? HH: We are all becoming more data driven and the welding environment is no exception. Traditionally, welding facts have been difficult to pin down, but not today. Kemppi offers a suite of software solutions under the WeldEye brand which optimise welding production. WeldEye solutions enable welders, welding management and welding quality personnel to analyse welding data, monitor quality and identify areas of high performance and areas for improvement. With WeldEye you can track the performance of the welder and see who is welding where, when and how. The software also lets you trace individual welds, their quality and ensure they comply with the welding procedure specifications. Management is notified of any welding deviations and they can be rectified in real-time. In addition to monitoring a welder’s performance, WeldEye also lets welding supervisors keep track of their welder’s qualifications and whether they need updating. This data-driven approach enables real world optimisation and quality control for improved working efficiency. Welders and management can make informed decisions based on accurate data and reference materials to reduce errors and rework, and enhance overall welding performance, productivity and quality.
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AMT: Does Kemppi work with governments and associations to help with training and certifications of grading welders in their trades, in local areas of Scandinavia, or further out in Europe, US or here in Australia? HH: Kemppi has a long history of working with training establishments and vocational training centres, not just in Scandinavia, but worldwide, including Australia. We also support industry events such as the Worldskills Competition. In Australia, we work closely with TAFE. We train welding teachers on our Kemppi machines and also on our software so that they can pass on best practices to students. Our partnership with TAFE is an important relationship as welding technology is constantly evolving and TAFE teachers are at the coalface of ensuring that students are taught the correct skills set. AMT: How has the use of advanced materials, such as highstrength alloys and composite materials, influenced welding processes, and has Kemppi answered that with hardware? HH: The use of high-strength alloys and composite materials such as 3CR12 stainless steel has indeed influenced welding processes. The key challenge when working with such materials is that they need to be welded at the right temperature. If the welding temperature is too high it can destroy the chemistry of the base material and the metal will likely crack. To ensure welders can attain the right heat and other correct parameters when welding such materials, we have introduced our special MAX processes software packages, which together with our WISE software solutions address these concerns. Our MAX processes and WISE solutions can be combined with our welding machines to optimise welding performance. These processes offer reduced heat input and controlled fusion plus more, to minimise distortion and ensure high-quality welds when dealing with highstrength alloys and composite materials. AMT: How does Kemppi mitigate the potential health hazards associated with welding fumes and radiation? HH: For Kemppi, every welder’s health is paramount and to help ensure their well-being we introduced personal protective equipment (PPE) decades ago. Today, our safety portfolio is far broader and includes first class, stand-alone welding helmets that protect the eyes and facial skin. We have also developed our own fresh-air helmet solutions - both fan-assisted and compressed-air fed to protect the lungs of the welder against particles, fumes and gases. Our range of fume extraction torches further improve the safety of the welder. They are equipped with an efficient vacuum system that extracts the welding fumes directly from the gun nozzle to provide a safer and cleaner working environment for the welder and those around them. And to protect the hands of the welder, we also recently added welding gloves to our range.
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AMT: Please speak about emerging trends or technologies in the field of welding that are gaining traction, welding cobot research for instance. HH: Welding automation has seen a great deal of development in recent years in the industry. Advanced sensing technologies and user-friendly programming systems have helped drive automation. Kemppi is developing and investing significantly in automation. Cobots, a name derived from ‘cooperative robotics’ is one such area, and many of our welding machines interface with welding robots and cobots. For example, our X5 FastMig and Master M350 series machines are developed to serve both hand welding and cobot/robotic welding requirements. Given the shortage of skilled welders worldwide, automation and cobots will continue to be embraced. AMT: I was so impressed with the Kemppi stove welding day where over 500 stoves were built in Finland, for the Ukrainian people. Can you talk about other Kemppi work in community programs like this? HH: Kemppi is committed to giving back to the community and our work in this space is quite diverse. Apart from assisting with the Ukranian humanitarian project, we are also involved in environmental and health initiatives. For instance, Kemppi has had a long association with the Vesijärvisäätiö Foundation, which is responsible for restoring Lake Vesijärvi. This lake is the biggest in Lahti, Finland and we have been working with the Foundation and other local companies to rid it of pollution. Kemppi also has its own Blood Group at Blood Service for its employees. The purpose of the group is to encourage Kemppi employees to regularly donate blood to support the functionality of our extremely valuable heath care system. AMT: Thank you so much for giving us your time today, and please enjoy the Australian weather, people and business. kemppi.com.au
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Metal powders Custom metal powder manufacturing in-house. Dr. Cameron Chai and Peter Airey give some advice on alloys. Are you involved with 3D printing of metal powders, but only need a small quantity of powder? If you are interested in an alternative that allows you the freedom to make small quantities of powder yourself of alloys of your choosing, with the added benefit of being able to recycle any waste powder, read on.
Vibration frequency versus particle size relationship
composition can be controlled by the frequency of vibration of the sonotrode, with higher frequency vibration leading to smaller particle sizes. The Amazemet rePowder system offers the option to use an induction furnace for alloys with melting point below 1300°C, or an arc/plasma furnace that caters for alloys with melting temperatures up to 3500°C. To date there are over 30 installations around the world, including several in the USA and China.
Key benefits of ultrasonic atomisation For those looking to produce their own powder for AM and other processes, ultrasonic atomisation has many benefits:
Gas atomisation Gas atomisation is the traditional method for producing metal powders and is excellent for producing large quantities of material. The process involves melting a metal in a crucible or similar vessel. Once the melt has been homogenised, the molten metal flows down to a refractory nozzle. Upon exiting the nozzle the stream of molten metal is hit with a jet of high-pressure inert gas such as nitrogen or argon which turns the metal into droplets, which solidify to form metal powders. The entire process is typically carried out under an inert atmosphere to prevent oxidation. While the process is extremely effective, it generally involves large scale production, of the order of 50kg plus and are not geared up towards small batch orders in the sub-5kg realm. Furthermore, there are significant time and costs involved in changing alloy compositions which can drive the price the price of small orders into the stratosphere as well as requiring extended lead times.
Evolution of ultrasonic atomisation In 2016, Łukasz Zrodowski as a Ph.D student needed 200g of powder. A batch of this size was simply uneconomical to produce by gas atomisation, and so he went on the hunt for a way to produce small quantities of spherical metal powders. In the process he rediscovered the ultrasonic atomisation process that was been dormant for the past 40 years. Over the subsequent years he repurposed the technology and refined the process to suit his requirements while at Warsaw University of Technology. In 2019, Łukasz founded Amazemet and all the ultrasonic atomisation IP and other expertise for support removal was transferred to them. Since then, Amazemet have been supplying laboratory scale systems for in-house manufacturing of powders and other associated equipment for additive manufacturing.
•
Suitable for any alloy composition – The process suits anything from pure elements to exotic and refractory alloys • Any form or feedstock – Suited to any form e.g. chips, failed AM prints, damaged samples, rods, wire, powder, etc. • Controllable particle size – Particle size a function of sonotrode vibration frequency and alloy composition • Low running costs – Relatively low gas consumption • Variable capacity – Run batches from just a few grams to multiple kg per day • Recycling – Reprocess printed or failed parts or scrap material • Modularity – Add new modules at any time to expand capabilities • Versatility - Prepare new compositions, alloy homogenisation, ultrasonic atomisation, suction casting and further options in development • Multiple alloys in one day – Easily clean and modify the instrument to produce multiple alloys The flexibility of the process makes it ideal for alloy prototyping and refining of alloy compositions. In addition, its ability to deal with a wide variety of feedstocks makes it ideal for recycling left over powder from processes metal additive manufacturing processes like direct metal laser sintering (DMLS) while others call it selective laser melting (SLM) or even failed parts.
Powder properties
A
B
C
D
The ultrasonic Atomisation Process The ultrasonic atomisation process involves pouring a stream of molten metal into a vibrating part, or sonotrode. This causes tiny metal droplets to be ejected from the surface. In doing so, they solidify in the surrounding inert atmosphere, producing spherical metal powders with very narrow particle size distributions. The actual particle size of the powders, while dependent on the alloy
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Examples of powders produced using ultrasonic atomization A. Aluminium alloy 6061, B. 316L stainless steel, C. iron alloy FeCrNi and D. titanium alloy Ti6Al4V
ADDITIVE MANUFACTURING
Ultrasonic atomisation produces metal powders with unrivalled sphericity, up to 0.98. By ensuring the frequency is kept constant, the particle size distribution remains very narrow. The air locked processing chamber also prevents unwanted oxidation, while the clean working environment (at 10-2 to 10-5) prevents contamination. The tight control over particle size also benefits AM processors by facilitating a more consistent and repeatable process, while the high degree of sphericity encourages even flow and packing of powder beds. If the metal powder consisted of particles of different sizes, the laser would interact with the different sized powder particles differently, which will result in different degrees of melting, influenced by the particle size.
Gas atomisation vs ultrasonic atomisation Process
Gas Atomisation Ultrasonic Atomisation
Particle morphology
Various shapes
High sphericity
Particle size distribution (PSD)
Wide
Narrow
Throughput
High – suits industrial scale
Low – ideal for laboratories
Powder yield
Moderate
High
Flexibility
Poor
Excellent
Equipment size
Enormous
Compact
Feedstock
Any
Any
Inert gas consumption High
Low
Table 1. Head-to-head comparison of gas and ultrasonic atomization processes.
Applications While primarily developed for producing powder for AM, ultrasonic atomisation technology is equally at home generating feed powders for cold spraying, thermal spraying, catalysis, powder metallurgy processes and any other application requiring spherical metal powders. It has also been shown to be compatible with almost any metal alloy, pure metals as well as some metal matrix composites (MMC) and glass ceramics.
Instrument features
infrastructure. The sealed working chamber permits oxygen-free processing while rePowder comes pre-programmed with recipes for many basic materials to help you get up and running in the shortest possible timeframe. The easy clean design prevents powder adhesion and facilitates metal losses and contamination, while accurate temperature control prevents evaporation of alloy ingredients such as Cu or Sn. The system itself is modular and can be tailored to the needs of the client i.e. the types of feedstocks that are going to be processed. In addition, this design allows you to add more modules down the track.
Feedstocks The rePowder system is extremely flexible. As mentioned, it can be equipped with either an induction furnace or arc/plasma furnace depending on the melting point of the alloys you are working with. It can also be adapted using purpose-built modules to work with a range of feedstocks of almost any composition including: • • • • •
Rods and bars with round, square or irregular cross-sections Wire – round or square from 0.8 to 2.0mm Homogenised or cast ingots, buttons and irregular shapes Powders Scraps, leftovers and samples e.g. from mechanical testing
Summary Metal powders have many applications such as additive manufacturing and thermal spraying. For those involved in research, alloy prototyping etc. where only small quantities are required, or custom formulations that are uneconomical to source from the traditional channels. Using systems like the rePowder from Amazemet you can now produce small batches of powder from tens of grams up to several kilograms using ultrasonic atomisation technology in your own lab. This system has been proven to work with most alloys and elements where it produces highly spherical powders with tight particle size distributions and excellent flow properties from any feedstock, including waste powder from processes like direct metal laser sintering (DMLS) while others call it selective laser melting (SLM). amazemet.com
The thoughtfully designed system can be installed into a small space, requiring only a few square metres, including associated
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Microwave 3D printing Fully recyclable 3D printing breakthrough uses microwaves to enable sustainable additive manufacturing. Additive manufacturing has shown immense promise as an engine for modern manufacturing transformation. By rapidly printing complex objects on demand, the technology has disrupted industries from aerospace to medical devices. However, an urgent roadblock has threatened the sustainability of wider adoption across consumer and industrial sectors alike: plastic waste. Most commercially available materials for 3D printing, from PLA plastics to high-end polyamides, share two traits after printing. They aren’t recyclable and pose dangers from pollution. That's because these plastics contain highly stable carbon polymer backbones resistant to cost-effective recycling methods once cured into products. As global volumes of 3D printed plastic parts have skyrocketed 1500% over the last decade, vast piles of postindustrial and post-consumer waste with no recycling pathway have built up behind the technology’s celebrated rise. For years experts have pointed to an alluring alternative – reversible polymers that can rearrange their covalent bonds when exposed to certain stimuli, enabling repeat processing, reprinting and full recycling. Also called dynamic covalent polymer networks or covalent adaptable networks (CANs), these transformable materials have remained just out of reach for reliable 3D printing despite intense R&D attention. Until now. Groundbreaking new research from scientists in Israel introduces reversible polymers tailored for 3D printing that can be fully recycled using only a standard microwave oven. This pioneering methodology finally unlocks the promise of sustainably printing objects without toxic waste piling up our landfills and oceans. Led by Professor Shlomo Magdassi, the researchers developed fully recyclable and reprintable polymeric compositions for fused filament fabrication 3D printing at much lower temperatures. This is achieved through purposeful design of polymers undergoing reversible photopolymerisation via cycloaddition reactions that form new bonds when exposed to UV light. Critically, an everyday microwave oven can then rapidly depolymerise the polymers for complete recycling. This enables multiple printing cycles without compromising mechanical properties or needing to add any new materials. At the core of this new approach lies the design of a custom monomer containing triethylenetetramine and cinnamaldehyde groups. This monomer can form cycloadducts through [2+2] and [4+4] cycloaddition reactions under 365nm UV irradiation. The presence of a specialised tin-based catalyst developed by the researchers accelerates these reversible photopolymerisation reactions. Printing is conducted via direct ink writing 3D printing methodology, with the UV light causing simultaneous polymerisation and crosslinking to retain the desired printed shape. Remarkably, the printing temperature is only 70°C – 50°C lower than the previously reported lowest temperature RCBP printing method. To recycle the printed parts, the researchers make an innovative use of microwave radiation. Just ten minutes in a standard microwave oven at a power of 216W caused liquification and 97.6% reversion back to the original functional monomers. While microwave exposure did heat samples to 180°C, heating alone at this temperature did not enable recycling. This suggests unique microwave effects are enabling accelerated bond reversion. “Typically, reversing cycloaddition reactions requires irradiation at the harmful range of UVC (<260nm for cinnamaldehyde-based moieties),” Dr. Hanna Dodiuk says. “The instability of four and eightmembered rings resulting from bond angle stress makes them susceptible to ring-opening via excitation under UVC.”
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“An alternative approach was explored to avoid UVC irradiation, based on microwave irradiation (25–38mm), which is known to cause rapid heating through the rotation of polar molecules. Some cycloaddition reactions can dissociate under high temperatures that cause vibrations of the rings, leading to steric stresses, which results in conversion to the more sterically stable form – the original molecules.” Remarkably, the researchers successfully demonstrated 11 integrated print-recycle cycles with no loss in mechanical or thermal properties. Tensile strength, elongation at break, and glass transition temperature remained effectively unchanged between the first and eleventh iterations. Complete dissolution of printed parts after microwave recycling confirmed excellent reversibility. The researchers also analysed polymer conversion at each stage using NMR studies and UV-vis spectrophotometry to quantify recycling efficiency. The approach enables sustainable additive manufacturing with widespread potential applications, from electronics to biomedical devices. It overcomes key barriers that have challenged previous efforts to apply reversible polymers to 3D printing over the past decade. “This research presents a sustainable approach to 3D radiation printing by utilising reversible cycloaddition reactions,” Professor Shlomo Magdassi summarises. “The new synthesized monomer demonstrates printability at significantly lower temperatures than previously reported RCBPs. The presented approach allows multiple printing cycles without compromising the printed objects’ mechanical and thermal properties and without replenishing materials.” With further development, this pioneering methodology could finally unlock the promise of fully recyclable 3D printable plastics. Given the vast volumes of plastic waste challenging communities across the world, more sustainable materials science breakthroughs like this have never been more crucial. Professor Magdassi believes this research represents, “a promising step towards advancing sustainability, polymers, and material science.” nanowerk.com
ADDITIVE MANUFACTURING
Innovync New Kreator technology empowers Australian innovators. By Tijana Trifunovich. Decades ago, Australia was known as the Innovation Nation. Then, the era of cheap off-shore production began. Now, we’re turning the page on a new chapter - one sparked by new technology, never before seen on local shores. Advanced Materials and Plastics lead for Sydney-based manufacturing distributor Innovync, Anthony Cruz, has his finger on the pulse of global manufacturing innovation. Innovync’s exclusive deal with Italian CNC leaders CMS is a gateway to some of the most interesting machines on the market – including the groundbreaking Kreator. Developed in collaboration with Germany’s Fraunhofer Institute, the large-format Screw Extrusion Additive Manufacturing (SEAM) technology merges with 5 axis CNC milling. A powerful fusion, to say the least. The potential for catalysing product innovation is enormous. Australia is about to receive one of its very own in the coming months. Purchased by a public facility with a view to make prototyping in a test environment more accessible to manufacturers, the role of Australia's Kreator is to realise big ideas with minimal investment. “For example, a company can reach out to the facility and they can provide access to advanced capabilities for the development of parts, processes, people and partnerships. They are designed to deliver advanced manufacturing solutions to the customers in a production-relevant environment,” explained Cruz. With CMS’ Advanced Materials range used by the likes of SpaceX, Boeing, and Lockheed Martin, The Kreator immediately piqued interest. The ability to 3D print parts and quickly achieve a highquality finish is extremely useful for high-precision industries that work with specialised materials – like the marine, automotive, and aerospace sectors. A build volume of up to 10m, in three different directions (vertical, horizontal and 45 degrees), offers the room to create anything from tooling, trimming and assembly jigs to machining fixtures or direct lamination molds. On the printing side, materials such as PLA, PET, PA6 and ABS reinforced with up to 50% glass fibre or carbon are commonly used. Two versions of the machine are available: one with a flow rate of up to 100kg/hour, and the other - which Australia is receiving - at ten kg/hour, with two bridges to support milling and printing. But before all that, the on-board slicing software generates optimised printing paths, 3D printing simulations and estimated print times, plus weight estimates. “The Kreator has been supplied to the Aerospace industry internationally and is used to produce jigs and fixtures. An example is a CFRP machining vacuum fixture. The material that’s being used is ABS + 20% carbon fibre. They print the part and then mill it to achieve a high-quality finish,” said Cruz. To illustrate the impact of this hybrid machine, if a part is to be produced via traditional process, fabricators would have to: 1. 2. 3. 4.
Cut and bond epoxy boards Do pre-form milling Do the CFRP mold lamination on the pre-form. Do CFRP mold autoclave curing
5. CFRP mold preparation and surface finishing 6. Then CFRP part lamination and curing And that’s when you get the finished part. Until recently, this process was the only route to get high-quality aerospace parts made. Its expensive, time-consuming, and requires a significant amount of relatively expensive materials. The Kreator, with its milling-printing capabilities, compresses the process from six steps to just three. • • •
Mold production by additive process Mold milling and surface finishing, and CFRP part lamination and curing.
The difference is huge. “Using a traditional process, machining of epoxy tooling boards with a size of 1000 x 600 x 300mm, made from ABS + 20% carbon fibre weighs in at approximately 150kg. Using the Kreator, weight goes down to 40kg. That’s a 60% savings in materials used and weight of the part. In terms of time-saving, you would probably save about 50%,” explained Cruz. With such a streamlined process in place, local industries have the room to innovate on-shore. No need to send parts overseas and wait weeks for the finished product. No worries about having IP stolen during the manufacturing process. The Innovation Nation is primed to produce once more. Production on the Kreator is set to commence later in the year. If you're curious to see this machine in person, head to the Innovync stand this April for Sydney’s Australian Manufacturing Week. innovync.com.au
Returning to Sydney for 2024! Parramatta Rydges Resort Ballroom
Tuesday 18 to Thursday 20 June Details and Bookings online
In conjunction with
19-20 June, Rosehill Gardens
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Transforming aerospace General Atomics and the power of additive manufacturing. In the world of aerospace, innovation is not just a goal; it's a necessity. General Atomics Aeronautical Systems Inc. (GA-ASI), a leader in developing unmanned aircraft systems, has embraced this truth by integrating Additive Manufacturing (AM) into its core processes. From experimental beginnings to becoming a manufacturing cornerstone, GA-ASI's journey with AM exemplifies innovation at its finest.
Revolutionising design and production GA-ASI's foray into AM has revolutionised how unmanned aircraft like the MQ-9A Reaper and MQ-9B SkyGuardian are built. By adopting AM, GA-ASI has not only streamlined its manufacturing processes but has also unlocked new potential in aircraft design and functionality. The result? Thousands of parts produced via AM, now flying across multiple GA-ASI platforms.
A systematic approach for optimal results GA-ASI's success with AM isn't accidental. It's the outcome of a systematic, refined approach aligning with business objectives. Key strategies include developing a robust AM ecosystem, establishing a solid business case for AM, and partnering with industry leaders. This disciplined approach ensures each AM project aligns with the company's mission, ensuring quality and innovation at every step.
Stratasys: a partnership that elevates In its quest to master AM, GA-ASI partnered with Stratasys, leveraging their Fused Deposition Modeling (FDM) technology. This collaboration has been pivotal in GA-ASI's ability to produce flightworthy AM parts, ensuring cost-effectiveness and efficiency. In-house AM capabilities let GA-ASI respond to rapid-reaction development efforts where designs are in flux, and AM provides
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the right tools for a high level of iteration. In contrast, outsourcing to qualified, reliable contract manufacturers like Stratasys Direct Manufacturing delivers the best solution for overflow and forecastable production. “You have to partner with the Stratasyses of the AM world to understand the best practices, the best lessons learned, and assimilate and share knowledge in a win-win situation,” says Senior Manager, Steve Fournier. To put meaning behind that statement, GA-ASI consults with Stratasys Direct Manufacturing’s engineers, and the two companies’ workflows emulate each other. Fournier also makes distinctions between contract manufacturers like Stratasys Direct and service bureaus. “They’re not the same,” says Fournier. “A service bureau will deliver something, but there’s no quality clauses or the rigor of manufacturing to deliver a fully functional flight part repeatably, at least from our industry standpoint. A contract manufacturer will take responsibility for the quality and will be audited and take that level of stringency to deliver that hardware, not only once, but always to the same quality level,” he says.
The future of aerospace with AM The impact of AM at GA-ASI is profound: over $2m in tooling cost savings and achieving more than $300,000 in recurring cost avoidance, and enhanced design possibilities. But the journey doesn't end here. GA-ASI continues to push the boundaries, using AM not just as a manufacturing method but as a catalyst for innovation in aerospace design and production. For Australian Aerospace manufacturers, Stratasys Direct Manufacturing Global Network Services are available through local partners, Objective3D Direct Manufacturing. objective3d.com.au stratasys.com
ADDITIVE MANUFACTURING
Listening for defects in AM Researchers from Ecole Polytechnique Federale de Lausann (EPFL) have resolved a long-standing debate surrounding laser additive manufacturing processes with a pioneering approach to defect detection. Story by Michael David Mitchell. The progression of laser additive manufacturing—which involves 3D printing of metallic objects using powders and lasers—has often been hindered by unexpected defects. Traditional monitoring methods, such as thermal imaging and machine learning algorithms, have shown significant limitations. They often either overlook defects or misinterpret them, making precision manufacturing elusive and barring the technique from essential industries like aeronautics and automotive manufacturing. But what if it were possible to detect defects in real-time based on the differences in the sound the printer makes during a flawless print and one with irregularities? Up until now, the prospect of detecting these defects this way was deemed unreliable. However, researchers at the Laboratory of Thermomechanical Metallurgy (LMTM) at EPFL’s School of Engineering have successfully challenged this assumption. Professor Roland Logé, the head of the laboratory, stated, “There's been an ongoing debate regarding the viability and effectiveness of acoustic monitoring for laser-based additive manufacturing. Our research not only confirms its relevance but also underscores its advantage over traditional methods.” This research is of paramount importance to the industrial sector as it introduces a groundbreaking yet costeffective solution to monitor and improve the quality of products made through Laser Powder Bed Fusion (LPBF). Lead researcher Dr. Milad Hamidi Nasab remarked, “The synergy of synchrotron X-ray imaging with acoustic recording provides real-time insight into the LPBF process, facilitating the detection of defects that could jeopardize product integrity.” In an era where industries continuously strive for efficiency, precision, and waste reduction, these innovations not only result in significant cost savings but also boost the dependability and security of manufactured products.
How does LPBF manufacturing work? LPBF is a cutting-edge method that is reshaping metal manufacturing. Essentially, it uses a high-intensity laser to meticulously melt minuscule metal powders, creating layer upon layer to produce detailed 3D metallic constructs. Think of LPBF as the metallic version of a conventional 3D printer, but with an added degree of sophistication. Rather than melted plastic, it employs a fine layer of microscopic metal powder, which can vary in size from the thickness of a human hair to a fine grain of salt (15–100μm). The laser moves across this layer, melting specific patterns based on a digital blueprint. This technique enables the crafting of bespoke, complex parts like lattice structures or distinct geometries with minimal excess. Nevertheless, this promising method isn't devoid of challenges. When the laser interacts with the metal powder, creating what is known as a melt pool, it fluctuates between liquid, vapour, and solid phases. Occasionally, due to variables such as the laser’s angle or the presence of specific geometrical attributes of the powder or of the part, the process might falter. These instances, termed “inter-regime instabilities,” can sometimes prompt shifts between two melting methods, known as “conduction” and “keyhole” regimes. During unstable keyhole regimes, when the molten powder pool delves deeper than intended, it can create pockets of porosity, culminating in structural flaws in the end product. To facilitate the measurement of the width and depth of the melt pool in X-ray images, the Image Analysis Hub of the EPFL Centre for Imaging developed an approach that makes it easier to visualise small changes associated with the liquid metal and a tool for annotating the melt pool geometry.
Detecting these defects using sound In a joint venture with the Paul Scherrer Institute (PSI) and the Swiss Federal Laboratories for Materials Science and Technology (Empa), the EPFL team formulated an experimental design that melded operando X-ray imaging experiments with acoustic emission measurements. The experiments were conducted at the TOMCAT beamline of the Swiss Light Source at PSI, with the miniaturised LPBF printer developed in the group of Dr. Steven Van Petegem. The amalgamation with an ultra-sensitive microphone positioned inside the printing chamber pinpointed distinct shifts in the acoustic signal during regime transitions, thereby directly identifying defects during manufacturing. A pivotal moment in the research was the introduction of an adaptive filtering technique by signal processing expert Giulio Masinelli from Empa. “This filtering approach,” Masinelli explained, “allows us to discern, with unparalleled clarity, the relationship between defects and the accompanying acoustic signature.” Unlike typical machine learning algorithms, which excel at extracting patterns from statistical data but are often tailored to specific scenarios, this approach provides broader insights into the physics of melting regimes while offering superior temporal and spatial precision. With this research, EPFL contributes valuable insights to the field of laser additive manufacturing. The findings have significant implications for potential industrial applications, particularly in sectors like aerospace and precision engineering. The study not only underscores the need for consistent manufacturing techniques. It further suggests the potential for early detection and correction of defects, enhancing product quality. Professor Logé concludes, “This research paves the way for a better understanding and refinement of the manufacturing process and will ultimately lead to higher product reliability in the long term.” This article appeared in Nature Communications. “Harmonizing sound and light: X-ray imaging unveils acoustic signatures of stochastic inter-regime instabilities during laser melting.” Provided for republishing by Ecole Polytechnique Federale de Lausanne epfl.ch/en/
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Unleashing the potential Validating quality in additive manufacturing. Philipp Pruesse, Sales Manager, at Dimensionics Density. In the world of modern manufacturing, additive manufacturing (AM) has emerged as a revolutionary technology that holds the promise of transforming industries through its capability to produce complex geometries, reduce lead times, and enable on-demand production. However, as the adoption of AM grows across sectors ranging from aerospace to medical devices, one critical challenge remains. That is ensuring the quality and reliability of 3D printed components. Quality validation in AM is a multidimensional endeavour that encompasses a range of testing, verification, and analysis techniques aimed at guaranteeing the structural integrity and functional performance of printed parts. At the heart of this validation process lies the crucial aspect of density determination, which plays a pivotal role in unlocking the full potential of additive manufacturing.
The promise and challenges of Additive Manufacturing AM has captured the imagination of designers, engineers, and manufacturers alike due to its ability to fabricate intricate structures and custom designs that were previously unattainable through conventional manufacturing methods. As everyone today knows, unlike subtractive manufacturing, where material is removed to shape a part, AM builds objects layer by layer, often using powdered materials or metals/polymers that are selectively fused or cured to form the final product. This layer-by-layer approach allows for greater design freedom, reduced waste, and the consolidation of parts, leading to more efficient production processes. Yet, as the technology continues to evolve, ensuring the quality and reliability of 3D printed components has emerged as a critical concern. The intricate nature of AM processes introduces complexities that demand a comprehensive quality validation strategy. Unlike traditional manufacturing techniques, where the mechanical properties of a material are relatively predictable, the properties of 3D printed parts can be influenced by factors such as layer adhesion, cooling rates, and local material variations. These nuances can lead to internal defects, such as voids and porosities, that may compromise the mechanical integrity of the final component.
Quality validation: A multifaceted approach Quality validation in AM necessitates a multifaceted approach that combines advanced testing methodologies, thorough verification processes, and rigorous analysis techniques. This approach seeks to uncover potential defects, assess mechanical properties, and validate the parts' performance against specific industry standards and requirements. The journey from digital design to physical part involves multiple stages, each of which presents unique challenges and opportunities for quality validation. The first stage involves pre-printing validation, where the digital design is meticulously examined to ensure its suitability for AM. This includes considerations such as geometry optimisation, support structure generation, and the integration of internal channels or lattice structures that can enhance a part's performance. By simulating the printing process digitally and evaluating factors such as heat distribution and stress accumulation, engineers can preemptively identify potential issues that could arise during actual manufacturing. Once the design is deemed suitable, the printing process commences. During printing, monitoring and process controls are essential for maintaining the desired quality. In-situ sensors and cameras can provide real-time data on parameters like temperature, humidity, and layer adhesion, allowing for immediate adjustments if irregularities are detected. Post-printing, non-destructive testing (NDT) techniques, including X-ray and CT scanning, can reveal
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internal defects that might not be visible to the naked eye. NDT is particularly important for safety-critical applications like aerospace and medical devices, where even small defects can have catastrophic consequences.
Density Determination: The key to reliability At the heart of quality validation in AM lies the critical factor of density determination. Density, in the context of AM, refers to the mass of a part per unit volume. It serves as a direct indicator of the material's structural integrity and porosity. High density implies a solid, homogeneous structure with minimal voids, while low density suggests the presence of internal defects that could compromise the part's mechanical properties. Achieving optimal density in 3D printed components is imperative for ensuring their reliability and functional performance. Thorough density analysis allows manufacturers to identify regions of potential weakness, porosity, or irregularities within the printed objects. By understanding the density distribution, engineers can fine-tune printing parameters, such as print speed, temperature, and material composition, to minimise defects and achieve consistent, desirable properties throughout the part. Density determination holds profound implications for a component's mechanical behaviour. A part with higher density is likely to exhibit enhanced mechanical strength, as the reduced presence of voids and porosity improves load-bearing capacity and resistance to fractures. The absence of internal imperfections also leads to improved fatigue resistance, which is critical for parts subjected to repetitive loading cycles. Furthermore, optimal density contributes to dimensional accuracy, ensuring that the final part closely adheres to design specifications. This accuracy is vital for functional compatibility and assembly, especially in industries where precise tolerances are essential. On the other hand, inadequate density or excessive porosity within 3D printed components can lead to compromised mechanical properties. Lower density regions are prone to reduced strength, potentially resulting in premature failures under load. Porous regions can impair thermal and electrical conductivity, limiting a part's suitability for applications requiring these properties. In safetycritical sectors like aerospace, medical, and automotive, even the slightest compromise in mechanical integrity can have far-reaching consequences.
ADDITIVE MANUFACTURING With this in mind, the most recent and disruptive density determination technology developed by Dimensionics Density effectively uses the Archimedes method but in combination with modern automation technology. The samples to be measured are placed in a special component carrier, which is provided with openings on the underside. These component carriers are transported through the system by an axis robot and thus lowered centrally and precisely onto the scales. On the scales themselves, a lift-out rack with pins is placed, which lifts the component over the openings in the component carrier and thus lifts the component out of the carrier. The automated handling eliminates human influence on the measurement, as the parts are always placed identically onto the scales. The scales are designed to be insulated from vibration. In addition, all ambient conditions such as temperature, air pressure, and water temperature, are recorded via climate sensors, and their influence on the measurement result is taken into account directly in the evaluation algorithm when determining the density.
Advances in density analysis techniques Recent advances in AM have brought forth sophisticated density analysis techniques that empower engineers and researchers to gain deeper insights into the internal structure of 3D printed components. X-ray computed tomography (CT) scanning, for instance, enables the visualisation of internal features and defects in a non-destructive manner. This technique reconstructs crosssectional images of a part and allows for the identification of voids, porosity, and even the characterisation of complex internal geometries. Micrographs also have a role in assessing the density of AM parts. These high-resolution images, obtained through techniques like optical or electron microscopy, provide a detailed view of the internal structure of AM components at a microscopic level. By analysing micrographs, engineers can identify variations in material distribution, pore sizes, and voids within the parts. This information enables accurate density determination and aids in evaluating the overall quality of the AM parts, guiding process optimisation and ensuring the production of structurally sound and reliable components. Finite element analysis (FEA) is another powerful tool that enables predictive density analysis by simulating the mechanical behaviour of a 3D printed part under various loading conditions. FEA models take into account factors such as material properties, layer adhesion, and geometry, providing a virtual environment to test and optimise designs before physical manufacturing begins. This computational approach offers insights into how density variations influence a component's response to external forces and helps in making informed decisions about design modifications. The Archimedes method for density determination remains the easiest to use, but can also be the least accurate as it can be negatively impacted by changing environmental conditions, the accuracy of the balance, as well as the precision of the experimental procedure. It is difficult to reproduce the results, which are strongly influenced by human factors. Test specimens are never placed exactly the same on the balance, and the manual operation of the balances leads to measurement deviations.
This automated density determination solution can easily determine the density of freeform parts and highly complex AM parts and can measure density repeatably to 0.001 g/cm3. With a cycle time of less than two minutes per component and the possibility of inspecting up to 18 components simultaneously in one inspection process as standard, the automated Archimedes solution supports the optimisation and efficiency of manufacturing processes. It is also non-destructive and, therefore can be used to verify parts that conform to density requirements and those that don’t in a speedy, precise, and cost-effective manner. The key to effective AM part density determination is that it must offer reliable results quickly and at the same time be easy to use. Dimensionic Density’s solution is much quicker than analysing density determination with a CT scan or through microsection analysis. It is therefore a perfect fit for companies producing parts in large numbers. As industry in general is moving towards the use of AM for serial production, the place of a non-destructive, reliable but also speedy quality control method for density determination is therefore ensured.
Driving AM forward Quality validation in AM is not only about ensuring individual part integrity but also about building trust in the technology as a whole. As industries increasingly turn to AM for the production of critical components, the need for comprehensive validation becomes more pronounced. Achieving optimal density, backed by advanced analysis techniques, contributes significantly to this validation process by enhancing mechanical properties, dimensional accuracy, and overall reliability. The journey towards unlocking the full potential of AM demands a collaborative effort among designers, engineers, researchers, and manufacturers. While challenges persist, strides are being made in refining printing processes, optimising materials, and developing advanced analysis tools. Through a holistic approach to quality validation, AM can continue to revolutionise industries by delivering innovative, efficient, and reliable solutions that meet the stringent demands of modern manufacturing. dimensionics-density.com/additive
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Top 3 AI trends Mathworks Country manager Stephane Marouani lists the top three AI trends for the year ahead. As the adoption of AI grows across countless industries, it continues to enable impactful progress and revolutionise various aspects of technology and human interaction. Forrester predicts that Enterprise AI initiatives will boost productivity and creative problemsolving by 50% in 2024. AI will impact the work of engineers and educators alike, saving time to free them up to tackle other projects that advance scientific and engineering causes. Here are three major trends that will drive AI’s continued momentum in 2024:
AI Prediction #1: AI and simulation become essential in the design and development of engineered systems. As AI pushes toward the mainstream in all industries and applications, complex engineered systems that don’t contain AI will become outliers. Engineered systems combine components and subsystems from multiple domains to create intelligent systems that perceive and respond to the world around them. An example is a wind turbine, which combines mechanical (turbine blades and gearbox), electrical (generator), and control (blade pitch) components. The rise in the success of complex AI systems is mainly due to the rise of simulation being incorporated into the design and development of those systems. Simulation is a proven way to perform multi-domain modeling and simulation necessary to develop complex systems. AI can process data from sensors to assist in developing perception systems and autonomous systems. However, as system complexity increases, some simulations can become too computationally intensive for system-level and embedded design, especially in testing that requires a model to run in real-time. In this scenario, AI can also enhance simulations by using Reduced-Order models. Reduced Order Models (ROMs) can speed up simulations while still providing acceptable accuracy for system-level testing of control algorithms. ROM models can complement first-principles models, creating variant implementations that enable a tradeoff analysis between accuracy, performance, and complexity. Increasingly, more engineers are exploring incorporating AI-based ROM models into their systems. This can help accelerate desktop simulation affected by a third-party high-fidelity model, enable Hardware-in-the-Loop testing by reducing the complexity of the models, or speed up Finite Element Analysis (FEA) simulations.
AI Prediction #2: Smaller models are preferred for embedded AI; large models will persist for computer vision and language models. AI models can have millions of parameters that require a large amount of memory to run. In research, accuracy is top of mind, but when deploying AI models to hardware, the tradeoffs between memory and accuracy will collide. AI practitioners must consider how their model’s performance will differ when deploying to devices where speed and memory are crucial. AI can be added as a smaller component in existing control systems rather than relying on endto-end AI models, such as those typically used in computer vision to detect objects. An especially relevant topic when discussing smaller AI models is Incremental Learning. Incremental Learning is a machine learning approach that enables the model to learn continuously by updating its own knowledge in real-time as new data becomes available; it is considered an efficient method for edge deployment.
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AI Prediction #3: GenAI helps engineering professors teach more advanced topics. Generative AI is a disruptive technology engineering professors will use in their classrooms to help students on a large scale in 2024 and beyond. Much like the internet or mobile phones, GenAI is launching a revolution that will enhance the entire engineering education landscape. The main advantage of using GenAI in the classroom is its time-saving capabilities when teaching engineering students foundational skills, such as computer programming. By freeing up the time professors previously used to present low-level concepts, they can now focus on teaching high-level topics such as complex engineering system design and implementation. Professors can save time and better engage students by using technologies like ChatGPT to run simulations and create interactive exercises and labs. Professors can teach students the skills necessary to effectively use GenAI, such as prompt engineering. This will help students develop critical thinking skills that they can employ rather than relying exclusively on machines for solutions. As a result, students will be encouraged to practice independent learning in various engineering disciplines while engineering educators can expand their curriculum further than before as they share their expertise in more advanced concepts.
Conclusion As AI matures, its role in enhancing productivity and potential for engineers and educators is becoming more pronounced. When building complex engineered systems, engineers would be wise to employ AI-assisted simulation and smaller AI models. In academia, generative AI saves effort for educators and enables students to be more independent. AI enables more informed decisions, actionable insights, and improved efficiency across a multitude of industries and educational institutions. mathworks.com
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AI surveillance in Australia Arkeus secures $4.45m to scale real-time, AI-powered search and surveillance systems for mission-critical environments. Arkeus is an Australian optical autonomy company developing AI-powered hardware for autonomous drones and aircraft, today announced it has raised $4.45m in seed funding. The round was led by deep tech venture capital firm Main Sequence, with participation from Steve Baxter from Beaten Zone Venture Partners and Salus Ventures. The new funding will help Arkeus scale manufacturing and enhance the capabilities of its core product suite, the Hyperspectral Optical Radar (HS-OR), which is designed to give customers the ability to ‘see’, understand and act on their environment in real time. Funding from deep tech and industry expert investors Main Sequence, Beaten Zone Venture Partners and Salus Ventures will enable Arkeus to scale its next-generation hardware-enabled software platform for search, intelligence, surveillance and reconnaissance missions. In high-risk environments like defence and search and rescue operations, first responders need to make split-second decisions based on their knowledge of the landscape, objects and people around them. Yet too often, those decisions rely on systems built decades ago that capture only a narrow visual range, are blinded by darkness or weather, and require extensive and time-consuming manual analysis before any recommendations can be made. Arkeus’ optical systems are built from the ground up for modern operating environments, giving responders the ability to ‘see’ and respond in real time, using data from a wide range of visible and non-visible light spectra with autonomous capabilities capable of real-time detection, recognition and tracking of relevant people and objects in complex environments. “In high consequence situations where every second counts, defence and emergency responders are often hampered by outdated sensors built for a narrow range of light wavelengths,” said Arkeus CEO and co-founder Simon Olsen. “Arkeus is pioneering a new way of sensing, built from the ground up to overcome these limitations and deliver mission-critical information at the point of contact.” Arkeus was founded in Melbourne by Olsen, a defence expert, and aerospace engineer Dr. Jonathan Nebauer after witnessing the challenges posed by existing equipment. “We saw an opportunity to build something new — hardwareenabled software. Our technology is customised and optimised to operate in the most adverse conditions, with minimal to no human involvement. Our job is to extract the hardest to get information from the most challenging environments, quickly.” Since its founding in Melbourne three years ago, Arkeus has secured multiple defence contracts for its autonomous optics technology, validating the company’s approach and unlocking opportunities across both public sector and commercial applications. Beyond defence, the company’s AI-powered customisable systems can be applied to tasks like disaster recovery, search and rescue missions, border security, and more. “We were impressed by Arkeus’ ability to build a thriving company in Melbourne during the COVID-19 pandemic,” said Alezeia Brown, Investment Manager at Main Sequence. “In a short time, they have developed market-leading products, secured major contracts, and shown the versatility to solve operational needs in both defence and commercial sectors. Their novel approach of combining hyperspectral imaging, radar, and AI has tremendous potential to save lives by giving first responders greater situational awareness.” “Arkeus has already demonstrated itself as a standout Australian company providing crucial, cutting-edge technology for defence
Simon Olsen
Dr. Jonathan Nebaue
worldwide. Simon, Jonathan and the entire Arkeus team should be immensely proud of the advancements they have achieved so far. As their growth continues, Beaten Zone Venture Partners looks forward to remaining strong partners and champions of Arkeus’ groundbreaking work into the future,” said Steve Baxter, Investor and Founder at Beaten Zone Venture Partners. “Arkeus’ autonomous optical systems have the potential to revolutionise the search, intelligence, surveillance, and reconnaissance landscape, providing critical information in challenging environments,” said Salus Ventures Managing Director Mike Ferrari. “Their rapid innovation and domain expertise make them a global leader in the field.” Arkeus is initially focused on use cases in search, intelligence, surveillance and reconnaissance missions including in defence, search and rescue, firefighting and police operations. The seed funding will enable Arkeus to scale up production of its HS-OR systems and continue R&D into new capabilities. To support its continued growth, Arkeus is also actively hiring additional technical staff in mechatronics and engineering at its Melbourne headquarters. Arkeus specialises in the rapid design, innovation and fabrication of autonomous optical capabilities – designed to deliver transformative effects for Search, Intelligence, Surveillance and Reconnaissance (SISR). arkeus.com
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Solid concrete Graphene oxide study strengthens the case for smart concrete. Engineers have added graphene oxide to cement mixture to make stronger 3D printed concrete that is easier to print, paving the way to create potential ‘smart’ walls that can monitor cracks. The research, conducted by RMIT University and University of Melbourne, is the first to investigate the effects of graphene oxide on the printability and compressive properties of 3D printed concrete. It found the addition of graphene oxide, a nanomaterial commonly used in batteries and electronic gadgets, gave concrete electrical conductivity and increased the strength of concrete by up to 10%. Research supervisor and RMIT Associate Professor Jonathan Tran said this concrete has the potential to create ‘smart’ buildings where walls can act as sensors to detect and monitor small cracks. While current detection methods, such as ultrasonic or acoustic sensors, are non-destructive and widely used in the construction industry to detect large cracks in concrete structures, detecting smaller cracks early is still a challenge. “The equipment for these methods is often bulky, making it difficult to regularly use for monitoring very large structures like bridges or tall buildings,” said Tran, from RMIT’s School of Engineering. “But the addition of graphene oxide creates the possibility of an electrical circuit in concrete structures, which could help detect structural issues, changes in temperature and other environmental factors.” While the research is preliminary, Tran said graphene oxide has the exciting potential to make 3D-printed concrete more viable in the construction industry, which could have positive impacts on cost and sustainability. “Current concrete structures are created using formwork, which is where you create a mold before pouring fresh concrete mixture into it,” he said. “Formwork requires a lot of labour, time and money, and it often creates a lot of waste. With 3D printed concrete, not only does it help save time, money and labour, but you can also create more complex structures and reuse some construction waste in cement-based materials.” As 3D printed concrete uses layer-by-layer printing, it can potentially lead to weaker bonds between each layer, but the addition of graphene oxide in concrete makes it easier to extrude, creating better inter-layer bonding, which can also help maximise strength. “Graphene oxide has functional groups on its surface, which are like sticky spots on the surface of a material that can grab onto other things,” Tran said.
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“These 'sticky spots' are mainly made of various functional groups containing oxygen, which play a crucial role in facilitating its stronger bonds with other materials like cement. This strong bonding can improve the overall strength of the concrete.” “However, more research is needed to test if concrete with graphene oxide can match or surpass the strength of traditionally cast concrete.”
Too much of a good thing Lead researcher RMIT PhD candidate Junli Liu said the strength of the concrete could be increased if the bond between graphene oxide and the concrete mixture was improved. The research tested two dosages of graphene oxide in cement and found the lower dosage (0.015% of the weight of cement) was stronger than the higher one (0.03% of the weight of cement). Tran said adding too much graphene oxide could impact the strength and workability of the concrete mix, which can cause potential issues with printability, strength and durability. “Concrete is a carefully balanced mixture. Adding too much graphene oxide can disrupt this balance, particularly the hydration process, which is crucial for concrete strength,” Tran said. “Too much graphene oxide can impact the flow of concrete, making it harder to extrude and therefore creating a structure with more gaps between layers of concrete,” Tran added. “Graphene oxide can also clump together instead of spreading out evenly, which can create weak spots in the concrete and reduce its overall strength.” The next phase of the research will study the electrical conductivity of graphene oxide in concrete and test its viability as a potential smart material. unimelb.edu.au rmit.edu.au
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Up to MYOB Advanced A move to the cloud rings true for Codecom. Established in 2006, Codecom has grown to be a leading supplier and manufacturer of cutting-edge telecommunications equipment. Based in Melbourne and the Gold Coast, Codecom covers a broad range of telecommunications needs for companies big and small. Their sphere of work includes initial scoping requirements for major commercial installations, creating connectivity solutions and definitive implementation strategies, as well as the ‘hands-on’ installation of structured cabling, fibre optic cabling, plus the backend supply of equipment and accessories. Meeting demands and expectations “We deliver industry-leading communications solutions, and build our reputation on quality, innovation and professionalism,” Courtney Purcell, General Manager (Commercial) for Codecom said, “so we have to ensure every aspect of our own business is equal to what we give our clients.” As growth continued, Codecom realised that running two platforms — MYOB AccountRight for accounting and Excel for logistics, invoices, quotes etc — was putting a strain on the business. Purcell notes, “The way we were working had become inefficient, with many functions being manual and time consuming, and this in turn impacted on managing stock, purchase orders, invoices, not to mention a lack of visibility across all functions of our business.” Futureproofing calls for Cloud-based ERP Solution Given that the cost of purchasing and implementing a completely new business management system is significant, the team at Codecom carefully evaluated their options. After dismissing several products, they contacted David Taylor at BusinessHub and after much consideration Codecom settled on MYOB Advanced. “The functionality of MYOB Advanced met our many needs including customer special pricing, advanced stock management, a customer portal as well as CRM,” Purcell explains. “And beyond these features, we definitely wanted the system to be cloud-based.” A detailed scope and understanding of Codecom’s business was initiated. This ‘business diagnostic’ mapped Codecom’s current business processes and helped determine where they wanted to be in the future. Existing data was reviewed, and migration and configuration options were suggested, with requirements around customer special pricing & inventory (orders and codes to use) a major priority. The team at Codecom then went through the MYOB Advanced beta program, followed by a pilot program which gave them the opportunity to understand the operation of the software. Finally, once the migration of all the excel information including customer price deals, stock sheets and purchase order details etc was locked in, the BusinessHub team completed functional training prior to the ‘go live’ as well as providing the post ‘go live’ support to assist with the basic processing.
Connecting with future success Codecom’s move up to MYOB Advanced has been an unqualified success says Purcell, “Running every aspect of our business is 100% easier, particularly as we’ve really streamlined our processes and improved the accuracy of inventory and our customer pricing,” and she added, “now that we’re cloud-based all aspects of our business are accessible everywhere, to the staff that need it.” With MYOB Advanced, Codecom now has many valuable insights into their business that were previously unknown. Things like customer buying patterns and back-order visibility and fulfilments, which enable them to make more informed and agile business decisions. With their ERP software in the cloud, Codecom’s business has been transformed, with all team members having access to accurate information at their fingertips, anywhere, anytime. This is vital to the decentralised workforce around AU and NZ and ensures accurate landed costing, accurate invoicing for quoted prices by sales reps, and accurate inventory to meet customer demands. From a financial perspective, another positive for Codecom has been the significant changes to the invoice structure that has driven a decrease in days to pay and increased overall cash flow, which is always good for the bottom line. “Now that we’re cloud-based all aspects of our business are accessible everywhere, to the staff that need it.”
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Running two platforms across the business was becoming increasingly inefficient. Many functions were manual and time consuming. Limited visibility across the operations meant less informed business decisions.
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Cloud-based system allows team members to have accurate information at their fingertips, anywhere, anytime. Business processes at every level are now streamlined with big gains in efficiency. Precise insights into inventory ensure accurate quoting and more satisfied customers. New invoice structure has delivered a decrease in days to pay and improved cash flow.
Introducing MYOB Advanced for Australian manufacturers In the dynamic landscape of manufacturing, staying ahead requires a comprehensive and future-ready approach to business management. For ambitious manufacturers and wholesale
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INDUSTRY 4.0 distributors seeking streamlined operations and sustained growth, MYOB Advanced has emerged as a vital asset.
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MYOB Advanced Manufacturing integrates manufacturing, inventory management and accounting to help businesses ensure raw materials are available to production, efficiently manage the manufacturing process, maintain revisions, and track the financials. Seamlessly integrated, it offers an end-to-end business management solution that empowers you to efficiently streamline business processes, generate accurate pricing, and calculate your total manufacturing costs.
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Empowering Manufacturers for the Future Built to harness the advantages of cloud technology, MYOB Advanced offers a sophisticated and future-proof ERP solution. Designed with a forward-looking approach, this solution ensures that your manufacturing operations remain agile and competitive. Here's a glimpse into the core features that set MYOB Advanced apart: •
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Comprehensive Financial Control: MYOB Advanced encompasses a robust suite of features, including financial management, GST handling, and more, to empower you with complete control over your business's financial aspects. Complete Management: Gain control over lead, supplier, distribution, and stock management across various departments and locations, fostering seamless collaboration. Enhanced Automation: The ability to use mobile devices to capture and access data, drive real time insights and quicker movement from the production floor. Diverse Functionalities: Explore a range of functionalities including CRM integration, fixed asset management, projectbased accounting, multi-company consolidation, and customisable workflows.
The Manufacturer’s Advantage MYOB Advanced Manufacturing Edition is tailor-made to resonate with manufacturers, offering a cloud ERP solution that addresses your present needs while laying a solid foundation for future growth. Manufacturers who adopt MYOB Advanced can expect to reap substantial benefits: •
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Informed Decision-making: Drill-down capabilities within reports facilitate swift decision-making, enhancing operational responsiveness. Increased Efficiency: Streamlined processes result in heightened productivity and resource utilisation. Simplified Financial Management: Multi-entity workflows simplify financial oversight, promoting efficient management. Plan and Coordinate: Reduce complexities around product management and be able to track designing/assembling activities. Data Visibility: Gain enhanced visibility into data, fostering improved corporate financial management. Balance Supply and Demand: Respond to demand and market changes while optimising inventory and resources for effective cost control. Quality Control: Track quality control measures at every stage of the production process and have complete visibility. IT Simplification: Minimise IT complexity and costs, so you can focus on your core operations.
Harnessing the Cloud's potential: In addition to these benefits, the cloud-based nature of MYOB Advanced offers distinct advantages: •
Web Accessibility: Access business-critical information anytime, anywhere, enabling better decision-making and flexibility.
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Robust Security: Enterprise-grade security and data backup safeguard your vital information against threats. Defence against Cyberattacks: Cloud storage mitigates the risk of server-based attacks. Enhanced Monitoring: Remote access facilitates efficient financial and productivity monitoring.
Is MYOB Advanced the right fit for you? When evaluating ERP systems, factors such as features and functionality, cost, support quality, and availability play a pivotal role. For manufacturers, MYOB Advanced emerges as a compelling choice for those in discrete manufacturing and batch processing, by streamlining supply chain management processes to production and order management. Its cloud-based architecture reduces reliance on your internal IT resources and offers financial predictability. Furthermore, its robust security measures, data backup, and 24/7 guarded access ensure the safety of your critical data. In conclusion, MYOB Advanced stands as an indispensable tool for Australian manufacturers seeking a scalable, efficient, and future-ready business management solution. By harnessing cloud technology and integrating comprehensive features manufacturers need to succeed, MYOB Advanced empowers users to unlock their full potential and excel in the evolving industry landscape. “We could not have achieved this level of growth and efficiency without the streamlined processes and real-time data we now have thanks to MYOB Advanced and BusinessHub,” said Sergio Correa, Managing Director, DAABON Organic Australia.
Your partner for streamlined success: BusinessHub At BusinessHub, we are committed to aiding businesses in streamlining their operations and achieving their financial and growth objectives. Our expertise lies in delivering integrated solutions that span from accounting to logistics, ensuring your business is poised for future success. As an esteemed MYOB Platinum Partner and a three-time Customer Experience Award recipient, we have a proven track record of excellence.
Unparalleled industry involvement BusinessHub proudly aligns itself with AMTIL as an active member who participates in AMTIL led initiatives and events such as Australian Manufacturing Week held in Melbourne and Sydney. This commitment reflects our dedication to staying at the forefront of industry advancements and trends in the manufacturing sector.
Pioneers in MYOB Advanced We stand as pioneers in driving the rapid expansion of MYOB Advanced. With the distinction of delivering the very first MYOB Advanced solution across Australia and New Zealand, we possess a high level of expertise in guiding businesses through this innovative transformation. At BusinessHub, we don't merely offer, implement, and support MYOB Advanced – we also leverage it internally to streamline our own operations. By incorporating this solution into our processes, we ensure that we continue to grow and excel, enabling us to better serve our clients and drive their success.
Ready to transform your business with MYOB Advanced? If you're ready to unlock the full potential of your business and experience the transformative power of MYOB Advanced, take the next step by connecting with our dedicated BusinessHub team. Our no-cost, no-obligation consultations are designed to show you how transitioning to the cloud with MYOB Advanced can bring about remarkable improvements for your business. businesshub.com.au
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mRNA The University of Queensland and Oxford Nanopore Technologies team up to accelerate research into quality control testing for mRNA vaccines. Researchers at The University of Queensland are harnessing the latest sequencing technology developed by UK-based biotech Oxford Nanopore Technologies to analyse mRNA vaccines and therapies. This approach promises to simplify and better ensure the quality of manufactured mRNA-based vaccines and therapeutics worldwide. The BASE team at UQ’s Australian Institute for Bioengineering and Nanotechnology (AIBN) is already recognised as the biggest supplier of research-use mRNA in Australia, having built more than 200 mRNA vaccines and therapies for academic, clinical and industry use. As mentioned in the Nature Communications magazine abstract: “The success of mRNA vaccines has been realised, in part, by advances in manufacturing that enabled billions of doses to be produced at sufficient quality and safety. However, mRNA vaccines must be rigorously analysed to measure their integrity and detect contaminants that reduce their effectiveness and induce sideeffects. Currently, mRNA vaccines and therapies are analysed using a range of time-consuming and costly methods. Here we describe a streamlined method to analyse mRNA vaccines and therapies using long-read nanopore sequencing. Compared to other industrystandard techniques, VAX-seq can comprehensively measure key mRNA vaccine quality attributes, including sequence, length, integrity, and purity. We also show how direct RNA sequencing can analyse mRNA chemistry, including the detection of nucleoside modifications. To support this approach, we provide supporting software to automatically report on mRNA and plasmid template quality and integrity. Given these advantages, we anticipate that RNA sequencing methods, such as VAX-seq, will become central to the development and manufacture of mRNA drugs.” Building upon this work, under the new research partnership with Oxford Nanopore, BASE researchers will use the latest and improved nanopore-based sequencing technology to optimise performance and reduce the time needed to measure mRNA vaccine quality attributes.
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“Currently, mRNA vaccines and therapies are analysed using a range of different methods that are time-consuming, complicated, and costly, and often outdated,” said BASE mRNA technologies researcher Dr Helen Gunter. BASE researchers showed how nanopore sequencing can analyse the quality of mRNA vaccines and therapies, in the study published in Nature Communications. “By using Oxford Nanopore Technologies sequencing, we can directly analyse each individual mRNA vaccine molecule as it passes through a protein nanopore, providing a real-time measurement of the mRNA sequence identity and integrity,” Dr Gunter said. This approach could also provide a useful research tool to better understand how mRNA vaccines work by studying how they behave within cells. Crucially, Dr Gunter said in the future, mRNA vaccines could be analysed in real-time, providing testing within hours of mRNA manufacture so quality control issues could be quickly detected. Such rapid analysis is critical during the rapid manufacture of mRNA vaccines needed during a pandemic — or to support the future development of personalised therapies. The recent success of COVID-19 mRNA vaccines had focused considerable attention and investment on the development of mRNA vaccines and therapies, with estimates valuing the mRNA market at $100bn by 2030. However, to realise this potential, Dr Gunter said mRNA products must be manufactured at the high quality needed to ensure their effectiveness. “Ultimately, we anticipate the use of nanopore RNA sequencing methods will become central to the development and manufacture of mRNA drugs,” Dr Gunter said. "We are excited to partner with the BASE team at The University of Queensland to further research supporting the manufacture and quality control of mRNA vaccines and therapies,” said Gordon Sanghera, CEO of Oxford Nanopore. “Nanopore sequencing is the only sensing technology that can read native RNA in real time, making it an essential part of the toolkit supporting the development of mRNAbased therapeutics.” aibn.uq.edu.au
INDUSTRY 4.0
Sovereign Phasio Phasio secures $3.8m to digitise manufacturing and accelerate Australia’s sovereign capabilities. Generating over $113bn in value in 2020-21, the manufacturing industry is a driving force behind the local economy. But compared to international counterparts, Australia’s manufacturing industry is falling behind. Globally, manufacturing contributes an average of 16% to a country’s gross domestic profits (GDP). But in Australia, the manufacturing industry is responsible for just 5% of GDP. Amidst the backdrop of current geopolitical tensions, there’s a need to increase high-value manufacturing and prioritise sovereign manufacturing capabilities to create a more resilient economy. Phasio, a manufacturing tech startup has announced it has raised $3.8m in a seed round, led by AirTree Ventures to accelerate the manufacturing industry and global productivity. “Manufacturing accounts for about a quarter of Australia's national research and development investment. But right now, the industry is stuck with inefficient, siloed processes that are slowing manufacturers’ ability to imagine, design, and create, and with it, our economy,” said Harry Conor Lucas, CEO and Co-Founder of Phasio. Co-founded by Australian entrepreneur, Harry Lucas and ex-CSIRO researcher, Sudharshan Raman, Phasio is digitising how manufacturers quote, design and interact with customers to unlock new ways of working. Phasio’s manufacturing interface provides an end-to-end workflow between stakeholders (buyers and manufacturers) to create instant quotations, collaborate on designs, and manage personalised order experiences. By empowering manufacturers to build better, Phasio is helping to secure supply chains and accelerating the pace of manufacturing.
“Our vision with Phasio is to elevate a new wave of local manufacturers onto the global stage. We believe that local manufacturing is the lifeblood of product innovation, and that by empowering local manufacturers to do more, we can in fact grow the manufacturing industry for everyone globally. Phasio offers an alternative to the usvs-them mentality. We can have our local manufacturing industry, but also benefit from working with the right partners,” added Lucas. “Our manufacturing interface is not just a tool. It's a carefully designed ecosystem rooted in a deep understanding of the challenges that both manufacturers and customers face. Securing this seed funding allows us to come out of stealth mode and accelerate our go-tomarket strategy. This includes scaling our engineering team to further develop Phasio’s interface, and support growing demand,” explained Sudharshan Raman, CPO and Co-Founder of Phasio. Among those contributing to the round include 500 Global, Entrepreneur First, Michael Sorkin’s Gattaca Ventures. Founded in 2021, Phasio’s solution is rapidly scaling the digital manufacturing industry. In addition to its core interface, Phasio has developed ManufacturingGPT (mGPT), an AI agent on its interface to instantly answer customer questions about manufacturing processes and therefore improve industry productivity. Phasio’s platform includes a number of integrations across the manufacturing workflow from Computer Aided Design software (Fusion360, CREO, Solidworks), accounting software (Xero, Quickbooks, Zoho) and shipping providers (Australia Post, UPS, FedEx). Today, more than 50 manufacturers use Phasio across a growing number of markets including Australia, South East Asia and Europe. phas.io
L-R: Sudharshan Raman (CPO and Co-Founder), Harry Conor Lucas (CEO and Co-Founder)
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The shift log goes digital Shopfloor Operations Management solution from Schuler’s Digital Suite, system downtimes can be prevented early. When an unexpected downtime occurs, it is no surprise that operators often have other things on their mind than recording the precise cause in the shift log. But this is really important to prevent repeated incidents in future. The latest application in the Digital Suite from Schuler makes life easier here for users: ‘Shopfloor Operations Management’ (SOM) automatically retrieves the relevant data from the system controller and processes them, together with other performance indicators, into a clear form. “SOM shows at a glance the current situation in production and reveals any potential problems early,” according to Product Manager Andreas Gebele. “The performance indicators can be compared with past shifts and orders to optimize processes in future.” The reporting provides an ideal basis for the daily shopfloor meeting:
“An increase in the availability of a system by 30% is entirely realistic.” Since SOM is directly integrated into the coordinating control, best possible data quality including precise time stamps is assured. Moreover, the accurate production data also ensure a more realistic cost calculation. Full connectivity to customer ERP/ MES systems as well as open data interfaces to AI solutions are also guaranteed. Via a user-friendly terminal for entering machine data, external causes of system downtimes – for example the forklift that delivers the blanks too late – can be quickly and easily recorded. Custom notes are supported, as well as addressing specific issues to the relevant responsible person using a ticketing system. schulergroup.com
UR30 Universal Robots continues its innovation journey by launching new 30kg collaborative robot. Universal Robots, the Danish manufacturer of collaborative robots (cobots), has announced that it will expand its leading product portfolio with a new 30kg payload cobot. UR30 is the second in Universal Robot’s new series of innovative, next generation cobots and is built on the same architecture as the award-winning UR20. Despite its compact size, UR30 offers extraordinary lift, and its superior motion control ensures the perfect placement of large payloads allowing it to work at higher speeds and lift heavier loads. This makes UR30 ideal for several applications, including machine tending, material handling and high torque screw driving. For machine tending, the high payload brings new possibilities as it allows the cobot to use multiple grippers at the same time. This means it can remove finished parts and load more material in one single pass, shortening changeover times and maximizing productivity. UR30 will also effectively support high torque screw driving as it can handle larger and higher-output torque tools, and thanks to a steady mode feature UR30 delivers straight and consistent screw driving. This will be beneficial in, for example, the automotive industry. In addition to this, the 30kg payload makes UR30 a great match for material handling and palletizing of heavy products across all industries, with the small footprint enabling it to fit into almost all workspace – relieving humans of the heavy lifting. Weighing only 63.5kg, it can also be easily moved between work cells. “The higher payload and greater flexibility underpin a new era in automation,”
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said Universal Robots President, Kim Povlsen. “Industries around the world are embracing more agile manufacturing and modularity in production – part of achieving that modularity and agility is about mobility and this cobot delivers that despite its payload. As industries evolve, the UR30 not only meets but anticipates shifting demands, enabling businesses to adapt and respond to changing needs effectively. As we continue to innovate, the UR30 is another step in UR's journey in pushing the boundaries of what is possible in the world of automation.” The UR30 is available for pre-orders now and will begin shipping in Q1 2024. universal-robots.com
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Supashock Specialist in mobility, motion, vibration and logistics – Supashock continues to expand. Founded in 2005, Supashock Advanced Technologies has built an international reputation for high quality products which help improve safety, ride quality and handling through vehicle dynamics. Following a successful motorsport engineering career spanning 25 years, Chief Executive Officer and company Founder of Supashock, Oscar Fiorinotto, has developed products and technology that successfully serve the automotive industry and global motorsport racing teams. Today Supashock holds an enviable international position as a specialist in mobility, motion, vibration and logistics control systems servicing diverse markets such as defence, automotive, aeronautics, mining and commercial solutions. Supashock has two manufacturing sites in South Australia plus a sales office in USA employing more than 125 staff overall including 60 engineers. As well as servicing the domestic market, the majority of its sales are now going to export markets in USA, Europe and South East Asia with an ever expanding range of new products and new markets being developed. “Within our state-of-the-art manufacturing facilities the company has eight advanced technology Okuma machines. These machines have a worldwide reputation for tight tolerances, agility and repeatability due to the rigidity and construction of the machines,” said Fiorinotto. “This enables us to produce large scale military parts of critical dimensions consistently which is particularly important with the high quality steels and materials we operate with,” he said. Supashock has implemented Okuma Connect into its digitised manufacturing lines and is working towards Manufacturing 4.0. The on-going training and the selection of highly qualified engineers is at the heart of the company. It has a close working relationship with leading Universities and has established a University Sponsorship Program covering all engineering disciplines. The company also works closely with TAFE Colleges to encourage
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young people into apprenticeships. Apprentice training also plays a key part in the company’s employment strategy and it currently has eight under training. Supashock has aerospace accreditation, ISO 9001:2019 and AS9100D, ISO 38340-2:2005, ISO 14001:2015 Quality Standards plus Metrology and Performance Testing facilities and has developed special testing equipment internally to meet customers’ specific requirements. “Our engineering personnel operating the Okuma machines love them and the support they receive from Okuma South Australia plays an important part with their exceptional service, backup and training. In association and partnership with Rheinmetall of Germany, Supashock has been awarded major military contacts for innovative suspension systems for military vehicles. The company is developing components and systems for aerospace and further defence projects. “Engineering innovations and amazing achievements have been achieved due to the efficiency the Okuma machines provide and the flexibility, ability to retain high precision tolerances in aerospace and defence products.” “Key business outcomes have been achieved as a result of the flexibility, capacity, repeatability and total quality output from the Okuma machines and the strong partnership we have established with Okuma Australia,” said Oscar Fiorinotto. “Supashock is a company at the peak of manufacturing excellence and we are privileged to be part of this excellence with such a highly accredited and innovative Australian manufacturer,” said Okuma Australia Managing Director Dean McCarroll. “Since its inception in 2005 Supashock has made remarkable growth in size and markets through innovation, drive and advanced technology and we are proud to be part of it,” he said. supashock.com/en/ okumaaustralia.com.au
MATERIALS HANDLING
Maersk measures Maersk doubles down on growth and Omnichannel Fulfilment (OCF) in Australia with opening of seven new facilities. International logistics and shipping leader Maersk is strengthening its omnichannel-fulfilment capabilities in Australia, with the opening of seven new facilities across the country. As the integrated container and logistics company celebrates its 30th anniver-sary in Australia, plans are in place to grow its already extensive operations and land-side capabilities. The seven new facilities are being delivered over the 12 months to Q1 2024 as part of Maersk’s global integrator strategy with clear opportunities identified to expand the re-gional logistics landscape. This will bring the company’s total number of sites in Aus-tralia to eight in total, serviced by 550 full-time employees. Four sites opened earlier this year and three more are coming online between now and Q1 2024. Two of these facilities were integrated into the Maersk network as part of its acquisition of LF Logis-tics. Maersk invited AMT magazine to the new Derrimut warehouse in Melbourne to meet with staff and view the complex matrix system. The network space was rolling with ro-bots, pickers and a massive blizzard of tracks. Each single package is clearly trackable from the moment a customer ordered the goods, to the point the parcel is sent to through to Australia Post or other for delivery. The vast network of tracks within the ma-trix autonomously moves each order, delivering it to the correct outlet. This actually has to be seen be believed. Maersk now boasts five gateway ports and owned warehouse services in Sydney, Melbourne and Brisbane, with additional co-owned warehouse services in Perth and Adelaide. Maersk’s addition of seven facilities in Australia brings its footprint from 15,900sqm in Q1 2023 to 142,500sqm by end of Q1 2024, adding a total of 126,600sqm in 12 months.
“Our expansion throughout Australia is giving our customers a more efficient and sus-tainable service right throughout the supply chain,” said Maersk’s Managing Director of Oceania, Kylie Fraser. “Australia imports a high volume of consumer goods, and we are excited to be able to continue to efficiently deliver goods while growing our business and contributing significantly to regional economic growth.” Six of the seven new sites will be omnichannel facilities, harnessing a variety of chan-nels to interact with customers to fulfil orders. Omnichannel capabilities provide Maersk with better levels of availability and service, reduced working capital and better efficiency. It allows for an improved focus on sustainability by utilising renewable en-ergy sources such as solar panels, smart power management systems and low energy consumption equipment. maersk.com
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4-Head Auto Filler Packserv’s 4-Head Auto Filling Machine: A testament to quality and longevity in manufacturing. In the ever-evolving landscape of manufacturing, Packserv’s 4-Head Auto Filling Machine emerges as a true technological powerhouse, redefining industry standards & ushering in a new era characterised by unparalleled efficiency and versatility. What sets this machine apart is not just it’s cutting edge design but also the continual groundbreaking technological improvements Packserv is tirelessly making on their machinery – in function, design, materials & construction - solidifying the 4-head filler as the undisputed leader in the manufacturing domain. One of the standout features of the new design is the inclusion of 2-litre cylinders, a strategic enhancement that allows for greater variance in fill volumes. This innovation ensures adaptability to a wide range of production needs, further underlining the machines commitment to versatility. In the intricate craftsmanship of the 4-Head filler, Packserv has elevated the art of manufacturing by integrating formidable 316 stainless steel into its mechanical drive components. This choice, though demanding in the cutting and machining process, represents a profound commitment to longevity, serviceability, and unparalleled craftsmanship. The use of 316 grade stainless steel translates into a machine that transcends the ordinary, enabling technicians to seamlessly service and repair the unit for many years for come. The upgrade in construction materials extend beyond mere function – it embodies a defiance against rust, pitting, and corrosion, essentially rendering the machine’s lifespan indefinite. This embodiment of enduring quality is not just a design choice; it’s a cornerstone of Packserv’s manufacturing philosophy – build for life, buy for life. In an era where machinery is often treated as a commodity purchase, Packserv’s stands against this cheapening of the industry is resolute. Packserv Managing Director, Nathan Wardell,
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sheds light on the prevailing trend of mass-producing cheap and unreliable equipment, especially on an international scale. The conventional sales pitch of “replace it when it breaks down” finds no resonance at Packserv. Their mission isn’t about saturating the market with disposable alternatives; its about crafting machinery that stands as a testament to reliability, quality, and enduring value. The industry echoes with tales of regret as manufacturers, enticed by online platforms like eBay or AliBaba, find themselves grappling with dysfunctional machinery. When these machines fail, the lack of support, unavailable parts, and compromised safety standards become evident. It’s a cautionary tale that seems to be slowly reaching the ears of those navigating the manufacturing landscape. Australia, fortunately, boasts a cadre of onshore quality equipment manufacturers, and distributors, exemplified by Packserv. Immediate technical support, a ready supply of parts, and efficient service are not mere promises; they are integral to the ethos of a local business like Packserv. The repercussions of relying on international parts and support, with the looming spectre of extensive downtime, underscore the wisdom of investing in local solutions. Buying local isn’t just a patriotic sentiment, it’s an insurance policy for the uninterrupted operations of your manufacturing facility. Packserv’s commitment goes beyond their own products – they manufacture parts not only for their machines but for various industry-standard machines. Their Sydney warehouse is a treasure trove, stocked with parts ready for immediate dispatch and installation, ensuring that their clients never face the debilitating effects of prolonged downtime, and having to deal with substandard service providers. In a world saturated with shortcuts and compromises, Packserv stands tall, an emblem of craftsmanship, reliability, and a steadfast belief that machinery should be built with an unwavering commitment to quality. packserv.com.au
MATERIALS HANDLING
The logistics of manufacturing How technology is revolutionising material handling in warehousing, Frank Baldrighi, Business Development Manager – Australia and New Zealand, GETAC. The warehousing and manufacturing sector is undergoing significant transformation, largely driven by digitalisation and technological advancements. The process of moving materials within a warehouse or manufacturing site can drastically impact capital durability, inventory cost, worker safety, and overall operational efficiency. To remain competitive in an evolving market, organisations must make smarter, faster, and cheaper decisions, particularly when it comes to material handling. Traditionally, material handling has relied heavily on manual, timeconsuming processes and rudimentary tools. However, digital transformation is reshaping industrial manufacturing, operations, and supply chain logistics like never before. Technologies such as artificial intelligence (AI), digital twins, autonomous mobile robots (AMRs), and vehicle mounts are driving material handling innovation. For example, digital twins can reduce the transition time between physical and digital worlds, speeding up reaction time and enabling quicker adjustments in operations. Similarly, vehicle mounts shorten the physical distance between the operator and technology, making it easier to execute tasks with increased efficiency. These tools not only capture and analyse data in real-time, but also decentralise the digital interface, giving manufacturers invaluable insights that help to streamline processes, reduce bottlenecks, and mitigate human errors. Complementing these are robust warehouse management systems (WMS), which further facilitate seamless material movement and increased operating efficiency. Bridging the gap with vehicle mounts As the demand for real-time data access grows, hardware interfaces in industrial settings are evolving. Vehicle mounts are at the forefront of this change, letting businesses attach removable computing devices to various material-handling equipment such as forklifts, cranes, and transport systems. Vehicle mounts come in different forms, each with unique functionalities. Docking stations, for instance, offer port replication, whereas cradles are device-specific and do not. Such versatility accommodates a multitude of applications, from machines that scan barcodes or radio-frequency identification (RFID) tags to those involved in the transfer of materials within the warehouse. The adaptability of these mounting options both facilitates real-time data access and enhances operational efficiency and worker safety. For example, hands-free data access minimises disruptions and lowers the risk of accidents.
While integrating this technology, it’s important to consider how it will fit into daily operations. Mount placement should be within the operator’s reach without obstructing their typical range of motion or creating potential blind spots. Engineers designing the mount location must consider the operator’s way of working and likely movement patterns. Consideration should also be given to mount durability, factoring in elements like excessive vibration which could dislodge the device, shock, or vibration fatigue, extreme temperature cycles, and dusty environments. The material should be both strong and lightweight, offering the needed resilience without adding unnecessary bulk. One of the most immediate benefits of using vehicle mounts in material handling is the significant increase in operational efficiency. Demountable rugged computing solutions enable quicker scans which lead to increased material processing and throughput per hour worked. However, it’s not just about speed and efficiency; it’s also about safety. Properly designed vehicle mounts offer controlled access to the computing device only when the vehicle is stationary, reducing the risk of safety incidents. These solutions also reduce vibrations and shocks to the device, extend port replication, and increase safety and security by locking the device in place.
The future is now The industry is on the brink of a new era in warehouse operations. Cutting-edge technologies, from smart software to robust hardware solutions, are ready to be deployed for optimising material handling practices. These technologies offer immediate gains in terms of operational efficiencies and provide a complete mounting solution— from the dock to accessory mounts like keyboards and printers— that can withstand challenging environments and situations in the warehouse and fit the unique requirements of each facility. Beyond immediate efficiency, smart technology adoption lets organisations build a resilient and future-proof operational framework. In addition to software, durable mounting solutions for computing devices are integral to this vision. Crafted from highstrength materials, vehicle mounts provide the requisite versatility and robustness for industrial settings. By embracing innovation, organisations can achieve more than just immediate improvements in operations; they can lay the groundwork for future success. Solutions are now available that offer opportunities to enhance various aspects of warehouse operations, from material handling and asset durability to inventory management and worker safety. getac.com
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Heat Exchanger How to reduce the effects of heat exchanger fouling. A leading manufacturer of industrial heat exchangers is warning engineers and those specifying heat exchanger installations not to underestimate the effects of material fouling on performance. Light fouling can impact the heat transfer process, reducing energy efficiency or preventing the heat exchanger operating within its designed parameters. In extreme cases, fouling can completely block heat exchangers, requiring significant intervention to remove or replace the affected equipment. Victoria-based HRS Heat Exchangers says that in many cases the effects of fouling can be reduced by specifying the correct type of heat exchanger in the first place. “Heat exchangers can be particularly susceptible to the effects of fouling when they handle difficult materials, such as sewage sludge or corrosive chemicals,” explains Matt Hale, International Sales & Marketing Director at HRS. “Fouling can generally be divided into one of four categories: chemical fouling, biological fouling, deposition (or sedimentation) fouling, and corrosion fouling. Prevention is always better than cure, but as each type of fouling is caused by a different combination of chemical and physical reactions, prevention requires different actions in each case.”
Chemical fouling Chemical fouling can take many forms but is caused by the deposition of different chemicals found in the solution being treated. Limescale (usually a mixture of calcium and magnesium) is the most familiar chemical fouling agent, regularly building up in our kettles and pipework. Limescale build up in heat exchangers can be prevented by dosing the solution with suitable chemicals, such as acid salt, while chemical agents are required for cleaning or removing limescale deposits. Struvite (magnesium ammonium phosphate) is a phosphate mineral which can be a problem in sewage and wastewater applications. Keeping water temperatures below 65°C will help prevent struvite formation, as will restricting the amount of phosphorus added to sludge digesters. Another chemical which causes fouling is vivianite (ferrous phosphate), a particular problem where ferric chloride (pickle liquor) is added to sludge to control hydrogen sulphide (H2S) emissions. Prevention also relies on keeping operational temperatures below 65°C.
Biological fouling Various forms of biological fouling can occur in heat exchangers. Algal fouling is often encountered where untreated river water is used for cooling. Environmental regulations may prevent the use of chemical additives, so using high water velocities or scraped surface heat exchangers can prevent algal fouling. In some wastewater treatment sites, final filtered effluent (FFE) taken after the filter press is used as a free cooling medium. However, due to the high level of biological material contained in FFE, it has a high fouling potential and fouling can quickly occur, depending on the exact nature of both the FFE and the heat exchanger design. UV treatment can reduce the biological load, but the use of scraped surface heat exchangers is the most efficient way to prevent this type of fouling.
Deposition fouling Deposition fouling occurs when particular materials present in a mixture or solution drop out and attach themselves to the heat exchanger surface. Fouling from sediment is the most common type of heat exchanger fouling seen. It can usually be prevented by good heat exchanger design. For example, making sure that the fluid has sufficient velocity and pressure; the use of
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Struvite (magnesium ammonium phosphate) is one of the most commonly encountered fouling agents. Companies, such as Ostara, recover it as a valuable nutrient for reuse
corrugated tubes to prevent sedimentation; or specifying scraped-surface heat exchangers to continually remove sediment to ensure efficient operation. Burn-on fouling occurs when fluid temperature is too high, causing sediment (particularly organic materials) to become baked on to the heat exchanger surface, and can occur where a malfunction has occurred. Control of water temperature (keeping it below 80°C) will also help prevent burn-on.
Matt Hale, Director Internacional de Ventas _ Marketing de HRS Heat Exchangers
Corrosion fouling Corrosion fouling usually occurs in specific circumstances where either the material being treated, or the construction of the heat exchanger itself, is particularly susceptible to corrosion. For example, aluminium and copper can be highly reactive and frequently suffer from galvanic corrosion or the formation of oxides on the tube surface. Specifying a heat exchanger manufactured in a material which is resistant to such corrosion, yet maintains good thermal transfer properties, such as stainless steel, will overcome most of these issues. “In all cases, good heat exchanger design can greatly reduce the incidence of fouling, or assist with regular cleaning,” comments Matt Hale. “Many factors, such as increasing turbulence through the use of corrugated tubes, using rotating or reciprocal scraper surface heat exchangers, choosing the right construction materials, designing integrated system failsafes, and facilitating servicing with easily removable tubes can all be employed to prevent, reduce or manage fouling so that heat exchangers work more efficiently for longer with minimal interference.” hrs-heatexchangers.com
MOTORS & DRIVES
Data science toolbox Motor protection made easy with moneo wizard. Imagine having Gandalf protect your industrial motors. It would be a formidable force to reckon with. Well, according to Freddie Coertze, the ifm moneo Data Science Toolbox has a wizard that can provide just that type of protection – by predicting motor issues through the use of advanced vibration analysis (AVA). “A unique aspect of moneo is that this wizard can help users determine the vibration limits of their motor and predict failure well in advance, so there is enough time to act,” says Coertze, the National IoT Business Development Manager for ifm Australia. “It’s a great way for an industrial business of any size to start implementing a predictive maintenance plan – without the fuss and complexity that is often associated with this process. Because you’re starting just with the motor monitoring.” Unlike other condition monitoring solutions, moneo has been designed for ease-of-use. It is a self-service IIoT platform where the hardware, software and smarts – which are predictive formulas created by artificial intelligence (AI) – come in the one package. The AVA wizard is a tool that comes with moneo and can be used as a simple way to start monitoring and protecting motors. “It’s very easy to set up. Basically, the wizard tool will talk you through the steps so you can do everything yourself without the need for an IT or analytics expert,” says Freddie. “It’s a matter of connecting your sensor, dragging and dropping that into the moneo dashboard, selecting the motor configuration, and then moneo has an inbuilt AI tool that will create baselines for you in regards to what the acceptable limits of motor vibration will be for that configuration.” Users can then start seeing the vibration levels of their motor installation on the dashboard. The set limits suggested by moneo appear as red and yellow dots to indicate if the motor is running outside of its determined limits.
“If vibration levels exceed the yellow, you have early notification that your motor needs attention and if it reaches red, it goes into alarm,” explains Freddie. “It’s the difference between having a warning that something is about to fail, and having early notification that is predicting a failure later on. Essentially, this wizard gives you time to fix motor issues before they become bigger problems. As we say, to protect, you need to predict and this wizard helps you do that.” Importantly, moneo has been designed to keep it simple for users, but also to expand as requirements change. “You can extend on this form of motor protection by adding a device that provides a more intensive vibration and into other aspects of predictive maintenance as well,” says Freddie. “But if we think about businesses just wanting a starting point, this is a great way to begin. You might have an asset such as a conveyor where if it breaks down due to a motor failure the whole production of a facility might come to a halt. So having this tool will let you know in advance if the motor has issues such as if it’s misaligned or it’s out of specification, and you can save it before any event like that occurs.” ifm.com/au/en/shared/moneo
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Navigating the deceleration Analysing the low voltage AC motor market performance in 2023 and beyond. Following 2022’s double-digit growth in revenues, the low voltage AC motor market slowed substantially in 2023. While still positive, the market grew by a modest 4.2% in realized revenue terms over the year. Compared with 2021 and 2022’s growth of 21.5% and 16.4% respectively, a 4.2% growth rate indicates a significant slowdown in the market. As we approach 2024, the market is poised to continue this deceleration, moving further away from the double-digit growth experienced during 2021 and 2022. The projected contraction of -0.7% underscores a market which is nearing the trough of its natural cycle. Over the past three years, the low voltage AC motor market has experienced significant revenue growth, with year-over-year growth rates reaching 16.4% in 2022. While the rate of revenue growth decelerated substantially in 2023, it is important to note that much of this deceleration is due to lack of price rises. When viewed through the lens of unit shipments, the slowdown is less dramatic. 2023 is expected to post year-over-year growth of 2.9%, down from 4.0% in the previous year. While the decline is modest, the timing and nature of the decline is indicative of what the market can expect for the near future. Between 2020 and 2022, demand for motors significantly outstripped the production capabilities of many suppliers. As a result, backlogs increased and the benefits from a post COVID-19 surge in demand were spread across 2021, 2022, and into 2023. The market for low voltage AC motors benefited from this through the first half of 2023, however, this quickly changed during the latter half of the year. New orders for motors saw a significant downturn beginning in June 2023, as interest rates continued to climb and projects became delayed amid economic uncertainty. This resulted in backlogs largely drying up for motor suppliers and many vendors experiencing a contraction during the last 6 months of the year. Consequently, 2023 went from being a continuation of above average growth, to a mediocre year.
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At the start of 2023, evidence of the coming slowdown was already beginning to show. Within the US market, the Federal Reserve produces a series which tracks year-over-year percentage changes for industrial machinery production on a monthly basis. As early as February 2023, the value of industrial machinery production had begun to contract. As shown below, production has continued to slide. This downward momentum is expected to continue into 2024, as the market enters the low point in its cycle, and we are expecting the market to contract by -0.7% this year. While performance varies across regions – with some still maintaining growth during the year – nearly all regions are performing below their 2023 levels. While underlying manufacturing industry performance is the core driver of this decline, we are forecasting a slight decrease in average selling price which is further exacerbating the decline in revenues. Prices remained steady in 2023, following two years of rapid increases. However, with a year of lower demand expected for 2024, we anticipate large customers will have stronger negotiating power with their suppliers. This is likely to manifest as downward pressure on the average sale price for the market. With a down year expected in 2024, the question becomes: what is the expectation for 2025? Our forecast shows a return to growth in 2025, as underlying industrial machinery production increases and the price growth of motors returns to the expected 2-3% per year. Globally, over the 16 years of data that Interact Analysis has analyzed, the value of machinery production has never had backto-back years of contraction. We do not expect 2025 to be any different. Blake Griffith is an expert in automation systems, industrial digitalisation, and off highway-electrification. He has written indepth reports on the markets for low voltage AC motor drives, predictive maintenance, and mobile hydraulics. interactanalysis.com
MOTORS & DRIVES
Wieland Electric with LAPP LAPP Australia expands functional safety and electrical automation range with new Wieland Electric partnership. Wieland is a solution provider and the world market leader for pluggable, electrical installations in the field of building technology. LAPP Australia is bringing this proven technology to the Australian market. LAPP Australia is expanding its ranges of electrical automation technologies, including multiple products in the functional safety category, through a new partnership with Wieland Electric. Wieland is a German-based global leader operating in more than 70 countries, supporting industries including building technology, engineering, wind power, EV charging, horticulture, and lighting. “The partnership with Wieland is a natural fit for LAPP Australia, as we continue to expand our industrial IT, automation, networking, and electrical interconnection ranges,” said LAPP Australia Managing Director, Simon Pullinger. LAPP Australia will sell more than 28,000 Wieland product lines, with 1,000 to be stocked locally in Australia, and the others to be air freighted from Germany in 1-3 weeks, depending on the product and destination.
Functional safety Wieland is known for its leadership in functional safety products, where it has built up a global pedigree for reliability and performance. Functional safety refers to technologies that enable the safe operation of machines and reduce the risk of equipment causing harm to people or property due to malfunction or incorrect operation. “As industrial processes become more automated, with more complex machinery, there is an increased need to meet strict functional safety requirements. Wieland’s range includes electro-sensitive and mechanical safe sensors, compact relays,
and powerful safety controllers to reliably support industrial clients in motion monitoring, analogue signal processing, industrial press control, and material flow,” said Pullinger. “LAPP Australia has the in-house technical expertise to assist with specifying the right Wieland products for the job, as well as ongoing support to keep everything running smoothly and operating to optimum efficiency,” he added. At the heart of each functional safety solution is Wieland’s SAMOS® PRO COMPACT safety logic controller (pictured right). The most compact and versatile in its class, this safety controller includes a large library of TÜV-certified safety functions, integrated status and diagnosis functions, and easy-to-use programming software. “Wieland shares LAPP’s focus on customer service, and getting each application right, no matter how complex or unusual. Both companies have extensive resources and highly trained personnel, which will provide direct benefits to the Australian market,” said Pullinger. Tradition and innovation – Wieland Electric has been representing the synergy of these two guiding principles for more than 100 years. At Wieland Electric, we are proud to be the world market leader in electrical connections, and have been focusing on safe and innovative technologies since our founding. The beginnings of our success lie in the legendary Wieland Clamp, the first-ever safe electrical connector. Since then, innovation has pushed us to develop safer and more efficient ways to electrify the world. Expanding from a component-only manufacturer, we are now one of the leading suppliers of innovative, future-oriented, and complete electrical solutions. lappaustralia.com.au
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Ignite Digi Ignite Digi couldn’t find the perfect mount for the kinds of shots called for by their TV production clients. So they made some themselves. It caught on. Paul Hellard gets to grips with this niche manufacturer in Hobart. Tasmania-based Ignite Digi first opened its doors in 2014, established by Tom Waugh as inhouse cinematographer, and Aeronautical Engineer/Gimbal Operator Chris Fox operating and engineering the drone camera platforms. Originally forming as an Aerial Cinematography duo, they built Unmanned Aerial Vehicles (UAVs) or drones, and modified gimbal and camera setups to enhance their business offering. Today their products have been used on some of the biggest film and television productions around the world: Including Disney's Mulan, Transformers: Rise of the Beasts, Marvel's Venom, Amazon’s The Marvelous Mrs. Maisel and many other film, television and Netflix programs. Ignite Digi bought their first CNC machine back in 2017, from OKUMA. “Having just come off a big government job, we were making our own small widgets in our bench to help our jobs along,” explained Waugh. Chris Fox is an aeronautical engineer by training. He self-taught himself the CNC system and the CADCAM process. “We were in his garage and his granny flat was our office. Over the period of 2017 to 2018, Ignite Digi transitioned the business from just being a film team, to where manufacturing became more of our income than the filming,” Waugh added.
Chris Fox (L) Tom Waugh (R) in their workshop with 3 OKUMA CNC Mills.
Using a small CNC router to cut carbon fibre sheets, they built drones and modified gimbal and camera setups to enhance their filming service. They added an OKUMA Genos M560V 3-axis CNC Mill to the garage to make aluminium parts. Chris taught himself the CAD and CAM process, continuing to use Fusion 360 due to the ease of a single program. From there they gained interest via social media from other gimbal and drone operators around the world and so the e-commerce store was started. In 2018 they won two awards for their product ecosystem: the Bob Miller ACS Technical & Innovation Achievement Award; and the Cine Gear Expo LA : Best Camera Accessory. From that point on they shifted main focus from film/TV service to design and manufacturing. “Our products are mostly 6061-T6 aluminium, and then some Ertacetal® plastic parts. We use an OKUMA 3-axis Genos M560V and two OKUMA 4-axis MB4000H horizontals with ten pallet APC. The horizontal 4-axis enables us to make a wide variety of products in smaller batch production runs,” said Fox. “With the additional benefit of the pallet pools meaning we can run overnight with no staff on site.” Since moving from Chris' flat and garage at the beginning of 2019 to a large workshop, they have grown to a team of eight people, with significant investment in three OKUMA CNC Mills. They also have mechanical, cable and PCB design and assembly, as well as a photo/video studio in house. “With significant investment in two OKUMA MB4000H 10-Pallet Horizontal CNC machining centres, each with OSP-P300MA Control which run un-manned virtually 24/7 plus the latest precision OKUMA CNC Vertical Machining centre Genos M560Ve, it has enabled Ignite Digi to be highly competitive and to cater for small batch size production runs,” said Fox. “With total design, development and manufacture in house now including a new electronics division, the company is able to move quickly to meet the needs of customers throughout the world including USA, Europe, Asia, Africa, South America and further afield. This total inhouse design to manufacture allows the company to move much faster with significantly improved costs.
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Dolly Grip On larger film/TV productions, there is a grips department, looking after cranes, cables, dollies, tracks and other kinds of camera support, meaning: literally, supporting the camera. In these days of gimbals, the job might be handed to a hybrid crew like Ignite Digi allowing dynamic camera movement, as well as the usual camera operation in cinematography. “There are always local commercials being produced in Tasmania for some of the bigger brands we have down here,” explains Waugh. “These TVCs can bring better budgets because they’re destined for a national or international market. The budgets influence the kind of shots being planned.” The motivating force for Ignite Digi starting to make their own parts was when they invested in their own broadcast digital camera, the ARRI Alexa Mini cinema camera in 2015. “We bought the Alexa when it first came out, and found we were doing some big drone aerial work from the very beginning,” said Tom. “I guess it came from our own work on ‘spec. We had to have a CNC router to make carbon fibre plates to attach the cameras to the drones.” “We'd done a bit of design work with another guy trying to get stuff made to do drone optimisation,” explained Waugh. “It became frustrating, so we made some widgets for the Alexa Mini. We owned
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this camera, and we had the only one in Tasmania. A director we were working with told us he’d love to be able to take the camera from a tripod, to a drone mount, to a car mount, to whatever kind of purpose, quickly, because well, time is money. We started down the wormhole of optimising that process.” Waugh and Fox posted a lot of their work on social media, @ ignitedigiaustralia. This gathered a following from other camera and drone operators and soon they found a new organic market for plates, attachments and lugs for the range of professional digital cameras from Arriflex, RED and Sony. These attachments are solid and strong enough to attach handles to. Cameras can be quickly attached to cranes, pulley systems and even to high-powered drones for those ubiquitous aerial shots. No camera operator is in business these days without the ability to shoot from the sky. As the small IgniteDigi team became more experienced in CNC work, they looked at refining the functionality of their camera attachments, and decided to combine an aesthetic look as well. “There was an organic growth to our market because these attachments were fitting so many cameras, and many more small studios were kitting up. Our customer base are cinematographers and other visual creatives, they appreciate the functionality, look and robust design for years of onset use/abuse.”
Government help The Tasmanian Government has been on board in supporting small business manufacturers in the state. Waugh tells me they were assisted in acquiring a Coordinate Measuring Machine (CMM) earlier in 2022. “Having the CMM enables us to measure parts with the precision for assemblies, tight tolerances and means if there is an issue, we know it’s a design issue, not a manufacturing issue” “We are one of the only places with a CMM in Tasmania and we hope we can pass that knowledge onto other manufacturers down here or even just the accessibility to see it in action. Rather than just say, it's just ours, we want to collaborate with people. 'A rising tide lifts all boats', as they say," added Waugh. ignitedigi.com.au okumaaustralia.com.au
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Drilling down Walter is focusing on innovations in turning. Changing components, small batch sizes and high price pressure, new materials and the highest demands on the surface quality of the manufactured components: In principle, all machining companies are currently moving within this coordinate system. Working economically here also places the highest demands on the machining tools used. Manufacturers like Walter are therefore continuously working on their portfolio of machining solutions. Incremental improvements or the differentiation of solutions that are already known are typical. However, the ambition of the machining experts at Walter in Tübingen goes beyond that: Optimisations or innovations that do not bring significant productivity improvements for real customer processes are viewed with scepticism. The developmentally strong manufacturer therefore focuses primarily on innovations that have the potential to become the new benchmark in the market. In the last two years, the turning and grooving segment has benefited the most from this.
Innovative Tiger tec® Gold coating solution increases performance In milling, Walter's Tiger·tec® Gold indexable inserts have been the gold standard for productivity and performance for five years. Last year, the machining experts from Tübingen also launched Tiger·tec® Gold indexable inserts for turning. These are a completely new development. Compared to the previous indexable inserts for this application, the new grade provides up to 50 percent more tool life when turning components made of ISO P steel as well as for special machining of martensitic stainless steels and ductile graphite iron. The decisive difference for the new Tiger·tec® Gold indexable inserts is the structure and orientation of the coating: Usually only the aluminium oxide layer is highly textured during CVD coating but, with Walter Tiger·tec® Gold, this is also done with the titanium nitride layer. This significantly increases the homogeneity and, therefore, the wear resistance of the coating. In the application, this is reflected in the greatly reduced flank face wear and in the massively reduced crater wear. Thanks to the multilayer TiCN coating, the Tiger·tec® Gold indexable inserts offer improved resistance to cracking and increased toughness. Under the electron microscope, you can see that three interruptions are built into the last third of the layer. These make the entire layer more elastic and improve the residual stress characteristics. When the cutting edge meets the component to be machined, the layer designed in this way dampens the forces acting on it. This makes the Tiger·tec® Gold indexable inserts the optimum solution when the tool has to repeatedly engage with the component during a turning process, such as when machining cranks or gears. To exploit the full potential of the Tiger·tec® Gold indexable inserts, Walter also uses a special three-stage finishing process: This further improves toughness, friction behaviour and crack resistance. The golden colour increases the contrast to the dark, already worn cutting edges. This makes it much easier for machine operators to assess their status and ensures that all cutting edges are used. Currently, the Walter Tiger·tec® Gold WPP10G, WPP20G and WPP30G grades are available: They primarily cover typical applications when steel turning in automotive series production, general mechanical engineering or power generation, such as machining drive shafts, rotor hubs or flanges. In a field test, for example, it was possible to increase the output of drive shafts per indexable insert from 170 with the previous solution to 250 components with the Walter Tiger·tec® Gold WPP20G. Across all 130 field tests, it was possible to increase the tool life by an average of approx 50%. The grades can also be used for machining
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Rotor shaft for an electric drive: Turning that is 20% faster. Image credit: Walter AG
Highly textured crystallites provide exceptional flank face and scour wear resistance – the multilayer nature of the TiCN increases toughness. Image Credit: Walter AG
ductile graphite iron (GGG), and for roughing martensitic stainless steels. There are 24 different geometries available, including special geometries for optimised chip breaking on long-chipping, low-carbon steels (MP3) or geometries specially developed for interrupted cuts (RP7). The new high-performance grades WKP1G (for finishing) and WPP05G (for roughing) will be introduced on 15th April 2023. With them, the cutting speed can be increased by 2030% compared to a P10 grade, thus increasing productivity.
CUTTING TOOLS G4014-P parting-off tool specially developed for Sliding head lathes. Image credit: Walter AG
Tiger·tec® Gold indexable inserts for turning. Image Credit: Walter AG
Copy turning systems: More precision, increased tool life quantities With its W1011-P system, Walter has also launched a technically innovative solution for copy turning, which brings a significant improvement in the cost-efficiency of the process when compared to conventional indexable inserts. The insert seat is a key issue for process reliability and precision in copy turning. In the conventional systems with VCMT or DCMT inserts, they have only a small amount of play, but that is enough for micro-movements during turning. As a result, the stability of the tool suffers, especially with undercuts up to 50°, but also the precision of the components in general. In the new W1011-P copy turning system, the new three-edged WL25 indexable inserts are fixed in the toolholder via a prism, both in the insert seat and on the insert itself, in such a precise fit that they no longer move. The system not only ensures that the insert is really correctly seated, it can also accommodate higher cutting forces. The precise fit also improves the accuracy of insert changes by over 50 percent when compared to ISO inserts. In addition, the system offers the option to work in both directions of movement. This means that both sides of the cutting edge can be used. The new WL25 indexable inserts have a total of three cutting edges and four different designs. For this purpose, the system has precision cooling. It can be used universally: All four insert types (neutral, left and right design as well as full radius) for different copying angles and applications fit in the same toolholder. All ISO materials P, M, S and K can be machined with it. In addition to copy turning (for example, on drive shafts, ball bearings, valves, etc.), dynamic turning is an important field of application, especially operations with different or alternating machining directions.
Tiger·tec® Gold WPP10G in use. Image Credit: Walter AG.
Fixed insert seat and easy handling: Walter Cut DX18 parting-off system The Walter development team has also set itself the goal of fundamentally improving the stability and handling of the Walter Cut DX18 parting-off system. The system is suitable for diameters up to 35mm. The new Walter Cut DX18 cutting insert geometry locks the insert securely in place via the form fit on the face. Thanks to the form fit, the new cutting insert adjusts 100% correctly, even with very narrow insert widths from 1.0mm. Another innovation is the SmartLock system, which considerably simplifies insert indexing on long centre lathes. With conventional screw-clamped systems, the machine operator has to remove the entire tool for this purpose – and this in cramped and not always user-friendly, ‘oily’ machine conditions. With the Walter SmartLock system, the clamping screw is located on the side of the tool: Simply insert the screwdriver, unscrew and change the indexable insert. walter-tools.com Australian Distributor – suttonhps.com
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Making decisions on selecting the right tools Staying competitive by maximising machining capabilities. In the dynamic world of manufacturing, staying competitive is the main goal. The rapid evolution of technology, changing customer demands, and increasing global competition continually challenge manufacturers to adapt and innovate. One of the key strategies for maintaining a competitive edge in this industry is by maximising machining capabilities. Efficiency in manufacturing has always been about doing more with less. It's about producing high-quality products faster, at a lower cost, and with minimal waste. Machining capabilities are crucial for producing high-quality, precise, and versatile parts, which drive innovation and competitiveness in various industries. Cutting tools are essential for machining, and selecting the right tool for the job can significantly impact productivity and costeffectiveness. Incorporating high feed cutting tools into your machining process can significantly improve efficiency, reduce downtime, and increase profitability for your machine shop. Palbit’s line of high feed milling cutters are available to accommodate diameters ranging from ØDc 10mm to ØDc 160mm and for machining a variety of materials. The advantages of high-feed milling are: •
High-feed operations can remove material quickly and efficiently, resulting in faster machining and production times.
Clamp that tool
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High-feed tools are designed to withstand high forces and speeds with high-feed operations, reducing the need for frequent tool changes and associated downtime and costs. • High-feed operations provide consistent, high-quality results, reducing the need for operator intervention and ensuring smooth and efficient production runs. • Optimising cutting parameters and tooling with high-feed operations can help minimise setup and changeover times. By embracing high-feed milling, manufacturers can gain a competitive edge in today's demanding environment, achieving greater efficiency and cost-effectiveness in their operations. livetools.com.au/pages/palbit
Importance of tool clamping technology. In the world of manufacturing and machining, tool clamping technology plays a critical role in ensuring precision, efficiency, and safety. Tool clamping refers to the process of securing cutting tools, such as end mills, drills, and inserts, to a machine tool or workpiece holder. A reliable and robust clamping system is essential to prevent tool slippage, minimise vibration, and achieve accurate results.
Effective tool clamping is crucial for several reasons:
Heat-activated clamping: Heat-activated clamping systems rely on the principle of thermal expansion to secure the tool. When heated, the clamping element expands, firmly gripping the tool in place. Magnetic clamping: Magnetic clamping is employed in nonconventional machining processes, where a magnetic field is used to hold the tool securely.
Accuracy and precision: Proper tool clamping ensures that the cutting tool is firmly held in place during machining operations. This stability translates to improved accuracy and precision in the finished workpiece.
Hybrid clamping: Some modern tool clamping systems combine different technologies, such as mechanical and hydraulic clamping, to optimize tool change speed and clamping force.
Tool life and performance: Correct clamping reduces tool wear and prolongs tool life by minimizing tool deflection and vibration. This directly impacts cutting performance and reduces the need for frequent tool changes.
Machining task: The type of machining operation, such as milling, turning, or drilling, affects the choice of clamping technology.
Safety: Inadequate tool clamping can lead to dangerous situations, including tool ejection during high-speed machining. A reliable clamping system is vital to safeguard operators and the surrounding environment. Types of tool clamping technology Mechanical clamping: This traditional clamping method involves using nuts, bolts, and other mechanical devices to secure the tool in place. Mechanical clamping systems are easy to use and costeffective but may require more time for tool changes. Hydraulic clamping: Hydraulic clamping systems utilise hydraulic pressure to clamp and release tools quickly and efficiently. These systems are known for their high clamping force, making them suitable for heavy-duty machining applications. Pneumatic clamping: Pneumatic clamping operates on compressed air, providing a fast and automated tool change process. It is commonly used in production lines with repetitive machining tasks.
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Factors influencing tool clamping
Material and cutting conditions: The material being machined and the cutting parameters (speed, feed rate, etc.) influence the required clamping force and stability. Machine tool type: Different machine tools have varying requirements for tool clamping, depending on their design and capabilities. Tool size and shape: The size, shape, and shank configuration of the cutting tool play a role in determining the most suitable clamping system. Productivity and automation: In high-volume production environments, automated clamping systems are preferred to minimise downtime and optimise productivity.
Conclusion Manufacturers must carefully assess their machining requirements and consider various clamping options to select the most appropriate system for their applications. As technology continues to advance, we can expect further innovations in tool clamping, leading to even more efficient and reliable machining processes. cuttingtoolsworld.com
CUTTING TOOLS
HOFFMANN ZeroClamp ZeroClamp clamping system offers significant advantages. Hoffmann recently introduced the ZeroClamp zero-point clamping system. Designed to significantly reduce set-up times and increase machining efficiency, the patent-registered new system provides an effective route to producing more components, quicker and at a lower cost. A number of features set this reliable and robust workholding solution apart from other competitor systems. Using the face and taper HSK spindle tooling principle the ZeroClamp clamping pots can achieve a repeatability of +/- 2.5 micron, around ten times more accurate than existing systems. As the hollow, tapered-shank bolt is drawn into the clamping pot the elastic properties of the seating ring expand slightly, allowing the taper to locate positively and the faces of the pot and the pallet or raw material to engage and locate solidly. Subsequently each fixing point has a break-out force of between 12.5kN and 60kN, depending on the clamping pot diameter. This principle also removes any machining induced vibration, minimises all thermal effects and compensates for hole misalignments of up to +/-0.1mm as the tapers always compensate towards the centre of the clamping position. The tapered bolts are produced from case-hardened 42CrMO2 steel and are very strong, allowing the workpiece or raw material to stand on them for storage. Only one design is used, avoiding the confusion caused by ‘fixed’ systems, which usually require three different bolt designs that are also known to magnify any thermal errors. “Thanks to the highly accurate repeatability of the ZeroClamp system parts can be unloaded and reloaded with the minimum of fuss. So, moving components from one machine to another can be carried out without any accumulated errors, and important features can be measured part way through the machining sequence with the safe knowledge that the part can be reloaded accurately,” says Simon Kolakovic, head of clamping technology development, ZeroClamp GmbH. Another advantage of the taper bolt design featured on the ZeroClamp design is the ability to tilt the pallet or workpiece during loading and unloading without fear of damage, making heavy and unbalanced workpieces easier to handle. It also means the units can be fitted at any angle, so they can be used in conjunction with tombstones or similar fixtures on horizontal machining centres. By contrast fixed systems are often only used on vertical machining centres as they need to be lifted parallel or they can deform or lock together. Fail-safe clamping is achieved on the ZeroClamp system by a stack of precision manufactured segmented spring steel collars that, by design, lock the taper bolt in. These collars are opened by an expanding bellows inflated with compressed air at standard shopfloor pressure. The bellows are guaranteed for one million operational cycles.
The simple design uses just a few high quality stainless or corrosion resistant steel components so it is very robust and is unaffected by swarf or coolant ingress, the pots can be quickly cleaned out with a blast from a standard airline gun. Avoiding all the disadvantages of a hydraulic system, the smart design of the Leader ZeroClamp system means that the units are around half the height of any alternative zero point fixtures, which allows the machine tool to keep more of its working envelope capacity. “This is an important point as the fixturing is often fitted to the worktable and it therefore reduces the distance between the spindle nose and the workpiece. We have kept this to a minimum so that larger parts can still be loaded and machined,” explains Simon Kolakovic. “The typical use of zero point fixturing involves manual pallets, which improve efficiency by allowing parts to be loaded and set-up outside of the machine tool,” he added. “However, the full application and benefits of the Leader ZeroClamp system is only really limited to the imagination of the engineer considering its use.” hoffmann-group.com Australian Distributor – suttonhps.com
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G-Mold Guhring hits the spot with new mould and die range. As a world-leading supplier of cutting tool solutions, Guhring has released a new range of innovative tools designed especially for companies working in the mould and die industry. As the company celebrates its 125th anniversary, the new range incorporates more than a centenary of expertise and technology to present the very latest innovations. One standout performer is the G-Mold milling line which allows manufacturers to benefit from the longest possible tool life and the best component surfaces. For maximum process reliability, precision and repeatability that delivers impeccable surface finishes, the rigid design is perfect for intricate parts that demand polished surfaces.
The new range, which can be seen in the new Mould and Die catalogue, presents a wealth of new product lines that include the latest milling, drilling, threading, reaming and countersinking innovations with the new G-Mold milling line for mould making already proving to be an extremely popular range. The new G-Mold milling series has been developed to maximise tool life when machining materials up to 65HRc. With the new Guhring Signum and Perrox coating technologies and the ultra-hard carbide substrate, the G-Mold demonstrates unprecedented levels of performance with long-lasting cutting-edge performance and impeccable levels of surface finish. The extended tool life and performance are further enhanced by the Guhrojet peripheral cooling system that delivers through tool coolant or compressed air to remove swarf while keeping the cutter body structurally sound and improving process reliability. The G-Mold series is available with ball nose, torus, finishers, radius finisher, universal and high-feed variants that all incorporate micron precision radius accuracy. Three prominent new arrivals include the new 55 and 65 G-Mold Series ball nose tools and the high feed range. The new G-Mold 65B series of high-precision 2 and 4-flute ball nose cutters for machining up to 65HRc incorporate a radius contour tolerance of ±0.005mm to ensure component contour accuracy and repeatability, with a centre cutting geometry, 25 degree flute and neck clearance for extended reach applications. Available in diameters from 0.2 to 12mm with a reach from 9 to 75mm depending upon the variant selected, the G-Mold 65B is suitable for hard materials, cast iron and steel machining where optimum performance, tool life and surface finishes are a necessity. Alongside the G-Mold 65B series in the catalogue, is the new G-Mold 55B series. More of an allrounder, the G-Mold 55B is suitable for machining steel, stainless steel, cast iron, super-alloys and hard materials up to 55HRc. Like the G-Mold 65B, the G-Mold 55B is available from 0.5 to 12mm diameter with neck clearance and a centre cutting geometry. For mould tool companies that demand the epitome of highperformance cutting, the G-Mold 65 HF high-feed series has been developed for high-feed roughing with low depths of cut and maximum feed rates to optimise metal removal rate. Presented in diameters from 1 to 16mm, the G-Mold 65 HF high-feed series incorporates Guhring’s Guhrojet peripheral cooling from 1 to 3mm diameter with central through coolant for 4mm diameter and above. With a corner radius and optimised tool geometry, the 4-flute end mills can perform high-feed rates on all material types. guhring.com.au
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PWR in QLD Australian manufacturer conquers international motorsport with advanced cooling technology. Dr Cameron Chai reports. If you know anything about motorsport, you will know that Formula 1 is the pinnacle. If you manufacture performance automotive parts, you would be justified in thinking that you have made it, if your parts are on board one of the F1 cars. How impressed would you be with a company that doesn’t just supply one team, but works with the entire field? What if I was to tell you, this same company was also the primary supplier for NASCAR, MotoGP and pretty much every other high-end motorsport category, including our very own V8 Supercars? Would you be surprised to hear that such a company does exist, and they are based in Australia? The company in question is PWR Advanced Cooling Technology, based on the Gold Coast. Originally a side business started by father and son team Kees and Paul Weel after various forays into motorsport categories, including the aforementioned V8 Supercars (or a previous incarnation thereof), they identified a need in the marketplace to design and manufacture high-performance, lightweight cooling systems to meet their exacting demands. And in 1997 Paul Weel Radiators was established and later morphed into PWR Advanced Cooling Technology. “From humble beginnings” Kees and Paul grew the business with the mission to build world-class automotive cooling systems, always having an eye on the international market. Driven by selfbelief and a can-do attitude, they experienced rapid growth. In 2006 they started construction of their state-of-the-art facility in Ormeau on the Gold Coast and have continued to expand on this location. With a focus on quality and performance PWR broke into Formula 1 in 2009 and haven’t looked back. The business now employs 350 staff in Queensland and export around 90% of their production. Through the acquisition of C&R Racing in the USA (in 2015) they now have manufacturing capabilities in North America along with another 140 staff and another manufacturing facility in Rugby, UK with 40 more staff, all sites now under the global brand of PWR Advanced Cooling Technology. When asked why PWR has been so successful, Matthew Bryson, Chief Technical and Commercial Officer, who has been on board for the vast majority of PWR’s 26-year journey explained. “We offer our clients opportunities. Through investment in technology we remove many of the limitations that encumber others and we can provide a full solution using flexible work methods, manufacturing processes and equipment, and leverage our broad range of capabilities.”
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He went further to explain, they don’t just supply standard radiators off the shelf and force them to fit an application, rather they look at the bigger picture with the process involving design, simulation, testing and proofing of the whole cooling solution. Matthew went further to say, “there isn’t a one-size fits all solution and we partner with our clients to design and build the optimal cooling system to suit their needs.” When dealing with the upper echelons of any industry, finding performance advantages requires pushing boundaries. In the context of cooling systems in motorsport, this entails maximising cooling efficiency while minimising weight and often working with minimal space and complicated geometries, all while ensuring reliability. Add aerodynamics i.e. minimising drag and optimising downforce, and the equation gets quite complicated. Thankfully for their clients, PWR’s manufacturing capabilities are almost limitless. Key to PWR’s ability to offer unbounded opportunities is their commitment to technology adoption. By constantly updating their capabilities they are able to offer increased levels of flexibility and options so they can manufacture solutions to suit any given application, from one-offs to large volumes. This has resulted in PWR going well beyond just supplying radiators. They also design and manufacture oil cooling systems as well as intercoolers for turbo and supercharged engines. Furthermore, their open mindedness and willingness to explore different cooling
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technologies such as tube and fin coolers, bar and plate coolers, and additive manufactured coolers. Different cooling modes such as liquid-liquid, liquid-air and cold plate technology has allowed them to expand into hybrid and electric vehicles for battery cooling as well as different industries such as aerospace, defence and electronics. It has also seen them expand into micro matrix heat exchangers (MMX) which can employ tens of thousands of fluid carrying micro tubes in a single system and are a highly efficient, lightweight and compact cooling configuration for space constrained applications. This commitment has seen PWR invest heavily in technology and equipment for production and fabrication including 50 CNC machines (3, 4 and 5-axis including self-loading and unloading systems), wire EDM, spark erosion EDM, TIG, vacuum brazing, laser welding, laser cutters and heat treatment equipment across their global sites. They have also embraced additive manufacturing. While they have had plastic 3D printers for 10 years, they have added metal 3D printers to their arsenal in 2020 providing even greater design freedom. Clean room assembly facilities round out their comprehensive list of manufacturing capabilities which all contribute to their overall capability making them self-sufficient. In-house expertise employs CFD (computational fluid dynamics) engineers to refine their designs to meet the demands of clients like those in F1 and aerospace who require custom solutions where factors such as size, weight, geometry, efficiency are common goals within a confined space. They are also uniquely positioned to achieve these goals with a proven solution thanks to a purpose designed wind tunnel. One of only a handful in the world, this system was designed with technical contribution from Red Bull Racing’s F1 team engineers. This allows them to run real world simulations on heat exchangers up to 1m x 1m in size and deliver air velocity and pressure equal to that seen in vehicle to determine such things as heat transfer, coolant pressure drop and airside pressure drop. To ensure the quality of the parts they manufacture they also employ a range of tests ranging from pressure testing to dimensional and integrity checks. They use CMM (co-ordinate measuring machines) to check overall dimensions and CT (computed tomography) for internal dimensions and more complex geometries that CMM can’t access. The non-destructive, 3D imaging nature of CT is ideal for inspecting the integrity of welds and other joints as well as the
geometrical accuracy of additively manufactured components. Their system is one of the largest in Australia and allows them to scan parts in the 1.2m x 0.8m range with sub-micron resolution. CT inspection forms part of the production process for high-end components and is now expected from these clients. As such their CT runs almost constantly in QC mode, but is also used to help refine new fabrication processes. Their commitment to quality extends to their quality management system. To meet the demands of a global audience, they are certified to international standards such as AS9100 (for aerospace), IATF16949 (International Automotive Taskforce), ISO 9001 and ISO14001. While being a household name in the automotive aftermarket industry, there are OEMs who have also sort the expertise that PWR has to offer. As has been the case in motorsport, it is the upper echelons of the auto manufacturers and hypercar producers like Porsche, Aston Martin, Pagani and Koenigsegg (to name but a few) who have called on PWR to help design and manufacture the cooling systems on their cars. While their Ormeau facility has served them well, PWR have just announced the next stage in their evolution. They are just about to embark on another expansion that will see them move into a new $21.9m facility up the road in Stapylton. Expected to be ready in 2025 following an 18-month construction phase, the expanded facility has the potential to increase manufacturing output by 114% using new equipment. They also anticipate the expansion will add another 488 new jobs over the next 10 years, more than doubling their existing workforce. These exciting plans have attracted the support of Queensland Treasury who will contribute up to $8.78m to support the venture and keep it on the Gold Coast. PWR are truly a one-stop shop for cooling solutions and are an Australian manufacturing success story that has made it on the world stage. Through commitment, ingenuity and investment in advanced capabilities, they have conquered motorsport and are no doubt looking to do the same in other fields such as aerospace, defence, electronics and others. If you have some spare cash, some shares in PWR might be a good investment if they continue on their current trajectory and experience the same levels of success in these new marketplaces! pwr.com.au
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DATRON CNC Prototypes delivered same day for designers using DATRON CNC milling machines. Timelines for fast-paced product development cannot wait weeks for functional prototypes to come back from the machine shop. In house designers are empowered to create precision prototypes in aluminium, carbon fibre, PCB materials and engineering plastics on DATRON CNC milling machines. DATRON milling machines are controlled by the intuitive DATRON next touchscreen control, with the goal to ‘make milling as easy as 3D Printing’. The large, 24-inch touchscreen feels closer to a smartphone than a powerful CNC machine controller. Smart software guides users through machine setup and operation via four simple steps;
The controller is developed by DATRON for their precision CNC milling machine range. Mechio provides sales, support and service for DATRON milling machines in Australia and New Zealand, including comprehensive machine training for operators.
Step 1: Select your program
Not a machinist? Not a problem! Typically Mechio finds that operators become confident and comfortable using their new DATRON machines within two days of on-site training. Mechio provides flexible training based on operator experience enabling all skill levels to run DATRON milling machines – from undergraduate intern to senior machinist!
Swipe through your programs and tap to select the desired part. Each file features a visualization of each part for easy program identification.
Step 2: Load tools Select your tools from the in-built DATRON tool library, or add your own custom tools. Loading tools is simplified by a graphical display showing tool data and physical position in the machine. The machine will automatically measure tool length using the built in High-Precision Renishaw touch probe.
Step 3: Load workpiece Using DATRON workholding solutions such as the vacuum table, pneumatic clamping, or centric vices – materials for processing can be loaded in seconds. Using the spindle mounted camera, operators swipe on the display to move the machine and locate the workpiece. Pinch to zoom and swipe to pan; its like navigating a photo on your smartphone, but for controlling a CNC milling machine! Workpiece probing has never been so easy. Simply draw the shape you need to probe on the screen and the control automatically generates a cycle for the Renishaw probe.
Step 4: Simulate and run program Using the on board simulation tool, users can view the toolpaths on the control in 3D before running the live program. Investigate your part geometry at the controller using the in-built 3D part viewer! When the program is ready to run, the PLAY button in the top right of the screen starts the program.
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Anthony at Above22 specialises in bespoke PCB development and hardware design for demanding government and commercial data acquisition applications; “When developing our remote monitoring and control modules, we relied on DATRON CNC milling machines for producing high-quality weatherproof aluminium electronic enclosures.” “The first aluminium enclosure produced on the DATRON milling machine had a flawless finish, but when fitting our PCB we noticed an assembly issue that was missed even after 3D printing a prototype enclosure.” “Because of these rapid prototyping capabilities, iterating the enclosure design on the DATRON resolved the fitment issue in minutes. If we had found the mistake after outsourcing the prototyping, we could have spent weeks resolving this issue.” DATRON precision CNC milling machines with DATRON next control available in Australia and New Zealand from Mechio. mechio.com.au
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Fiber laser and deburrer boosts MITS Alloy’s manufacturing capabilities Going from just a handful of employees to seventy-five in just a few short years is testament to the enormous popularity and demand for MITS Alloy’s range of heavy-duty aluminium Ute trays and canopies. Based in Newcastle, the company was founded by Tim Lightfoot and Tony Brooks in January 2015. Tim’s existing business, Safety MITS, supplied maintenance equipment for the Mining, Earthmoving, Transportation and associated industries. Together they identified the need for durable trays, canopies, toolboxes and service bodies for four-wheel drive Utes that could stand up to the harsh abuse of work and mine sites. Initially starting off manufacturing custom designed products, the company has evolved into developing a range of standard modular trays and canopies that would fit all popular Ute brands and models - with a number of optional accessories available to suit individual preferences and needs. This flexibility of the modular design extends to being able to remove the tray and canopy and transfer it to another vehicle at time of sale if required. A natural progression saw the company supplying the same high-quality products to the burgeoning recreational off road 4x4 market and more recently the fleet/trade market which has grown substantially in recent years. Modern vehicles have an array of safety features including reversing cameras, parking sensors, autonomous braking and blind spot detection. Many of these driver aids are located in the rear bumper; this necessitated MITS to develop its own harnesses, wiring and housings to ensure these work as per the factory settings once the new trays are fitted. The demand for the trays and canopies over recent years necessitated the need for new premises. Serendipity intervened when a large factory across the road became available earlier this year. The facility has been custom designed for MITS operations and features a 2,000sqm space for fabrication, an 1,800sqm assembly facility and 900sqm powder coating area allowing all work to now be done under the one roof. The company’s expansion and move to larger premises has seen a corresponding investment in new sheet metal equipment, allowing the company to introduce advanced manufacturing techniques, boost production efficiency and broaden its manufacturing capabilities. ‘We already had a good relationship with Applied Machinery following our previous purchase of two Yawei press brakes. We’ve been impressed with the Yawei’s performance and reliability so a Yawei fiber laser was the obvious choice,” Lightfoot said. “The 6kW high power fiber laser is perfect for our mainly aluminium processing environment and has dramatically sped up our cutting. What used to take us 16 hours a day, over five days has
now been reduced to just 23 hours a week over three days; we also have a much higher consistency of cut, a superior quality finish and our scrap rate is significantly reduced,” Lightfoot added. The auto load/unload function has also been a huge time saver for the company and reduced manual handling and minimised WH&S risks. All cutting is done with high pressure compressed air alone. “Whilst the fiber laser has been great, it is our new Weber deburrer that has been the biggest time saver - it takes all the sharp edges off parts quickly providing perfect surfaces and edges. We used to have four guys working 16 hours a day cleaning parts by hand to ensure they were touchable. We can now do a week’s work of deburring in just six hours a week with just two staff – and the quality is far superior,” Lightfoot added. Another benefit of the new equipment is that it has allowed MITS to produce more intricate parts and reduce weight; more detail can be put into products including logos and other aesthetic enhancements. “The Yaweis offer high performance at what is a very competitive price point. Evidence of this is the fact that we anticipate a ROI on the fiber laser in just 12-18 months,” Lightfoot added. “The back up and support from a local supplier like Applied has been great. We’ve always found the Applied team really easy to deal with; they have good tech support on the ground and get back to us quickly with a solution to any issue we encounter,” Lightfoot said. The company has recently launched in the US where its products have found a ready market both in the recreational ‘overlanding’ side and also in more specialised areas such as police and fire and rescue vehicles. The company’s recent application for ISO 1001 certification is likely to see these specialised type opportunities open up in the Australian market. Recognition of MITS Alloy’s success and contribution to supporting employment in the local Newcastle area was confirmed recently with the company being named Manufacturer of the Year 2022 (50 employees or more) at the Hunter Manufacturing Awards held in December last year. The future certainly looks bright for MITS Alloy and Lightfoot sees the new factory and the new Yawei and Weber equipment assisting the company chase down more contract manufacturing work. The company also has big ambitions for expanding its presence and market share in the US over the next few years. appliedmachinery.com.au
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Cheras Industries Pioneering aluminium castings for Honda lawn mowers, Cheras Industries shows a legacy of precision and process. Cheras Industries exemplifies excellence in the world of aluminium castings, raising the benchmark with its unparalleled dedication to quality and innovation. A subsidiary of G James Group, the company is backed by over 106 years of experience. Located in Eagle Farm QLD, Cheras Industries has established itself as a pioneer of custom made aluminium castings and is supported by a team of highly skilled operators and cutting edge technology. Cheras Industries provides customers with the option between gravity and pressure die-casting techniques, as part of a comprehensive selection of services. With an unwavering dedication to excellence, their team offers the complete spectrum of services, including engineering, design, cutting-edge casting techniques and the art of precision toolmaking, to achieve excellent results. Their foundry, which is located in Brisbane, is a dynamic source of custom components for domestic and international manufacturers alike. Having served Honda since 1988, Cheras Industries produce over 20,000 lawn mower bodies per year. Almost 40 years ago, in 1984, Cheras Industries had the foresight to see that automation was going to transform the manufacturing landscape and purchased a Unimate robot, largely recognised as the world’s first industrial robot. This signalled a significant turning point in the industry, with the incorporation of machines into assembly lines. A revolutionary innovation, at the time was a robotic marvel, with the ability to perform repetitive tasks with unprecedented precision and efficiency. In 2022, Cheras Industries came to Automated Solutions Australia (ASA) looking to reduce labour fatigue and also to replace their Unimate robot, which was showing signs of old age. Realising that deburring and deflashing duties were not only labour intensive, but also notorious for causing repetitive strain injuries and fatigue, Cheras Industries wanted to transform their operation with the incorporation of an advanced robotic system and intelligent technology. Hoping to improve worker safety and operational effectiveness, Cheras Industries were introduced to ASA through Okuma and their PIPE alliance (Partners In Productive Expertise). Working together with the engineering team at GJames, a cell was designed to load and unload castings from a conveyor into an 80
tonne hydraulic press. Once pressed, the robot would then transfer the casting onto a fixture and proceed to grind and deflash the casting before transferring the finished casting onto an outfeed conveyer. For this solution, the FANUC R2000iB/210F was chosen for both its payload of 210kg and reach of 2655mm. “The project incorporated many automation components that we needed to integrate together to achieve the different needs of the client,” stated Nathan Jones, General Manager of the Australian Business Unit at ASA. “We reached out to our partners in Industry such as Robofabrika, Rohmeld Automation and Schmalz to define the specifications of the equipment and enable seamless integration. We are very proud of the results we have delivered to Cheras Industries.” In conjunction with Robofabrika, ASA were able to integrate and supply a 2 axis compliant machining head for the robot. This allowed the robot to contour and follow the profile of the part achieving an excellent surface finish on a highly visual part of the mower deck. The servo spindle incorporated automatic tool changing of 5 cutting and deburring tools which are stored in a tool changer cabinet. Robofabrika also supplied a disc changing station which facilitates the automatic exchange of expired sanding discs. The integration of these proven automation technologies has unlocked the ability for continuous un-interrupted production of Honda Mower Decks for Cheras Industries. “This automation project has halved our labour time and we still believe that we can improve on that result a little bit more,” said Stuart Simi, Branch Manager at Cheras. “The introduction of an automated system eliminated the need for strenuous manual labour and addressed the problem of worker fatigue. Employees are now engaging in activities that promote upskilling and critical thinking. The automation cell has also resulted in a consistent level of quality, decreasing waste, and also increasing throughput.” Cheras industries continue to take revolutionary steps towards modernising manufacturing processes and upskilling their workforce. This innovative addition represents a paradigm shift in their operations, as the new automated system streamlines the labour intensive and painstaking processes that previously slowed down production. Utilising cutting-edge robotics and intelligent technologies, Cheras Industries has increased production efficiency, guaranteed consistent product quality, and prioritised worker safety. This bold move demonstrates not only their dedication to innovation, but also a progressive trajectory for the entire industry, establishing a benchmark for future advances in automated manufacturing. gjames.com/aluminium/castings automatedsolutions.com.au
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Sureweld Australia's trailblazing manufacturer of trailers and ramps that keeps the country moving. Australia's landscape is vast and rugged. As a nation thriving on development and progression, Australians demand portable, durable, efficient, and innovative solutions. Enter Sureweld, the country's leading aluminium loading ramps and plant trailers manufacturer and a company synonymous with quality and resilience. Focused on keeping Australian commercial contractors moving, Sureweld has grown exponentially since it was founded in 1976. Its ramps and trailers are 100% Australian-made, using locally extruded aluminium sourced from Capral and manufactured in Wangaratta, in northern Victoria. Sureweld sales manager Gareth Hansen joined his father, Sureweld managing director Carl Hansen, in the business when he left school. He has advanced from dispatch and welding to driving sales and supply relationships. “We manufacture the strongest and lightest weight ramps on the Australian market, on a strength-to-weight ratio,” Hansen says. This isn't just a claim. The company has consistently outperformed its competitors. “We have a ramp with a six-tonne capacity that weighs a little over 50kgs; others on the market weigh 70- to 80kgs,” Hansen points out, emphasising the immense value their products provide to operators who handle them in and out of the back of trucks all day. The company’s standard loading ramp range caters for machines from 450kgs to 11.5 tonnes, and the business can custom-build to suit machines up to 25 tonnes. After establishing its credentials in the ramp market, Sureweld noted the burgeoning demand for lighter-weight trailers to suit Australia’s braking requirements. In addition, while plant and machinery were getting heavier, towing vehicles were getting lighter, with less towing capacity. “We started with a trailer to suit machinery weighing up to 1.7 tonnes and now have models that can carry up to 4.1 tonnes,” Hansen adds. What sets Sureweld apart from its competitors? It's a blend of their ethos, the team, advanced machinery, and design innovations. “We invented the aluminium loading ramp and aluminium plant trailer in Australia,” Hansen emphasises. But the edge doesn't stop there. Sureweld's investment in toptier machinery like robotics, CNC water jet cutters, brake presses,
and guillotines ensures precision and consistency. Hansen asserts, “automation offers a better finish on our products and helps with the consistency of our products going out to customers. All of our products are good.” However, Hansen stresses that automation does not reduce staff numbers but attracts a different skill set. The 30-strong Sureweld team includes the in-house engineers who design and build prototypes that go into the field for months, even years, to test for any fatigue issues. Fabricators, a trailer fit-off team, and sales and dispatch personnel contribute to Sureweld's exceptional quality standards. The high quality of Sureweld products is also a testament to their partnership with Capral. “With aluminium, you can craft it to the correct size you need for strength-to-weight ratios. With steel, you are limited by what the steel mills produce. Working with Capral in aluminium, we can create the perfect extrusion,” Hansen explains. Over the years, this collaboration has evolved, bringing about innovations in product design and material usage. “Our engineers have been able to go to Capral and work out what is efficient to extrude,” Hansen mentions, reflecting on the synergetic relationship. Sureweld has also worked with Capral on the grade and temper of aluminium it uses. “We use a high marine grade, the highest you can get in Australia. The grade and temper we are using now have taken several years to master, and its weldability and structural integrity are the best Australia offers,” Hansen says. Looking to the future, Sureweld has grand plans. Their motto, ‘keep Australians moving, using our trailers and ramps,’ drives them to expand and innovate continually. Hansen shares, “It gives you a buzz when you go to the opposite side of the country, and you see a Climaxx by Sureweld ramp or a Rollmax by Sureweld trailer. It gives you a buzz to know that your product is well received and is slowly venturing into overseas markets.” Sureweld is more than just a manufacturing company. It symbolises Australian ingenuity, resilience, and commitment to quality. With a legacy of excellence, partnerships built on mutual respect and innovation, and a vision for the future, Sureweld is poised to keep Australia, and perhaps the world, moving and working for decades to come. sureweld.com.au
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J&T Steel Sales on Toolbox From quoting crunches to streamlined processes: ToolBox empowers growth of J&T Steel Sales. Expanding Australian metal fabrication specialist, J&T Steel Sales, has found that improved productivity and new equipment is only half the battle to boost customer service and sales – equally important is eliminating the outdated processes used to track and prepare quotes, delivery, and invoices.
“ToolBox has helped us immensely in delivering this guarantee to our customers. It has taken the stresses and late night quoting crunches and completely streamlined the process, freeing up more time for us to be able to focus on growing the business,” added Patterson.
J&T Steel Sales began as a small plate processing business in Victoria with a CNC Plasma machine, where staff used spreadsheets to develop quotes for customers, but the company has now made the move into the high demand laser cutting market.
“In the past, expanding our customer base meant we would fall increasingly behind when it came to invoicing and quoting. Now, with ToolBox, we really feel we have found a software that not only services us now, but also allows us room to grow in the future.”
Part of the motivation for the expansion was a need in the market for better lead times on laser cut metal products, including aluminium, stainless steel, and carbon steel.
Service is key
“We had customers come and beg us to purchase a laser machine, because they were fed up with the long lead times that were becoming increasingly common for laser cut products,” explained Luke Patterson, Operations Manager, J&T Steel Sales. “So we invested in a laser cutting machine, and prepared to grow our business to the next level. But with this change, we needed a quick and efficient software solution to export a presentable quote that we can forward directly to customers in a timely fashion. Spreadsheets just weren’t going to work anymore, so we did some research and found ToolBox, by Tempus Tools,” Patterson said.
Laser cutting quoting software streamlines operations ToolBox, by Tempus Tools, is a multi-functional laser cutting quoting software that is provided using a SaaS (Software as a Service) model. ToolBox was developed specifically for the laser cutting industry, and is designed to save job shops time, and make quoting more efficient, accurate, and consistent. “ToolBox has allowed us to streamline not only the quoting aspect, but also the tracking of active orders as well as invoicing,” said Patterson. “It has been able to take most of the heavy lifting in cutting back on excess paper waste in our offices, whilst also creating a digital paper trail to be able to track material usage and stock.” Since purchasing the laser cutting machine, J&T Steel Sales has committed to getting customers their parts when they need them, calling it ‘the J&T Guarantee’.
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Luke explains that in his business, customer service is the key to success. Customers have good memories, and they value pricing consistency, accuracy, and reliability. “Being a service-focused business, it’s something I look for in our suppliers too. In my opinion, the Tempus Tools team has been exceptional when it comes to responsiveness and availability to work through any challenges I’m experiencing,” Patterson said. “Coming from a small business ourselves it was an incredibly refreshing experience to have team members visit our workshop, and to also feel listened to when it came to our concerns or feedback for the future development of ToolBox.” “I met Mark Washington (Sales & Support) and Felipe Lechuga (Director) from Tempus Tools at a local manufacturing expo earlier this year, and they took the time to visit our job shop and discuss the functionality of ToolBox, and what more it could be doing for us. I was very impressed, and I’m grateful for all the support.”
A bright future J&T Steel Sales has seen steady growth since moving into the laser cutting business, and Luke has plans to continue this trend. “Our future plans are not only to focus on bringing in new customers – ideally ones that require repeat work – but also to let all our customers know about our bending and fabrication facility, so they know we can provide an end-to-end manufacturing solution,” he added. “ToolBox has a huge range of useful features, and the development team is always working on new functionality that can benefit job shops like ours, so it is a key component of our growth plans.” tempustools.com
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SkillUp and Placement Pilot program a win for long-term unemployed and employers. In an effort to get people who have remained unemployed long term into paid work, the Commonwealth’s Department of Employment and Workplace Relations has funded a pilot program that has delivered promising results. Called the Skill-up and Placement Program (SUPP), the pilot was initially launched in Victoria in 2022 and, due to its success, was expanded to include New South Wales during 2023. The SUPP project is the brainchild of the Australian Manufacturing Technology Institute Limited (AMTIL). The AMTIL association represents the interests of manufacturers, and its members wanted to see if a solution could be found to the labour shortage of CNC machinists in Australia. Working with the Federal Government and employer members of AMTIL, the association developed the framework around the SUPP project. The project aims to remove entry barriers for individuals who have been out of work long term due to genuine issues such as health or family constraints, to help improve their work and life outcomes. Simultaneously, the program is helping to fill labour shortages in the manufacturing industry. According to a Reserve Bank of Australia 2020 bulletin, titled Longterm Unemployment in Australia, the long-term unemployment rate between 2015 and 2020 has been 1.25%.
How SUPP works Run in conjunction with TAFE, the current program is voluntary. It involves identifying men and women of all ages, who are workplaceready and interested in pursuing a career as a CNC machine operator within the manufacturing sector. To determine their readiness, the individual initially undergoes mechanical, literacy and numeracy tests. They then attend TAFE where they acquire three weeks of training and learn to safely operate CNC machines. On fulfilment, they are awarded a Certificate of Completion for a CNC Operator Level 1 from AMTIL and TAFE. They then receive assistance to prepare their resumé and for an interview with a prospective employer. Successful candidates are awarded an immediate offer of employment that tends to provide wrap-around support. They gain on-the-job training and depending on the employer, and can take part in a company-run mentorship program and/or commence an apprenticeship.
SUPP support So far, the program has delivered win-win results for many of the candidates and employers. Of the 21 people who completed training in the Skill-up and Placement Program in Victoria in 2021, 18 people moved into permanent, full-time CNC machinist roles. And to date, eight of them have enrolled in an apprenticeship. In the case of the 11 individuals who participated in the recent SUPP project in NSW, nine of them completed their TAFE training, received their Certificates of Completion from TAFE and AMTIL, and entered fulltime employment as CNC machinists. In addition to opening up a career path for the long-term unemployed, the program has allowed participating employers to fill roles from this ready pool of CNC machinists that have long stood idle. “The labour market in the manufacturing sector is very tight and trying to find people to fill various roles on the shop floor, including CNC jobs, can be quite an ordeal. The SUPP project directly addresses this problem by placing employers in contact with candidates who genuinely want to work as CNC machinists and have the basic skills to start work immediately,” explains David Green, Chief Executive Officer, Sevaan Group. “The program not only gives people who want to work the opportunity to do so, it helps alleviate the staffing shortages many manufacturing firms are experiencing.”
The impact of SUPP on individual participants For many of those involved, the program has been transformative. The SUPP has allowed them to re-enter the workforce after a long absence with a set of skills that are needed and valued. It has also helped provide them with direction in a career that offers certainty. In addition, some of the employers engaged in SUPP are also offering mentoring programs to help the participants cement and grow their skills. Sevaan Manufacturing, a leading local metal parts manufacturer, provides mentoring through their Sevaan Academy as well as support for participants to complete a TAFE apprenticeship. “The Sevaan Academy provides a structured framework that allows the company’s staff to attain the skills and knowledge to best fulfil their various roles. It lets them consolidate their existing skills as well as learn new ones so that they stay abreast of new technologies,” explained Artemis Tzakos, Co-Founder, Sevaan Group. Given the success of SUPP to date and the positive results on both the long-term unemployed participants and for the employer, AMTIL is hoping to be able to take the program nationally. sevaangroup.com.au
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Eilbeck Engineering Okuma a key to Australia’s largest crane manufacturer’s success. With nine manufacturing facilities throughout Australia Eilbeck Cranes has come a long way from its beginnings as a humble blacksmiths shop more than 115 years ago. This fourth generation diverse family business, employing some 400 people, is today Australia’s largest and most advanced crane manufacturer with ever expanding exports extending to South America, Africa, the Middle East, Europe and New Zealand. Third generation Tom Eilbeck and fourth generation Charlie Eilbeck are both active in the company. In recent years Eilbeck Cranes has also expanded its heavy machining facilities investing two of the largest Okuma CNC machines in Australia to cater for its own production and to expand its heavy engineering division with contract and custom work and heavy engineering projects. With the successful business extension and expansion of the heavy machining division into major contract general engineering Eilbeck Machining is now one of the most prominent players in Australian heavy engineering and CNC Machining with contracts in defence, mining, rail, oil & gas and heavy industry. The large Okuma CNC Double Column Model MCR-A5CII with OSP-P300MA control is used for this work with the smaller Okuma machining centres producing almost 100% crane components. Apart from the first Okuma Double Column machining centre Eilbeck Cranes has invested heavily in a second Okuma Double column machine, Okuma CNC Lathe Model LB4000EX-II-BMYCx1500; CNC Horizontal Machining Centre Model MB8000H; CNC Vertical Machining Centre Model Genos M560V S15; CNC Lathe Model VTM-100 and CNC Lathe Model Multus B750 c 6000 each with OSP-P300SA-H Controls. “The high quality, reliability, durability and the precision of the Okuma machines has been a major factor in our success and the OEM support from the company within Australia and from Japan has been outstanding,” said Charlie Eilbeck, General Manager. “If we have an issue that cannot be resolved locally we can video link directly with the factory in Japan – such is the close working partnership we have with Okuma,” he said. As Australia’s largest crane manufacturer, Eilbeck Cranes has been well placed to take advantage of major infrastructure projects on the east coast of Australia with cranes up to 500 tonnes lifting capacity.
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As the only company in Australia with the capacity to manufacture one of this size, it has required Eilbeck Cranes to have a presence close to the infrastructure projects to provide high levels of support required. In the last two years staffing levels within Eilbeck have increased by 120 and the company places a strong emphasis on training, working closely with schools to provide work experience for young people and attract apprentices. Looking to the future the company currently has 30 apprentices under training. Recent engineering achievements and innovations for this exciting company include the current manufacture of a 550 tonne crane, the manufacture of a first hot metal ladle crane and a project covering the local manufacture of a three slab steel making cranes for the steel industry which will be a major three to four year development project and another first for Australian manufacturing. With some of Australia’s largest heavy machining capabilities new business opportunities continue to expand for Eilbeck Cranes and Machining with strong
national support flowing for high quality precision Australian made engineering. Supporting the development of Eilbeck Heavy Machining Centre, is its internal R&D design, fabrication, welding, modern blast and paint facility, mechanical fit out bays and electrical and commissioning specialists. Throughout production and its operations the company is accredited to ISO 9001, ISO 140001, AS/NZS 4801 international standards and is also accredited to NATA Technical Competence. ‘Working closely with our customers is a major part of the Okuma business philosophy and it is rewarding to see firsthand the benefits that are achieved through a sound business relationship such as the one we have with Eilbeck,” said Dean McCarroll, Okuma Managing Director Australia and New Zealand. “Eilbeck Engineering Division has established a major heavy precision engineering business in a relatively short period and Okuma is proud to be associated with this success,” he said. okumaaustralia.com.au eilbeckcranes.com
FORMING & FABRICATION
DAVI and Schlam since 2010 Manufacturing mining equipment requires rolling plates and sections, and to make this process more streamlined and productive you have one choice - Davi. bent by section bending machines (typical sections are H- and I- beams as well as THN Omega beams). Schlam is not only a leading provider of diversified mining and engineering services but an organisation that has an Australian focus, global reach, and a main goal of making mining equipment more productive with a real improvement to mine productivity and safety.
Since 2010, Davi has supplied four different rolling machines for the Schlam Group, which is based in Welshpool, WA. These include Plate Roll Machines (four rolls) and an MCP Angle Roll Machine. The latest MCB, Model R30 is currently the largest machine ever to be sold in Australia and boasts a rolling capacity of 3000x96mm. Australia’s mining sector is strong and along with this growth are the demands for mining products and services required for companies to reach their true potential. The thickness of what needs to be rolled in this industry is less than the capacity of the MCB R30, however, heavy-duty Plate Rolls are required because the materials used are very resistant. In fact, even though the thickness of the plates doesn’t exceed 40mm, the nominal rolling capacity goes up to 90mm, take for example the use of Hardox®, Xar® and Dillidur® products which are very common in this sector. Among these heavy applications, there are excavator buckets and dump truck bodies, with Schlam considered as the industry innovator in Australia. Schlam has the expertise, and design and engineering
capabilities, that enables them to engineer dump body solutions to meet individual site requirements and demands. The mining industry also requires medium rolling applications such as water truck tanks, thickeners, air blowers and processing equipment. The thickness of the plate for these applications is around 40mm, but the material is softer than for dumpers and buckets: in fact, it may require a nominal rolling capacity up to 50mm. Angle Rolls have a role in mining, since the reinforcement structures of tunnels are
The story of this relationship between Davi and Schlam is not only one of remarkable success but is an ongoing collaboration between two companies striving for excellence and promoting innovation. Davi is proud to have been selected to supply Schlam with superior machinery. The quality of the Plate and Angle Rolls is certainly fundamental in ensuring consistent quality demanded by valued end-use customers. Davi also offers its Australian customers with trusted and timely technical support through its Australian based agent Ottotech Services, as well as from its Italian Head Office. ottotechservices.com davi.com schlam.com
AMW 2024 Sydney — we’ll see you there! As the ‘go-to’ legal advisors for the manufacturing industry, Rigby Cooke Lawyers is pleased to offer AMTIL members the following exclusive benefits: >
Fixed-price business contracts, including terms and conditions of trade, supplier terms and conditions, and privacy policies
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A free one-hour consultation to determine your commercial and employment legal needs
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Discounted fees across all commercial and private client legal services
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Regular Workplace Relations legal updates
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Access to our Workplace Relations seminars and training workshops
Want to know more? Come visit us at AMW 2024 in Sydney to learn more about our exclusive AMTIL member benefits, and how we can assist you. In the meantime, please contact Julia Cameron, Lead Partner of our Manufacturing industry group, on +61 3 9321 7807 or JCameron@rigbycooke.com.au.
Our people: Your success T: +61 3 9321 7888 | E: info@rigbycooke.com.au | www.rigbycooke.com.au
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Improving thermal fluid safety Australia and New Zealand now have access to Global Heat Transfer products. To improve safety in businesses operating thermal fluid systems, Global Heat Transfer (GHT) has made its Thermal Fluid Analysis Kit and continuous Light Ends Removal Kit (LERK) available in Australia and New Zealand. These products will help manufacturers and other businesses operating heat transfer fluid (HTF) systems to better understand the condition of their thermal fluid, so they can take steps to proactively extend its lifespan and improve process efficiency and workplace safety. The Thermal Fluid Analysis Kit comes with equipment for drawing a fluid sample, containers to store it in, expert advice and instructions, and a fluid analysis service. First, to achieve the most accurate results, the customer must take a closed representative sample from a hot, live and circulating system. It can then be assessed for degradation products such as light ends, water ingress and carbon as part of Global Heat Transfer’s extensive eleven-point testing service. The kit means those in remote and offshore locations can accurately determine fluid condition without waiting for an external engineer visit. “Heat transfer fluid degrades over time, and it is essential that plant managers have an insight into its condition,” said Clive Jones, managing director at Global Heat Transfer. “The best way for plant managers to avoid unplanned downtime and manage the health and safety risks associated with heat transfer systems is with a proactive approach that includes frequent fluid sampling, followed by preventative maintenance.
“It can be difficult for companies in remote locations to access the skills and technology to draw a representative sample accurately and safely. We want all operators of heat transfer systems in Australia and New Zealand to benefit from expert frequent sampling and analysis,” added Jones. As fluid degrades, it forms long and short hydrocarbons — the shorter chains, known as “light ends,” will lower the flash point temperature (the temperature at which the fluid will ignite in the presence of an ignition source) of the fluid, increasing the risk of fire. A LERK releases light ends from the HTF as a gas by passing the fluid through a distillation vessel and recollecting it in the liquid phase of a condenser. The light ends are drained either automatically or manually from the system. The light ends removal kit can be retrofitted to any thermal fluid heat transfer system so customers in food and beverage, industrial, chemical, pharmaceutical, wood and plastics processing can remove volatile light ends and improve system, site and personnel safety. The LERK can be equipped with remote monitoring capabilities to enable a centralised solution that reduces the costs associated with call outs. Global Heat Transfer will also supply the sample kit and LERK to customers as a part of its preventative maintenance programme, Thermocare®, a proactive condition monitoring and maintenance plan to reduce the risk of downtime. Global Heat Transfer provides a range of heat transfer services to help manufacturers improve thermal fluid management. globalhtf.com
Air~Alert in Australia ELGi introduces smart monitoring and alert system for compressed air systems. ELGi Equipments has introduced Air~Alert, an IoT-based Air Compressor Monitoring System for the Australian market. Air~Alert is a data transmission and analysis service that monitors critical parameters and sends out actionable insights and alerts to users. With these insights, customers can improve uptime and maximise efficiency with smart monitoring and data related to air compressor performance. The service also enables customers to act in time and avoid potential failures. Additionally, Air~Alert enables 24/7 remote monitoring of the air compressor. It delivers trend graphs and information about operating parameters, including discharge pressure, oil temperature, variable frequency drive (VFD) speed (where fitted), total running hours, trips, and alerts on a live online interface accessible remotely from anywhere in the world. Air~Alert also notifies customers and ELGi dealers about scheduled maintenance and fault occurrences while predicting commonly occurring failures. Monthly summary reports on overall health and operating parameters, including upcoming service requirements and preventative maintenance based on the data obtained, are sent to customers. The operational and performance data from the compressors are acquired by Air~Alert from the compressor controller, transmitted in an encrypted form, and sent to secure and dedicated Air~Alert servers in the cloud. Smart algorithms then work on the data to
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enable intelligent prediction with actionable alerts, reports, and trends – which are returned securely to the operators as easy-toread actionable dashboards. Throughout the process, the data is structured and analysed to provide smart analysis that helps users to plan maintenance activities, enabling energy efficiency improvements with the compressor. The Air~Alert failure prediction module also predicts if the compressor is likely to fail in the future. At the end of the process, data is translated into comprehensible alerts and reports that allow the user to take timely action. With ELGi’s Air~Alert, users can track highly informative utilisation trends providing actionable intelligence and take corrective action, such as: •
Operating pressure band optimisation based on the utilisation rate • Replacing an existing fixed speed unit with a variable speed VFD unit/ or adding a retrofit VFD • Installing an energy efficient, lower size compressor in case of very low utilisation rate • Detecting leaks based on an unexpected change to a higher utilisation rate over time *The Air~Alert device can be factory-fitted on new ELGi EG, AB, and OF Series compressors or retrofitted on units with a Neuron III, III+, or IV controller. elgi.com.au
COMPRESSORS & AIR TECHNOLOGY
Kaeser’s new oil-free compressor CSG series rotary screw compressors. Purity and efficiency at the forefront. Pharmaceuticals, foodstuff, healthcare, chemicals and other specialised engineering applications have especially high demands when it comes to compressed air quality. For these sensitive processes, Kaeser Australia has released the latest class 0 oil-free compressor. Recently launched in Australia, the new CSG.1 rotary screw compressors have air flow rates ranging from four to 15 m³/ min and pressures up to 11 bar. Customers are offered the choice of air- or water-cooling, and can select an optional integrated refrigeration dryer or an i.HOC (Heat of Compression) dryer. The CSG.1 can be specified as a fixed speed, fixed flow rated machine or, for applications with fluctuating compressed air demand, variable speed controlled “SFC” versions are available with IE5 Ultra-Premium Efficiency synchronous reluctance motors. The risk of potential product contamination by oil from the rotary screw compressor is evaluated and minimised by means of an HACCP (Hazard Analysis Critical Control Point) analysis. Process validation is made easier for the customer, as KAESER’s diligence is confirmed by the TÜV Rheinland in the form of a residual oil class 0 certificate in accordance with ISO 8573-1. The CSG.1 has also been certified according to ISO 22000:2018, which covers the manufacture of food and beverage equipment. To further formalise the supply chain’s integrity, customers can also option the CSG.1 with Pharmaceutical, Food or Engineering Industry Certification Packages. Additionally, customers can request certification that the machine is free of silicone contamination, as per VW PV 3.10.7. Kaeser’s patented, energy-efficient Sigma Profile rotors now feature an innovative, wear-resistant PEEK
coating, which results in an airend that will exhibit no air flow loss during its lifetime. Developed in-house, the special coating has three layers; nanoceramic, PEEK basecoat and topcoat. This coating is biocompatible, FDA-certified and compliant with European requirement VO 1935 for food contact materials, making it ideal for use in the food and pharmaceutical industries. The latest iteration of the integrated Sigma Control 2 (SC2) controller not only provides dependable and energy-efficient control of the compressor operation, but also enables connection to any master compressed air management system. Furthermore, the SC2 continually monitors a number of sensors throughout the CSG.1 (including motor bearing temperature, winding temperatures and airend vibration) to ensure the compressor is operating within its optimal conditions at all times. Whether for the semiconductor, food or automotive industries, Kaeser’s two-stage dry-running compressors tirelessly prove that process-appropriate purity and cost-effectiveness can go hand in hand – even under adverse conditions. The updated CSG.1 series sees service intervals for the compressor as well as gear oil changes extended by 50%. This reduces service costs and also means less materials are consumed. Many of the materials used in the manufacture of the machines are recyclable. And the product’s exceptional durability means they can serve a company for long periods of time, reducing costs and environmental impact. au.kaeser.com
For sensitive applications meet the CSG.1, KAESER’s newest, certified class 0, oil-free compressor. The Sigma Profile rotors now feature an innovative, wear-resistant PEEK coating, so the airend will lose no air flow during its lifetime. Made in Germany to exacting standards, the ultraefficient CSG.1 gives you the most compressed air, for the least expenditure of energy. Where supply chain validation is imperative, customers can select ISO Certification Packages for food, or engineering or pharmaceutical industries. Documentation confirming the machine is free of silicone contamination can also be specified. See the CSG.1 at APPEX in Melbourne 12-15 March and Aust. Manufacturing Week in Sydney 17-19 April
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Varistat EXAIR’s Varistat Benchtop ionizer for hands-free static elimination. EXAIR’s Varistat Benchtop Ionizer is the latest solution for neutralizing static on charged surfaces in industrial settings. Utilizing ionizing technology, the Varistat provides a hands-free solution that requires no compressed air and provides a constant stream of particulatefree and static eliminating air. Easily mounted on benchtops or machines, this static eliminator is manually adjustable and perfect for processes needing comprehensive coverage, like part assembly, web cleaning, printing and more. The Varistat is the first fan-driven static eliminator to be offered by EXAIR, expanding available solutions while maintaining top-ofthe-line performance. Once plugged in, the Varistat provides rapid static decay capable of reducing 1000V to 100V in 0.8 seconds. This product features two replaceable ion emitter points and two 30 PPI foam filters to ensure optimal performance over extended periods, as well as LED lights to signify proper function. Offering customizable options like selectable voltage, variable fan speed and adjustable polarity, the Varistat is a comprehensive solution for eliminating static and removing dust, debris and other troublesome particulate. The Varistat joins an extensive line of static eliminating products from EXAIR that are UL listed and CE compliant. The complete
line of Gen4 Static Elimination products include the Super Ion Air Knives, Ion Air Cannons, and Ion Air Guns and are available from Compressed Air Australia. caasafety.com.au
Fresh air Energy efficient solution impresses leading PVC piping manufacturer in Perth. Air Tools WA, a trusted distributor of Chicago Pneumatic, have recently completed a successful installation for a prominent manufacturer and supplier of PVC piping to the construction and building industry in Perth. The installation featured the cutting-edge CPVS 120 90kW energy-saving Variable Speed Drive compressor, accompanied by the CPX 700 refrigerant dryer and a comprehensive pre/post filter package. The installation of Chicago Pneumatic's state-of-the-art machinery underscores the commitment to providing energy-efficient solutions for the industrial sector. The CPVS120 VSD OIS compressor is renowned for its impressive energy-saving capabilities, ensuring optimal performance while minimising energy consumption. Paired
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with the CPX 700 refrigerant dryer and a specialised filter package, the entire system aims to enhance operational efficiency and prolong the lifespan of the equipment. The manufacturer and supplier of PVC piping in Perth was very impressed immense satisfaction with the performance of the installed machinery. Happy with the success of the initial installation, the customer has taken a proactive step by placing orders for a second package comprising the same cutting-edge machines. This speaks volumes about the customer's confidence in the reliability and effectiveness of the compressed air system provided by Chicago Pneumatic. compressors.cp.com/en-au airtoolswa.com.au
COMPRESSORS & AIR TECHNOLOGY
Future energy Oxair and Cobalt Blue combine for future of energy storage. Oxair has supplied its on-site oxygen and nitrogen generators to the world’s only ethical cobalt mining operation, at Broken Hill in New South Wales, Australia. The proven standalone technology, that supplies a constant supply of pure oxygen and nitrogen, is anticipated to be at the forefront of Australia’s cobalt mining revolution.
achieve this, nitrogen is required at 99.5% purity. This can be a dangerous process as oxygen ingress can lead to the formation of sulphur dioxide, a toxic gas.
Oxair is an ISO 9001 certified company focused on the design and manufacture of packaged oxygen Pressure Swing Adsorption (PSA) Systems, Oxair manufactures very small, medium to large Oxygen PSA Tonnage plants.
“Investing in world class equipment is vital to achieving both safety and sustainability goals – something which is not lost on Cobalt Blue,” Adam Randall, Broken Hill Cobalt Project, Demonstration Plant Manager, explained. “Broken Hill Cobalt Project builds on 130 years of mining history and Oxair’s technology will help us to achieve commercial scale mining and processing operations in the near future. Together we are helping to create a renewable energy future and a community for our miners and their families here, and we’d thoroughly recommend Oxair’s systems for other mining operations.”
As the world adapts to renewable energy the demand for energy storage soars. With EVs, wind and other renewable power projects generating more and more electricity, the world will come to rely on batteries. Cobalt is a crucial part of that energy storage solution. Cobalt Blue, an ethical cobalt development and technology company, knows sustainable energy will lead to a decarbonised future, and the switch is creating massive demand for batteries and for cobalt. The mineral is critical to battery chemistry and is the reason why the Broken Hill Cobalt Project is projected to be scaled up to become a top 10 cobalt mine equivalent with the aim of producing enough cobalt to power five million EVs. The nitrogen generator is used in the project’s kiln. Pyrite concentrate is thermally decomposed in the kiln, during which sulphur is a released in a gaseous state, as a by-product of the process. An inert environment is vital for this process and, to
Oxygen is essential for the chemical reaction to leach cobalt from the pyrrhotite into solution. The Oxair oxygen generator is used to supply oxygen at pressure to the oxidation leach circuit.
“Battery power is undoubtedly the future across many industry sectors, but this can’t be achieved without vital components like cobalt,” Oxair’s David Cheeseman added. “Cobalt Blue is a unique endeavour and we are honoured that our systems are contributing to its current productivity - and to its ambitious targets to become one of the leading cobalt mines in the world. We very much look forward to helping Cobalt Blue shape the future of battery technology.” oxair.com.au
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Critical cash flow tips for manufacturers Managing cash flow effectively is crucial for any business, especially in the manufacturing industry where various financial challenges and uncertainties can arise. The Director, Business Advisory at William Buck, John Spender, gives an outline for managing the coin. Poor cash flow management can exert significant pressure on manufacturing operations, making it difficult to meet expenses and potentially leading to insolvency and liability for company debts. In light of rising inflation, supply chain issues, and the ATO intensifying efforts to recover outstanding debts, it becomes essential for manufacturers to have strong control over their cash flow. By gaining a comprehensive understanding of cash flow dynamics, manufacturers can proactively manage liquidity and address potential concerns early on. If your manufacturing business is facing tougher trading conditions and tighter cash flow, it is recommended to consider implementing the following strategies and processes:
13-week cash flow forecast A detailed 13-week cash flow forecast is a valuable tool for monitoring both cash inflows from debtors and cash outflows for the payment of creditors. This forecast should encompass various elements such as employment entitlements and historical debt repayments. By continuously monitoring existing and upcoming expenses, manufacturers can ensure the availability of sufficient short-term assets to meet obligations promptly. Having a cash flow forecast enables business owners and operators to prioritise payments and plan ahead, thereby avoiding penalties. By accurately projecting cash inflows and outflows over a 13week period, manufacturers can gain better visibility into their financial position and make informed decisions. This allows them to anticipate any potential shortfalls in cash and take proactive measures to address them. The cash flow forecast should consider factors such as sales projections, accounts receivable collections, accounts payable obligations, and any upcoming expenses or investments. Regularly reviewing and updating the cash flow forecast helps manufacturers stay on top of their financial obligations and make necessary adjustments to ensure sufficient liquidity.
Debtor management processes Once a cash flow forecast is in place, it is crucial to focus on debtor management and expedite the conversion of invoices into cash. Establishing robust cash collection processes is essential for timely payment collection. This includes promptly sending out invoices, following up on overdue payments, and implementing clear policies for credit terms and collections. Manufacturers should also identify key performance indicators (KPIs) for debtor management, such as average collection period and debtor turnover ratio, to measure the efficiency of their collections process. In cases where customers consistently delay payments, manufacturers may need to consider stricter measures, such as suspending supply until outstanding payments are made. Regularly reviewing and analysing debtor aging reports helps identify customers with overdue payments, allowing manufacturers to take appropriate actions to recover the cash. Efficient debtor management ensures a steady cash inflow, improves cash flow stability, and reduces the risk of bad debts.
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Budgeting and overhead reduction Implementing a comprehensive budgeting system for expenses is a vital practice that enables effective cash flow management and ensures desired profit margins are achieved. Creating a detailed plan of expected outgoings and regularly comparing them to actual expenses allows manufacturers to identify specific areas of concern promptly. By aligning expenses with revenue projections, manufacturers can control their costs and maintain a healthy cash flow. Budgeting should involve a thorough examination of all expenses, including raw materials, labour costs, overheads, and other operating expenses. Manufacturers should analyse historical data and market trends to make accurate revenue and expense projections. To reduce overhead costs, manufacturers can explore various strategies such as renegotiating supplier contracts, optimising inventory levels, improving operational efficiency, and exploring cost-saving technologies. By closely managing expenses and continuously seeking opportunities for cost reduction, manufacturers can improve their cash flow position and overall profitability.
Preparation and review of budgets/forecasts Budgets and cash flow forecasts are dynamic documents that should be continuously reviewed and adjusted based on changing circumstances and business objectives. Depending on the current conditions, it may be necessary to review and update these forecasts and budgets on a regular basis, such as monthly or quarterly. By regularly comparing budget forecasts with actual results, manufacturers can identify any cost overruns and take appropriate action. It is crucial to maintain accurate and up-todate data within accounting systems to generate reports that facilitate effective decision-making processes. Regular budget and forecast reviews enable manufacturers to identify trends, evaluate their financial performance, and make necessary adjustments. By analysing the reasons for any deviations from the planned budget, manufacturers can identify areas for improvement and implement corrective measures. This ensures that the budget and cash flow forecast remain relevant and aligned with the business's objectives.
Consulting a specialist In addition to implementing the above strategies, it is important for manufacturers to seek guidance from experts in cash flow management specific to the manufacturing industry. Consulting with a William Buck Manufacturing Specialist can provide valuable insights and tailored advice to optimise cash flow management practices. These specialists have in-depth knowledge of the manufacturing industry and can help manufacturers navigate the complexities of cash flow management during periods of instability. By adopting a proactive approach to cash flow management and implementing the recommended strategies, manufacturers can position themselves for success even in challenging economic conditions. Prioritising cash flow stability not only ensures the business's financial health but also enables manufacturers to take advantage of opportunities for growth and innovation. It is an investment that pays off in the long run by safeguarding the business against potential risks and uncertainties. John Spender is the Director of Business Advisory at William Buck williambuck.com
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eVTOLs The future of advanced air mobility: eVTOLs leading the way to Brisbane 2032 Summer Olympics. By Mark Metzeling, Principal Lawyer (IP, Trade & Technology) at Macpherson Kelley. The landscape of aviation is undergoing a transformative shift with the rapid development of Electric Vertical Take Off and Landing (eVTOL) vehicles, marking a crucial step towards the future of Advanced Air Mobility (AAM).
The essence of eVTOLs eVTOLs, often referred to as electric air taxis or drones, utilise electric propulsion systems for vertical take-off and landing capabilities, presenting an alternative to traditional aviation. This innovation has the potential to revolutionise urban and regional transportation. The electric propulsion not only contributes to a reduction in carbon emissions but also opens new possibilities for efficient and sustainable air travel.
Safety considerations in eVTOL development
Authority (CASA). This milestone allows Swoop Aero to centralise drone operations in one facility, providing logistical support across Oceania, Africa, and Europe. The company's partnership with Mater Pathology exemplifies the practical applications of eVTOLs, transporting medical samples with significant time savings. 3. Wisk's Autonomous Air Taxi Service: Wisk, formed through a partnership between Boeing and Kittyhawk, is eyeing Australia for the introduction of a safe, sustainable, and scalable autonomous air taxi service. A Memorandum of Understanding signed with the Council of Mayors South East Queensland aims to establish an urban air mobility ecosystem, envisioning pilotless air taxis as part of South East Queensland's transportation options.
The safety of eVTOLs, like any mode of transportation, relies on a multifaceted approach, including stringent design, engineering, regulatory compliance, and operational practices. As these vehicles are in the early stages of development, there is a growing push to accelerate their progress, particularly in Queensland, Australia, where the anticipation for the Brisbane 2032 Summer Olympics is driving innovation.
Key safety considerations for eVTOL development include: 1. Design and Engineering: Adherence to strict engineering and design standards to ensure structural integrity, reliability and safety in various flight conditions. 2. Battery Technology: Ensuring the safety of electric propulsion systems, with measures in place to prevent issues like overheating or fires in battery technology. 3. Flight Control Systems: Implementation of sophisticated flight control systems to guarantee stable and secure operations throughout the entire flight process. 4. Regulatory Compliance: Strict compliance with aviation regulations and standards set by relevant authorities, such as the FAA in the United States or CASA in Australia, covering aspects like airworthiness, pilot licensing, and operational requirements. 5. Training and Operations: Comprehensive training for pilots and ground crew members, coupled with adherence to operational procedures, is vital for the safe operation of eVTOLs. It is important to note that the eVTOL field is dynamic, and safety standards will evolve as technology matures.
Queensland's pioneering role in eVTOL development Queensland, Australia, is emerging as a hub for eVTOL development and deployment. Several significant initiatives highlight the state's commitment to advancing this transformative technology. 1. Skyportz Manufacturing in Queensland: Skyportz, a key player in the eVTOL space, has announced plans to manufacture these vehicles in Queensland. This move aligns with the state's ambition to be at the forefront of AAM development, fostering economic opportunities and sustainable transportation linkages. 2. Swoop Aero's Operational Approval: Swoop Aero, a company specializing in "Drones for Good," has obtained operational approval from Australia's Civil Aviation Safety
Wisk Aero Gen 6
The Roadmap for eVTOLs in Australia To support the development and integration of eVTOLs, Australia has outlined a comprehensive regulatory roadmap known as the "RPAS and AAM Strategic Regulatory Roadmap”: [[See QR code]]. Created by the Civil Aviation Safety Authority (CASA), this roadmap provides clarity on the country's future approach to aviation safety regulation for RPAS and AAM. It encompasses key areas such as aircraft and systems, airspace and traffic management, operations, infrastructure, people, safety and security.
The Future is Now As the eVTOL industry propels forward, manufacturers, regulators and operators play pivotal roles in shaping its trajectory. Queensland's commitment to being at the forefront of AAM development, coupled with the regulatory roadmap, sets the stage for a future where eVTOLs seamlessly integrate into daily transportation.
Up, up, and away! Macpherson Kelley’s Technology team has expertise in providing practical commercial advice to support advancement in areas of leading-edge technology. If you require assistance with protecting or commercialising your developments, or in cutting through the red tape of regulations and legislation, contact Mark Metzeling who can assist in avoiding the turbulence! mk.com.au
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Sustainable smarts Why intelligent manufacturing might be the answer to a more sustainable future. Andy Coussins, Executive Vice President, International at ERP provider Epicor. Changes in the Australian policy landscape, and growing pressure from stakeholders means sustainability is now front of mind for every organisation. Simultaneously, an increasingly competitive and uncertain global economy of fast-rising materials and shipping costs is forcing manufacturers to implement intelligent, agile, and cost-effective production processes to improve efficiency and throughput. Fortunately, despite these converging challenges, businesses today have the digital tools to support collaboration with industry peers on a global scale. The rise of Internet of Things (IoT) connected smart factories provide manufacturers with the capabilities to leverage data insights from their shop floor and supply chains to develop end-to-end circularity in their sourcing, production and distribution processes. This is helping to minimise unnecessary waste and reduce carbon emissions for more sustainable operations. As more manufacturers move into a circular economy business model, decision makers are turning to innovation to support this transition, with 80% of CEOs increasing digital technology investments to counter current economic pressures. Alongside this, we see 87% of business leaders are expected to increase their organisations’ investment in sustainability initiatives over the next two years, creating a huge opportunity for technology providers who can support their transition to net zero.
Cloud ERP plays a vital role in empowering manufacturers to diversify their capabilities with minimal disruption and lower onsite energy consumption for more sustainable and cost-effective operations. This also supports more sustainable hybrid working practices by enabling workers to easily monitor all warehouse and production processes from anywhere with an internet connection. Despite advancements in artificial intelligence (AI) and wireless connectivity helping to accelerate decarbonisation efforts, a recurring problem for many businesses leaders is how to effectively measure and embed sustainability across their extended supply chains. Many rely on an integrated ERP system to analyse supply chain data and calculate the true cost of compliance. This means any disruption to the sourcing or distribution processes can be acted on immediately, to ensure products are not just profitable for the business but affordable for their customers.
Sustainability versus cost and availability
With the Australian government committed to reducing Australia’s greenhouse gas emissions to 43% below 2005 levels by 2030, businesses that make, sell and move products are re-evaluating their extended supply and value chains to meet current industry expectations. The shift is significantly impacting manufacturers, who are turning to cloud-powered Enterprise Resource Planning (ERP) solutions and Manufacturing Execution Systems (MES) to maintain compliance with net zero legislation while remaining profitable.
For sustainable supply chains, manufactures need to have easy access to accurate data on product quality, traceability, trackability, reuse or repair. With stock shortages, logistics challenges and inflation continuing to affect the sustainability versus cost and availability balance, deploying powerful digital solutions that can quickly convert real-time data into actional insights is critical to ensure greater business agility and resilience. Manufacturers are expected to incorporate sustainable materials into their solutions right from the initial product design phase. In response we are seeing a rise in digital tools that integrate Computer Aided Design (CAD) into ERP systems with guiding rules to ensure sustainable processes and materials are being used from the build. We are also seeing increased adoption of low code/ no code automation and analytics tools to overcome resource, materials, production, and delivery challenges, especially when intelligence can be shared to make circularity efforts cost-effective.
More businesses are replacing their legacy system and switching from on-premises hardware in favour of cloud powered Software as a Service (SaaS) solutions, as part of this strategy. Based on the findings in 2023 Epicor Industry Insights report, a clear majority of enterprises in the care, distribution, and manufacturing industries are now more likely to use a hybrid cloud ERP solution - 96% of those surveyed are using some form of cloud ERP solution while nearly half (46%) are either primarily or entirely on the cloud.
To overcome the sustainability challenges of the 21st century, manufacturers must work more collaboratively with their ecosystem of partners, suppliers and customers, as they move away from rigid manufacturing in favour of onshoring and circular economy practices. Technology providers have an equal responsibility to listen and respond to their unique pain points, so they can customise industry-specific solutions that support intelligent manufacturing for a more sustainable future.
Innovation drives sustainable supply chains
epicor.com/en-uk/resources/interactive/industry-insights/
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Talking Safety Frontline workers’ top concerns for the future — and how leaders can navigate them. Sam Byrnes, Chief Product Officer for SafetyCulture talks the talk. For decades, employees were expected to leave their personal problems at the door. But in a post-pandemic world, that’s no longer the case. We’ve realised over the past few years just how impossible and unreasonable it is to expect workers to do this while on the clock, particularly when many of their concerns touch every aspect of their lives (including their jobs). Today, frontline workers’ concerns are more present than ever — and it’s up to frontline leaders to determine how to positively address those fears, rather than avoid them.
What are frontline workers most worried about? According to SafetyCulture’s recent report, ‘Feedback from the Field: Room for Improvement’, conducted in partnership with YouGov, cost-of-living reigns supreme among frontline workers - including those in manufacturing - across all three surveyed countries (Australia, the UK, and the US). While cost-of-living tops the list in all three countries (Aus: 79%, UK: 88% and US: 77%), other concerns vary depending on location. ‘Climate change and natural disasters’ is a top-three concern in all countries, as is political instability. Future job security was another commonly-cited concern in all three countries (Aus: 51%, UK: 44% and US: 42%), with the impact of AI also being high on the list. In short, today’s frontline workers have a lot on their minds. And overlooking or discounting these very real and meaningful worries will only worsen the ongoing burnout epidemic among frontline employees.
How leaders can manage concerns and fuel confidence Despite their concerns, our research also shows that an impressive 65% of frontline workers feel optimistic about the future of the organisation they work for. Frontline leaders need to find ways to feed that sense of hope and enthusiasm, without diminishing the fears that are top of mind. With 18 years of experience managing frontline teams in manufacturing, as well as more recent experience in developing technology and products to make frontline work easier, I’ve learnt a number of key strategies to manage workers’ concerns and lean into optimism without seeming out of touch.
1. Provide space for concerns While staying positive is important, it’s also necessary to create an environment where workers can connect with each other and provide helpful social support and camaraderie as they navigate those challenges. Leaders can also model and encourage this behaviour by being vulnerable and candid about their own anxieties. And if you think you’re already doing this? You might not be doing it as effectively as you think. Research shows that employees don’t feel heard on important workplace topics. That’s even more true on the frontline, where one in four employees say they don’t feel heard at all in their workplace.
2. Offer meaningful benefits and opportunities Workers don’t just want their employers to listen — they also want them to take action. You can use your employees’ concerns as inspiration for new benefits, programs, or improvements to your: •
Compensation: Frontline workers point to pay as the second most important advancement need, ranking behind only job growth. That makes sense when 55% of workers say their pay hasn’t kept pace with inflation.
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Career development: Frontline employees value job growth and learning opportunities. Providing chances for them to hone their skills (or learn new ones) as well as detailed paths to advancement can keep employees motivated and boost feelings of security. • Mental health support: 71% of employers believe they provide good support for frontline workers’ mental health, but only 27% of frontline employees agree. From counselling services to mental health training, consider the ways your organisation supports your employees’ mental wellbeing. There are no easy fixes to global problems like political instability and inflation, but these small steps can go a long way in helping workers feel more secure and supported.
3. Communicate openly and transparently As humans, we’re hardwired to avoid uncertainty, but it’s been a relentless constant these past few years. When you don’t communicate openly and honestly, the ensuing guesswork from employees only adds to the uncertainty they’re already struggling with. So, aim to keep workers informed as much as you possibly can. Our survey reveals that poor communication is the top factor workers point to when they say their organisation isn’t operating at its full potential, so there’s really no such thing as over-communicating.
Eye to the future: More hope, less hesitation Today’s workers are grappling with a lot of fears and anxieties. But despite those unique pressures, there’s still a lot of ambition and optimism as frontline employees look to the future. It’s up to frontline leaders to lean into optimism without side-stepping employees’ valid concerns. By listening, learning, and improving, leaders can cultivate work environments where employees feel empowered to voice their hesitations and know that they’ll receive adequate support and validation. After all, that’s when they’re set up to do their best work — regardless of what else is happening in the world. Full report: safetyculture.com/ebooks/feedback-from-the-fieldroom-for-improvement/.
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Welcome to a New Year 2024 promises to be another big year for our organisation with Australian Manufacturing Week in Sydney in April, a continued commitment to news and industry content through our AMT Magazine and associated digital platforms and a couple of funding initiatives that could provide great opportunity for our members Australian Manufacturing Week is being held at the International Convention Centre in Darling Harbour from 17th - 19th April and promises to be another great exhibition with 260 exhibitors across seven product zones including machine tools, additive technologies, welding & air technology, manufacturing solutions, plastic technology, robotics & automation and a dedicated area for Australian manufacturers called the Manufacturers Pavilion. In addition to the exhibition, a Future Solutions speaker program will also be an integral part of a visit with many great topics and speakers lined up already. Registration to AMW and the Speaker Program is free to attend by visiting australianmanufacturingweek.com.au Our AMT Magazine continues to be one of the most highly regarded industry publications in the country and we take great pride in this. A national controlled circulation list, with a readership in excess of 20,000 per issue, combined with quality content and well supported by the industry through advertising and editorial have given us the luxury of building this brand over 22 years into what it is today. We will continue to work hard on maintaining the credibility and integrity of our publication well into the future. The hard copy is complemented by our e-magazine, digital newsfeeds, electronic direct mail and other email marketing opportunities. The first of our proposed Government funded initiatives is what we are calling the ‘Skill Up and Placement Program’ or SUPP for short. This project involves us working with the Commonwealth, in conjunction with Albury/Wodonga TAFE, to deliver a 3-4 week CNC Operator course at a number of TAFE’s around the country. The training will be focused on taking people off unemployment benefits, qualifying them through a pre-training assessment process, putting them through training, mentoring them in confidence and
life changing skills, matching them to prospective employers and gaining full time employment outcomes as a result. Having piloted this program over the past two years, we are confident we have a model that is manageable and will achieve the results we are looking for, which is employment outcomes for around 250 people over the next three years. Please stay tuned for more information on this initiative or contact Greg Chalker at gchalker@amtil.com.au if the interest is there. Our second opportunity for Government funding is through a potential Cooperative Research Centre for Additive Manufacturing. A bid for the AMCRC has been put forward in Round 25 of the Australian Government CRC Grant Program, with AMTIL a major partner in the initiative. Through collaborative investment and research in AM applications, technologies, and innovation, the AMCRC aims to drive productivity, improve sustainability and create transformative change within Australia's manufacturing sector, which is crucial for the country's economic strength, resilience, and future viability. Funding for development of new AM technologies, disruptive business models, materials development, surface technologies and process development will enable companies to future proof their businesses and create pathways to excel on a global stage. In addition, our Events team is putting together a great calendar of activity for industry to get involved with during the course of the year. So you can see we have plenty going on and look forward to engaging with our members, readers and the industry in general through 2024. Wishing you all a successful twelve months ahead. Regards
Shane Infanti, CEO AMTIL
AMT FEB/MAR 2024
AMTIL HEADING INSIDE
AMTIL SUPP AMTIL has once again proven the power of practical training in skills our industry needs, brings people a new lease on life, purpose and a brighter future. Back in 2022, AMTIL approached the Federal Government in Canberra about supporting a small pilot program in Victoria which would provide some basic CNC machine training to a small cohort of people who’d been unemployed for a long period of time. This was to give them a new link to a future where they could attain valuable skills they could use as new employees in the manufacturing industry. “What we weren’t able to do for a long time, was attract young people into apprenticeships,” said Greg Chalker, AMTIL Corporate Services Manager. “But this was a new and different way of getting to that end goal. The Victorian pilot program was quite successful and so we wanted to expand the model into New South Wales. In this model, the NSW employers would sponsor the workers they have selected to go through the training, and they would be employed at the other end. While different to the Victorian model, the end result was just as successful. AMTIL turned to what was known as Job Active providers, now known as Workforce Australia employment services providers, for access to a known cohort of un-employed people. These people were from all ethnicities, social and age backgrounds. Consep Engineering employed and trained two people, as did CASF. Sevaan Group, Boval Engineering, Associated Gaskets, Mac Surgical and Sharp Tooling also took one person each, and set about training them before their employment.
Eleven people were selected to go through into training, nine completed training, and nine gained employment. “That is quite a successful set of numbers,” added Chalker. “The pilot in New South Wales has given us confidence in the program to submit a formal proposal through the Workforce Specialist program to begin a National Project in 2024.” “If AMTIL’s proposal is successfully funded it will work very closely with Wodonga TAFE and take the SUPP nationwide, delivering results across all States, in both mertropolitan and regional areas over the next three years,” said Chalker. (Read the story about Sevaan Group’s part in the SkillUp and Placement Program, on page 101) amtil.com.au 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.
amtil.com.au
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New Members AMTIL would like to welcome the following companies who have signed up as new members of our association.
3M AUSTRALIA
BOTTCHER AUSTRALIA PTY LTD
ENGINEERING TOOLING SUPPLIES
1 Rivett Road NORTH RYDE, NSW 2133
Unit 1, 364-384 Woodpark Road SMITHFIELD, NSW 2164
Unit 2, 1-5 Allan Street LOGANHOLME, QLD 4129
3m.com.au
bottchersystems.com.au
engtooling.com
ADVANCED BUSINESS MANAGER
CAD-IT AUSTRALIA PTY LTD
FIRE PROTECTION TECHNOLOGIES
13/1020 Doncaster Road DONCASTER EAST, VIC 3109
11, 53-57 Link Drive YATALA, QLD 4207
1/251 Ferntree Gully Road MOUNT WAVERLEY, VIC 3149
advancedbusinessmanager.com.au
caditaus.com.au
fire-protection.com.au
AMAZON WEB SERVICES (AWS)
COLBOTIC AUTOMATION
FISHBOWL INVENTORY
18/8 Exhibition Street MELBOURNE, VIC 3000
6 Adelaide Terrace ST MARYS, SA 5042
Office 503, Level 5, 45 Brisbane Road MOOLOOABA, QLD 4557
amazon.com
colboticautomation.com.au
fbinv.com
APPLE AIR
LASERLIFE TECHNOLOGY
HARRISON MANUFACTURING
Unit 3, 9-11 Redcliffe Gardens Drive CLONTARF, QLD 4019
1 Summit Road NOBLE PARK NORTH, VIC 3174
75 Old Pittwater Road BROOKVALE, NSW 2100
appleair.com.au
laserlife.com.au
harrisonmanufacturing.com.au
AWESOME SUPPLY
KOMATSU
INNOVYNC PTY LTD
711 Clayton Road CLARINDA, VIC 3169
15-17 McCourt Road MOSS VALE, NSW 2577
16/13 Holbeche Road ARNDELL PARK, NSW 2148
awesomesupply.com.au
komatsu.com.au
innovync.com.au
REAP THE BENEFITS OF AMTIL MEMBERSHIP Contact us to learn more www.amtil.com.au AMT FEB/MAR 2024
AMTIL INSIDE
AMTIL Christmas AMTIL lights up around the country for a celebration of 2023. A nice lunch at the Boatshed Restaurant in Brisbane and dinner at Electra House in Adelaide was a good start to our Christmas celebrations with members. More than 220 people turned out for the selection of events planned around the country for the end of a very busy 2023. Dinner at Adria Bar & Restaurant in Sydney was followed up by a fantastic evening at the MCG Olympic Room in Melbourne, finishing off our events for the year. Each of the events drew enthusiastic turnouts, and the AMTIL members who attended were very vocal with appreciation for the chance to finally relax and celebrate the busy year. Everyone looked great. Georga and the DJ Band once again hosted the Melbourne crowd with the best live music and a chance to let our hair
AMTIL Adelaide
down. There were also plenty of places to catch up with the view of the MCG
‘hallowed ground’ out before us. It was a great evening. amtil.com.au
AMTIL Melbourne
AMTIL Melbourne
AMTIL Sydney
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INDUSTRY CALENDAR During the COVID-19 pandemic, many industry events world-wide were postponed, rescheduled or cancelled. Readers are advised to check with all event organisers for the latest information. For the latest international travel advice, please visit smartraveller.gov.au For more events, please visit amtil.com.au/events INTERNATIONAL ATX WEST USA, Anaheim 6-8 February 2024
FABTECH MEXICO, Nuevo Leon 7-9 May 2024
AMB GERMANY, Stuttgart 10-14 September 2024
imengineeringwest.com
mexico.fabtechexpo.com
messe-stuttgart.de
SIMODEC FRANCE, La Roche-Sur-Foron 4-8 March 2024
NPE USA, Florida 6-10 May 2024 npe.org 3D PRINT CONGRESS & EXHIBITION FRANCE, Chassieu 4-6 June 2024
M-TECH OSAKA JAPAN, Tokyo 2-4 October 2024
salon-simodec.com
ASIAMOLD CHINA, Guangzhou 4-6 March 2024 asiamold-china.cn.messefrankfurt.com
ALL ABOUT AUTOMATION GERMANY, Friedrichshafen 5-6 March 2024 allaboutautomation.de
SITL FRANCE, Paris 19-21 March 2024 sitl.eu
KONEPAJA FINLAND, Tampere 19-21 March 2024 konepajamessut.fi
CCMT MACHINE TOOL FAIR CHINA, Pudong 8-12 April 2024 ccmtshow.com
MACH UK, Birmingham 15-19 April 2024 machexhibition.com
SIMTOS KOREA, Goyang 22-26 April 2024 simtos.org
HANNOVER MESSE GERMANY, Hannover 22-26 April 2024 hannovermesse.de
INTERTOOL AUSTRIA, Messeplatz 23-26 April 2024 intertool.at
MACHTECH SAUDI ARABIA SAUDI ARABIA, Riyadh 30 April – 2 May 2024 mactech-ksa.com
AISTECH USA, Ohio 6-9 May 2024 aist.org/conference-expositions/aistech
3dprint-exhibition-lyon.com
INTERTOOL AUSTRIA, Vienna 4-7 June 2024 intertool.at
ITM METALFORUM POZNAN POLAND, Poznan 4-7 June 2024
MOTEK GERMANY, Stuttgart 8-11 October 2024 motek-messe.de
BI-MU ITALY, Milan 9-12 October 2024 bimu.it
itm-europe.pl
EUROBLECH 2024 GERMANY, Hanover 22-25 October 2024
TAIWAN INTERNATIONAL FASTENER SHOW TAIWAN, Kaohsiung City 5-7 June 2024
JIMTOF 2024 JAPAN, Tokyo 5-10 November 2024
euroblech.com
fastenertaiwan.com.tw
jimtof.org
ASSEMBLY & AUTOMATION TECHNOLOGY THAILAND, Bangkok 19-22 June 2024
ADVANCED DESIGN & MANUFACTURING EXPO CANADA, Montreal 13-14 November 2024
assemblytechexpo.com
admmontreal.com
M-TECH JAPAN, Tokyo 19-21 June 2024
METEC INDIA INDIA, Maharashtra 27-29 November 2024
manufacturing-world.jp
ALUMINIUM CHINA China, Shanghai 3-5 July 2024 aluminiumchina.com
VME VIETNAM, Hanoi 7-9 August 2024 vme-expo.com
CIMIF MACHINERY INDUSTRY FAIR CAMBODIA, Phnom Penh 14-17 Aug 2024 chanchao.com.tw/cimif/
MMMM INDIA, New Delhi 29-31 August 2024 mmmm-expo.com
CAMX USA, San Diego 9-12 Sept 2024 thecamx.org
AMT FEB/MAR 2024
manufacturing-world.jp
metec-india.com
2025 METEF ITALY, Bolgna 5-7 March 2025 metef.com
MACHINEERING BELGIUM, Brussels 26-28 March 2025 machineering.eu
ADVANCED ENGINEERING SWEDEN, Goteborg 2-3 April 2025 advancedengineeringgbg.se
CMTS CA CANADA, Toronto 29 Sept – 2 Oct 2025 cmts.ca
INDUSTRY CALENDAR HEADING LOCAL SYDNEY BUILD EXPO ICC SYDNEY 1-2 MAY 2024 Connects all key players in the industry and attracts attendees from: contractors, architects, engineers, housebuilders, developers, government and construction professionals.
AUSTRALIAN MANUFACTURING WEEK ICC SYDNEY, DARLING HARBOUR 17-19 APRIL 2024 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.
sydneybuildexpo.com
WORKPLACE HEALTH & SAFETY SHOW MELBOURNE CONVENTION & EXHIBITION CENTRE 22–23 MAY 2024 Aiming to empower professionals with the knowledge, tools, and resources needed to enhance workplace health and safety practices. Discover interactive, innovative and collaborative solutions, hear from experts and meet key organisations. Explore the exhibition showcasing hundreds of health and safety products and resources or attend sessions featured in the Knowledge Centre or dedicated Spotlight Sessions.
australianmanufacturingweek.com.au
APPEX MELBOURNE CONVENTION & EXHIBITION CENTRE 12-15 MARCH 2024 Australasia’s Processing and Packaging Expo including machinery, ancillary equipment, materials and packaging, food processing and industry services. appex.com.au
AOG ENERGY PERTH CONVENTION & EXHIBITION CENTRE 13-15 MARCH 2024 AOG Energy drives opportunity, discussion and leadership in Australia’s oil, gas and clean energy sector. 2024 will strengthen our renewed focus on the energy transition.
whsshow.com.au
AUS SPACE 24 ICC, SYDNEY 28-29 MAY 2024 Two main stages, hosting over 70 speakers engaging with 1,000 passionate space enthusiasts. They’ll shed light on critical funding issues and unveil fresh opportunities for international collaboration that will fuel the growth of Australia’s space sector.
aogexpo.com.au/exhibit/
AUSTRALIAN AUTO AFTERMARKET EXPO MELBOURNE CONVENTION & EXHIBITION CENTRE 11-13 APRIL 2024 ’The Workshop of the Future is Here’, and debuting a range of fantastic new initiatives and features, the Expo is an unmissable event. The Expo showcases the latest vehicle repair and servicing equipment, parts, tools and accessories, new technology and trends, an Awards evening plus a comprehensive training and education program.
spaceconnectonline.com.au/events
CEMAT AUSTRALIA MELBOURNE CONVENTION & EXHIBITION CENTRE 23-25 JULY 2024 Leading technology and service providers in intralogistics, robotics and automation, warehousing, supply chain management and materials handling. Innovation and best practices from e-commerce to manufacturing, from the food industry to
autoaftermarketexpo.com.au
resources. cemat.com.au
AUSTRALIAN WASTE & RECYCLING EXPO ICC SYDNEY 24-25 JULY 2024 A full circle innovative products and sustainable solutions to collect, process and recycle waste more smartly. Future critical areas include Machinery & Equipment, Software & Services, Bins, Vehicles, Food & Organics and more. awre.com.au Advertiser Index AMADA Applied Machinery
9
Apureda International
67
Hare & Forbes
2,3
HG Farley Laserlabs
11
HiTech Metrology
37
IMTS
17
Industrial Laser
41
Kaeser Compressors
105
Kemppi
FEB/M AR 2024
MTI Qualos
7
Prestige
114
Raymax
53
Rigby Cooke
103
Stamac Engineering
93
Surface Mount & Circuit Board
63
TCL Hofmann
119
William Buck
15
Air Liquide
insert
Aurarum
insert
Sheetmetal Machinery
insert
STATE SPOTLIGHT: TASMANIA
Brisbane Servic e Centre Stafford Heigh ts, QLD 4053
Auckland Office and Technical Centr e Unit 2/67 Busin ess Parade South , East Tamaki, Auckland 2013 ys, SA 5032
Cable-less Data Collecti on
AMW 2024 PREVIEW CONSTRUCTION & INFRASTRUCTURE STATE SPOTLIGHT: SOUTH AUSTRALIA
U-WAVE reso lves measur
ing process issues!
Adelaide Servic e Centr Lockle
Call me now for a no-obligation chat about how AMTIL can help.
APR/MAY 2024
FEB/MAR 2024
CLEAN TECH •
Melbourne Office and Technical Centr e Unit 1/3-4 Anzed Ct, Mulgrave VIC 3170
OFC, 49, 79
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YOUR INDUSTRY. YOUR MAGAZINE.
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AUSTRALIA’S NO. 1 ADVANCED MANUFACTURING MAGAZINE
QUALITY & INSPECTION ROBOTICS & AUTOMATION SOFTWARE WORKHOLDING CUTTING TOOLS FORMING & FABRICATION ENERGY & SUSTAINABILITY
AMT FEB/MAR 2024
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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 58
THE CRUX OF THE MATTER There’s always some disappointment to every argument you win.
T
he Post-War Planning Committee mulled over my case and– to the surprise of most people–approved the plan in principle. Then it had to go on to the next stage: as a submission to the Executive Committee of the General Motors Corporation, to all the vice-presidents and the directors. I and our staff in New York worked solidly for weeks preparing for Stage Two. Typing, drafting, re-typing. Specifications of time, money, manufacture, employment. Detail, detail, detail. One might expect that the final conference of General Motors’ top executives which would give official approval to a project of this magnitude would have been a solemn meeting of cautious tycoons who’d debate the subject for hours. On the contrary, it was brief, informal, almost light-hearted: a most unlikely gathering for a decision of such historic importance to Australia. The meeting was held in the board room of the General Motors office in Detroit on a morning in November 1944. I was called to the meeting at room 45, introduced to a group of friendly faces, most of whom I knew, by the chairman, Alfred P. Sloan. Charles E. Wilson, the president, gave a cheery wave as I came in. The others grinned a welcome. I could sense from the way they sat easily in their chairs that no one stood on ceremony on this committee. They called each other by first names, and there was a general atmosphere of relaxation. Alfred Sloan said, “The Post-War Planning Committee has previously reviewed the Australia-car submission, and has agreed to the project in principle. Now it comes to us for formal approval.” He turned to Bob Evans, president of GM Diesel, remarking, “Bob, you know something about Australia. Have you any points to raise?” Evans asked me about the landed price of a Chevrolet chassis in Australia with duty paid. I said I was not sure of the exact figure, but it was about £60. Mr. Coyle, president of Chevrolet, asked if General Motors had made any money on their Australian investment. I replied, “About nineteen million dollars, after taxes.”
A hand-made Australian prototype Holden appeared in later months.
And that was all there was to it. The meeting formally approved the project, and I left, after thanking them personally, and on behalf of the 10,000 Australian employees in the various production plants. I had to resist the temptation to do an Irish jig for joy as I got out of the room. In a few minutes I had received their approval for a project I’d dreamed about for eight years. All that remained now was for the Finance Committee to give its formal approval for the expenditure of funds to get the project started. I hadn’t given much attention to this, because normally the Finance Committee moves in accord with the decisions of the Executive Committee. Three weeks later I heard the results of the Finance Committee meeting and I wasn’t prepared for the blow this news brought. The committee would not approve a large dollar investment in Australia. In effect, the Finance Committee had said, “We’re not going to spend one cent of U.S. money on this. If GM-H wants a car, it will have to find all the cash for it in Australia!” My first reaction was angry disappointment. How could they expect me to produce a car without the cash for tooling up? Without a cash allocation, the project was as far off as ever.
“Well, that sounds like a very satisfactory performance, doesn’t it? Some good earnings have been taken from the business. It’s about time we gave the people something back. I can assure Larry Hartnett of all the help and support from the Chevrolet Division.” Sloan then asked me for a brief resume of why we should make the car. But just as I got going, he interrupted, saying, “Has anyone else any points to raise?”
Next morning, in my office in the General Motors Building in Detroit, I had an unexpected visit from Walter Appell, a top GM engineer whom I’d known in England when he was chief engineer of Vauxhall Motors. He breezed in with a “Hah, Larry! My, you’ve got yourself a kettle of fish! How long do you think it’ll take to design your car, from the drawing board up? How long, eh?”
Al Bradley, the GM vice-president in charge of finance, asked me in jocular tones for another very good reason, apart from those I had given: good investment, economic good sense, and the fact that the Government of Australia would probably take on the job itself if it couldn’t find another manufacturer equipped and ready to tackle the project. “And another reason, Larry?” I couldn't think of another reason to tell Bradley. I didn’t know what he was driving at. But when he saw me trying to think, he laughed and said, “The other good reason is that Larry Hartnett wants to make a car!” Sloan commented, “And that’s a very good reason, too.”
“Not on your life, my boy. Five years. Five years of really hard flogging too,” he said.
The others laughed at that too, and then O. E. Hunt, the GM vicepresident in charge of engineering, said, “With this project virtually approved, there is a big job ahead of Larry in Australia, and we wish him luck. We will give all the help we can, because he will need it.” C.E. Wilson added to this by saying he felt sure all divisions of the corporation would give all possible help. He wished me and the Australian operation·success in “this big new undertaking.”
I grinned at him. “Three years, or two and a half if all goes well.”
Well, I respected Walter’s view, but I told him that we’d learned a lot in Australia during the war. I thought we’d do it in three years. He leaned in over my desk, assuming the air of a conspirator. “Larry,” said, “I’ve got a clue that will interest you. I can help you cut down your five years. Out at the proving grounds we’ve got a couple of jobs that are very interesting. Prototypes. “I’ll tell you about them. Bill Knudsen, president of Chevrolet, used to have a hell of a row in his committees. He reckoned a six-cylinder automobile could be made as cheaply as a four-cylinder job. This became literally a million-dollar argument. “So they drew up a specification of a car for the lower price-bracket and made one with four-cylinders and one with six. Identical basic performance to give the same torque and horse-power. I think the six won the argument, because with the four you’ve got to put more ‘beef’ in the gearbox and back axle and clutch. But both cars are out there now, gathering cobwebs.”
To be continued…
This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.
AMT FEB/MAR 2024
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