Inside the new vaccine facility pushing boundaries with digital integration p.10
The latest advancements helping manufacturers make faster decisions p.14
Shaping the future of autonomous flight through industry-wide collaboration p.18
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Being new to Design Engineering, understanding our audience has been my top priority.
As a result, we conducted a comprehensive readership survey over the past few months, and the results underscored some clear priorities from our audience. Our readers are eager for more insights into emerging research, advanced materials, simulation software and AI breakthroughs. These areas represent the future for Canadian designers and manufacturers, and it’s clear that the hunger for this type of content is stronger than ever—and in forms beyond our print and online magazines.
This was reinforced by the overwhelming response to our fall AI for Engineers webinar, which saw significant sign-ups and engagement. (Watch the full recording at design-engineering.com/webinars.) The main driving force behind this session was to help attendees understand how the role of the engineer is evolving. What’s more, the enthusiasm from that event told us exactly what we needed to know: there is a growing appetite for virtual events and content that digs into these advanced topics. We’re not only listening but actively building on this momentum to deliver more of what you want.
Following the success of AI for Engineers, we’re excited to announce the upcoming Future of Design Engineering online event this spring. This event will be essential for anyone who wants to stay ahead of the curve. We’ll explore cutting-edge advancements in AI, simulation technology, advanced materials and smart system integration, all with a focus on real-world applications and emerging research. Industry experts will share critical insights into the trends reshaping design innovation, providing the practical knowledge you need to remain competitive in the fast-evolving landscape of Canadian manufacturing. So save the date—March 26, 2025—and stay tuned for the official registration announcement.
Whether you’re an engineer, a plant operator or a machine builder, Future of Design Engineering will be a key opportunity to dive deep into the technologies that will define tomorrow’s manufacturing. It’s designed to equip you with the knowledge and tools to excel.
Do you have a topic you’d like to see covered? Or do you yourself want to present? Reach out to me, and keep an eye out for more information about this and other online events the coming months.
Let’s continue shaping the future of design engineering, together.
ANDRÉ VOSHART
Editor avoshart@annexbusinessmedia.com
Editorial Board
DR. ALAIN AUBERTIN
Special Advisor, Canada Consortium for Aerospace Research and Innovation in Canada (CARIC)
DR. MARY WELLS, P.ENG
Dean, Faculty of Engineering / Professor, Mechanical and Mechatronics Engineering; University of Waterloo
AJAY BAJAJ, P.ENG
President and CEO, Rotator Products Limited; Past President and Board Member, Power Transmission Distributors Association (PTDA)
DR. ISHWAR PURI, P.ENG
Vice President of Research; Engineering Professor, University of Southern California
NOVEMBER/DECEMBER 2024
Volume 69, No.5
design-engineering.com
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The Province of British Columbia is contributing $2 million to establish a Battery Innovation Centre at the University of British Columbia’s Okanagan campus (UBCO). This facility will be the first of its kind in Western Canada and will focus on research and development of new battery technologies, advancing British Columbia’s battery supply-chain sector.
“This investment will elevate that work even further by providing the necessary space to create and test battery prototypes on a larger scale,” UBCO principal and deputy vice-chancellor Lesley Cormack says.
In addition, the centre will support regional economic development through the battery sector’s circular supply chain, incorporating battery recycling and metal processing in the Kootenay region, battery manufacturing in the Lower Mainland and critical mineral mining throughout British Columbia.
Festo Canada has launched its Certified System Integrator Program, which will match end users with validated system integrators. The program ensures that participating system integrators are equipped with comprehensive technical knowledge and commercial benefits.
Festo’s direct role is limited to matching end users with a certified system integrator. The program is launching with an initial roster of certified system integrators and is welcoming applications from others wishing to join it.
The antimicrobial materials industry is experiencing unprecedented growth, fuelled by a heightened focus on hygiene and cleanliness post-pandemic. Manufacturers and other consumers in the plastics, coatings, textiles, fabrics and ceramics sectors are now prioritizing sustainability, hygiene and health impacts over aesthetics and utility.
This shift has spurred materials manufacturers to innovate, resulting in the development of new antimicrobial materials.
Frost & Sullivan forecasts a robust compound annual growth rate of 14.7 per cent for the antimicrobial materials industry from 2023 to 2030, projecting the global total addressable market to approach US$61 billion by the end of the period.
Antimicrobial materials have the ability to bind to the proteins in the cell walls and membranes of microorganisms and block the transport of essential nutrients needed for survival. Technological advancements are making these materials more effective, accessible and affordable, facilitating their application across various industries:
• Food packaging: Antimicrobial materials are gaining traction in regions with high consumption of meats, poultry and fresh-cut produce.
• Textiles and fabrics: Antimicrobial textiles are in demand for medical textiles, clothing and fabrics for curtains, coverings and mattresses.
• Health care: Alternative materials are revolutionizing packaging, medical devices, safe paints for health care environments and hospital utilities.
• Films and coatings: Antimicrobial films and coatings can be applied to various industries by coating existing materials, enhancing their properties without large manufacturing changes.
Frost & Sullivan anticipates close collaboration between end-user industries and additive companies to tackle challenges and deliver optimal solutions. “Collaborative efforts can streamline R&D, manufacturing and distribution processes, resulting in innovative antimicrobial solutions with broad applications,” says Brian Balmer, growth expert at Frost & Sullivan.
IDTechEx’s recent market research report, Antiviral and Antimicrobial Technology Market 2023-2033, looks at more than 100 companies that have developed their own antimicrobial technologies. It highlights silver as dominating the market, followed by silane quaternary ammonium compounds, copper, zinc and other alternatives, including titanium dioxide and calcium chloride. |DE
BY ANDRÉ VOSHART
MaRS Discovery District and the Toyota Mobility Foundation recently announced the first cohort of the Mobility Unlimited Hub, which represents ventures with a shared mission to address the unmet needs of millions of Canadians with disabilities.
According to a 2022 Canadian Survey on Disability, 27 per cent of Canadians aged 15 years and older—eight million people—had one or more disabilities that limited their daily activities. Additionally, 30 per cent of people with disabilities in Canada report unmet needs for assistive devices, highlighting the critical role of initiatives like the Mobility Unlimited Hub.
Design Engineering interviewed several members of the Mobility Unlimited Hub, and each company brings innovative solutions.
Montreal-based AWL-Electric’s Agile Station is a groundbreaking wireless charger for motorized wheelchairs, designed to enhance user autonomy and simplify the charging process.
The inspiration originated from co-founder Emmanuel Glen’s scientific
innovation in wireless power technology and his motivation to enhance people’s lives. Along with co-founder Francis Beauchamp-Verdon’s background and personal connection to rehabilitation, they developed the Agile Station to address the need for greater autonomy and ease of use in charging mobility devices.
Having a mother who was the president of a rehabilitation hospital and having suffered a spinal injury himself, Beauchamp-Verdon was deeply aware of the challenges faced by individuals with mobility impairments.
A standout part of the Agile Station is its ability to charge wheelchairs autonomously, simply by positioning them over the charging mat. “This feature is crucial as it eliminates the need for manual plugging, enhancing the autonomy of users and reducing the dependency on caregivers,” Beauchamp-Verdon says. “This design aspect is significant because it directly responds to the needs for increased independence among wheelchair users.”
The design challenge of creating a product that functions reliably in all environments, including outdoor conditions, was solved through advanced engineering and durable materials that ensure performance in various
climates. They incorporated high-end, cutting-edge technology into a robust mechanical design that was waterproof, functioned in all environments and could withstand outdoor conditions.
“This approach ensured that the charger not only met these rigorous standards but also maintained its performance integrity in diverse settings, from humid conditions to temperature extremes, thus broadening its applicability across different geographical location,” Beauchamp-Verdon says.
User feedback played a central role in shaping the design, ensuring the product was both practical and intuitive. Early iterations involved more complex indicators for proper parking on the charging mat, but user input led to a simplified design—a single green light indicator to signal correct placement. This process of listening to real-world users helps make the Agile Station more accessible and functional.
To ensure scalability and affordability,
Amélie Tétreault and Stefano Eugeni helped to streamline the production processes. “This dynamic duo plays a crucial role in supporting the engineering team to ensure that the Agile Station remains at a reasonable price and is manufacturable,” Beauchamp-Verdon says. “Their combined expertise has been instrumental in streamlining the production process, focusing on creating a scalable design from the prototype phase to mass production.”
Richmond Hill, Ont.-based Cheelcare’s innovative mobility solutions, Curio and Companion, were born from a personal connection to the challenges faced by individuals with limited mobility.
“Most devices on the market lacked features that support user dignity, independence, and personal expression,” says Allex Laurin, Cheelcare’s director of marketing. “We identified a significant gap in assistive technology that could integrate advanced robotics and intuitive design to meet modern mobility needs.” This led to the development of Curio, a mobility system with independently adjustable legs and self-levelling capabilities, and Companion, with its quick-connect mechanism and portable design.
One of the standout features of Curio is its self-levelling technology, which ensures that users with custom seating and posture supports maintain stability and comfort, even on uneven terrain.
“This feature is particularly beneficial for users who rely on custom seating and positioning systems, such as cushions and backrests, to support their posture,” Laurin says, as the system automatically adjusts to keep the user level. This ensures that the user’s posture always remains stable and comfortable, enhancing both safety and comfort—and setting a new standard in the industry.
User feedback played a key role in shaping both products. For example, Companion’s quick-connect mechanism, which allows users to easily attach and detach it in under 10 seconds, was directly influenced by customers’ need for convenience and ease of use.
Cheelcare’s collaboration with clinicians, therapists and users ensured their innovations were practical and impactful.
A key challenge Cheelcare
faced was aligning its advanced designs with existing funding frameworks.
“To address this, we worked closely with clinicians and funding specialists to ensure that our products meet necessary requirements and developed comprehensive clinical justifications to support funding applications,” Laurin says. “This collaborative approach has helped us make our cutting-edge mobility solutions accessible to more users.”
To ensure scalability, Cheelcare focused on modular design and prototyping, allowing them to efficiently transition their products from prototype to mass production while meeting growing demand.
“We also focus on modular design principles to streamline manufacturing and assembly with a focus on scalability in both self-manufactured and contract-manufactured scenarios,” Laurin adds.
Seleste CEO Shubh Mittal was inspired to create smart glasses after witnessing the everyday challenges faced by his blind friend in university. Realizing that existing technologies could be adapted to improve the lives of the visually impaired, he began volunteering with the Goalball Paralympic team, whose members became some of his first customers. He saw the potential to enhance independence by giving users a better understanding of their surroundings, rather than replacing tools like a cane.
A standout feature of Seleste’s glasses is the focus on natural language processing. “Previous products just have cookie-cutter buttons like ‘read text’ or ‘describe the environment,’ but users almost never want everything described to them,” Mittal says. Instead of overwhelming users with a full description, the glasses respond to specific questions. For
instance, a user can ask, “What are the vegetarian options on this menu?” which provides a more intuitive and personalized experience.
Feedback plays a key role in its development. Early on, Mittal and his team communicated with every user, gaining insight through direct interaction. Now, with 170 customers, they maintain an active feedback loop via a group chat, allowing customers to help each other while keeping open communication with the company.
A major challenge was ensuring that the glasses complement, rather than replace, traditional mobility aids like canes. The glasses address real-world problems, such as identifying closed bus stops or finding elevators, providing users with more confidence to navigate independently.
Based in Western Canada, Seleste continues to scale. They’ve partnered with a manufacturer in China to efficiently transition from prototype to mass production, ensuring the product can reach more users globally.
Ontario-based Braze Mobility offers the world’s first blindspot sensors for wheelchairs. This innovation was born out of co-founder and CEO Pooja Viswanathan’s drive to address the lack of safe, independent mobility for wheelchair users. After observing residents in
long-term care facilities unable to propel themselves in manual wheelchairs, she recognized that motorized wheelchairs, though beneficial, were often restricted due to safety concerns.
A standout feature is the multi-modal feedback system, offering visual, auditory and vibratory cues to suit various user needs, ensuring accessibility for those with different diagnoses. “This multi-modal method provides more options to our clients so that they are able to use our product regardless of their diagnosis and the associated challenges they may face,” Viswanathan says.
User feedback plays a significant role in Braze’s design evolution. “Our initial offering was based on and inspired by doctoral and post-doctoral research that consisted of in-depth user studies, as well as a beta client program that informed our minimal viable product,” she says. “We strongly
A standout feature of Braze Mobility’s blind-spot sensors is the multi-modal feedback system, offering visual, auditory and vibratory cues to suit various user needs.
encourage and actively elicit user feedback to continually develop and improve our offering.” As a result, many of Braze’s optional customizations and new offerings have stemmed from user feedback and feature requests.
A key design challenge was finding robust and consistent mounting solutions. Braze started with versatile GoPro-compatible mounts and now offers custom mounts that can be used for multiple configurations of the most popular chairs in North America.
To ensure scalability, Braze focuses on ease of manufacturability and assembly, selecting partners that can support low production volumes but scale as demand increases.
Seleste’s smart glasses focus on natural language processing, responding to specific user questions.
Manmeet Maggu co-founded Mississauga, Ont.-based Trexo Robotics with a personal mission to help his nephew, Praneit, diagnosed with cerebral palsy, defy the odds and walk. This pursuit revealed a gap in the market: there were no solutions allowing
children to walk consistently at home, which is crucial for neuroplasticity. Together with friend Rahul Udasi—from the University of Waterloo, where they studied mechatronics engineering— they designed Trexo, a robotic device that empowers children to walk in their own environments.
A standout feature of the Trexo is the initiation engine, which uses torque sensors to detect a child’s participation in walking, providing real-time feedback through visual cues.
In addition, the lights on the sides of the joints change colours depending on initiation or resistance.
“So a caregiver can see how much initiation a child is doing, and also on what parts of the gait cycle,” Maggu says. “This is a key aspect
of providing feedback to the users.”
The design of Trexo has evolved with the input of children, parents and healthcare professionals. This iterative process has shaped key features and hardware changes, as user feedback remains central to the ongoing development.
“We listen to the users and clinicians that work with the device,” Maggu adds. “They act as our boots on the ground and report back to us on the realities of Trexo usage in day-to-day life. We have identified various features and hardware changes as a result of this feedback.” After numerous iterations
and tests, they succeeded in creating a safe and effective product that children would enjoy using.
As Trexo moved from prototype to production, scalability became a key challenge. The team needed to balance functionality with manufacturing efficiency. By simplifying problems and following strict engineering principles, Maggu and his team ensured that Trexo could be scaled reliably for homes worldwide.
Today, Trexo Robotics continues to help children globally, expanding the possibilities of movement and mobility for young users.
“The journey was not without challenges,” he says, “but the Trexo was created and has evolved into the device it is today, helping children around the world.” |DE
Sanofi’s new Toronto vaccine manufacturing facility pushes design boundaries with digital integration and advanced modelling.
BY ANDRÉ VOSHART
Global healthcare company Sanofi opened a new state-ofthe-art vaccine manufacturing facility at its Toronto campus this past spring. As the largest biomanufacturing facility in Canadian history, this facility will significantly increase Sanofi’s capacity to produce pediatric and adult vaccines for diseases like pertussis, diphtheria and tetanus. These vaccines will be exported to more than 60 global markets, enhancing health protection both in Canada and internationally.
This new facility is part of Sanofi’s ongoing investment in Canada’s biomanufacturing sector, representing a total investment of more than $800 million, supported by federal, provincial and municipal governments. François-Philippe Champagne, the federal minister of innovation, science and industry, called this “a significant milestone in our vision to rebuild our domestic biomanufacturing sector,” emphasizing that it will help Canada be better prepared for a range of health threats—including future pandemics.
What type of design considerations went into the development of this cutting-edge facility? Design Engineering spoke with Jan Lutzen, head of engineering and technical services at Sanofi, to learn more about the innovative features and strategies behind the new facility.
Lutzen emphasizes that, when starting to design a facility like this, “you have to think of the future” to ensure long-term success.
As Canada’s largest biomanufacturing facility, it will significantly increase Sanofi’s capacity to produce pediatric and adult vaccines for diseases like pertussis, diphtheria and tetanus
One of the primary considerations during the design phase was to understand and optimize the entire production process. With manufacturing entering the era of Industry 4.0—where digital integration is transforming manufacturing at an unprecedented level—Lutzen highlights the need to prepare for this shift by building a smart facility designed for the future.
The design of the facility’s equipment and digital components were developed in parallel. “Understanding and defining your equipment, and integrating that with automation, allows you to design specifications around what your digital infrastructure needs to look like,” Lutzen says. In this facility, even the digital aspects were designed from the ground up, ensuring that every element was aligned with the overall vision of a smart factory.
With a life-cycle expectation of
40 years, he underscores the forward-thinking approach: “Smart factories are the future.”
Once the digital layers of the facility were established, selecting the right partners became essential. This involved establishing clear protocols from an IT perspective to guarantee all components could work seamlessly together.
During the design phase, Lutzen and his team made sure they had the right tools to optimize every aspect of the facility. “We have 22 meters of height to work with, where we need to fit pipes, equipment and information,” he explains. It was important to maximize density and optimize the ergonomic and process flows. The team achieved this through 3D modelling, which let them extract 2D renderings and optimize the space between skids.
He also emphasizes the importance of rightsizing each “unit operation” (i.e. the discrete step in a process where a specific function is performed) in relation to the next—a concept that is often underestimated by engineers. “It’s about creating scalability,” he says.
By focusing on these aspects up front, Lutzen and his team were able to achieve near-perfect alignment in the design, making sure each component of the process worked harmoniously with the others.
There are three 4,000-litre fermenters in the middle of
the facility, which are crucial to the manufacturing process. Without the use of 3D modelling, he says, fitting these huge structures into the layout would have been difficult. Advanced modelling made this possible and ensured that the integration was seamless, facilitating optimal flow.
Lutzen also highlights an aspect that often doesn’t receive much attention: serviceability. “Above our equipment, we have a walkable ceiling,” he reveals, which allows maintenance teams to access all necessary equipment and
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sensors without entering the clean space, thanks to an interstitial space. This design enables maintenance to be performed with minimal downtime and without compromising the cleanliness of the facility.
Reflecting on his extensive experience in the pharmaceutical industry, Lutzen notes, “I’ve been in the pharma industry for more than 20 years, and maintenance accessibility was often an afterthought.”
The Toronto facility also made a large investment in automation, incorporating a manufacturing execution system that monitors around 28,000 data points. This data infrastructure aligns with both the manufacturing and facility infrastructure, ensuring a truly smart factory. “Technology has advanced to the point where sensors now have chips in them,” Lutzen adds.
By having detailed data on hand, the facility is not only built for future needs but also ensures
It was critical to maximize density and optimize the ergonomic and process flows.
that every batch meets the required standards.
When issues arise, this data can pinpoint where things have gone wrong, which is particularly valuable during the development phases.
The Government of Canada’s Biomanufacturing and Life Sciences Strategy is a response to the country’s diminished biopharmaceutical capacity, which became evident during the COVID-19 pandemic, which exposed the need for a stronger domestic manufacturing base to produce vaccines and therapeutics.
Through this strategy, Canada aims to solidify its position in global biomanufacturing, enhance pandemic preparedness and create a robust ecosystem of innovation and production across the country. Since its launch in 2021, the federal government has committed more than $2.2 billion to develop cutting-edge biomanufacturing capabilities.
Investments include $250 million as part of the Canada Biomedical Research Fund to support applied research, training and talent development partnership projects; and $500 million as part of the Biosciences Research Infrastructure Fund to support the biosciences
infrastructure needs of postsecondary institutions and affiliated research hospitals.
Highlights of recent investments as part of this strategy include the following:
In July 2024, STEMCELL Technologies opened its new biomanufacturing facility, in Burnaby, B.C.—supported by a $22.5-million federal investment—where it can now manufacture products at the higher regulatory compliance standard required to support clinical trials for cell therapy, tissue engineering, immunotherapy, gene therapy and regenerative medicine.
• In August 2024, Mississauga, Ont.-based Eurofins CDMO Alphora Inc. received $22.4 million to support the construction of a new biologics facility, increasing domestic production capacity for antibodies and protein-based therapeutics that will help Canadians better respond to future pandemics.
“Data is a really powerful troubleshooting tool,” Lutzen says.
For example, during engineering batches, they encountered performance challenges and were unsure why a particular process step wasn’t working as intended. With the help of their data science team, they conducted a thorough analysis and identified a shift in data that correlated with changes in a few components.
“It removed the guesswork and experimentation,” Lutzen says. Within a few days, the data science group was able to pinpoint the cause of the issue, demonstrating the power of leveraging digital capabilities in a smart facility. “The smart factory is there to ensure issues are quickly resolved,” he adds.
Investments were made in monitoring and predictive equipment, utilizing the wide array of sensors to monitor the state of machinery. “We identified all those parts that make the process successful and monitored them,” he explains. This allows personnel to proactively address potential issues before they lead to failures. “We’re just beginning to experiment with what this means for a facility,” he adds.
Lutzen also emphasizes its closed-system approach, which provides enhanced protection for both equipment and operators. Although there are still protocols and requirements around personal safety, this design reduces risks and streamlines operations.
There are challenges in creating a fully closed manufacturing process. While it may sound simple, the reality is far more complex. “There are a lot of things humans do regularly, and transitioning those tasks to automation requires careful planning and supervision,” he says. To achieve this, it was necessary to build out the logical steps that automation will follow, ensuring that each action is carried out precisely as
intended. “The level of complexity in a fully closed system is very, very high,”
One advantage is the facility’s ability to automate transfers between each unit operation. “This means you don’t have employees doing these manual transfers,” he says, pointing out that automation takes on the grunt work, allowing the workforce to focus on higher-value tasks.
Lutzen and his team were also committed to not only meeting but exceeding regulatory requirements. “We’re global, so we take the most stringent of regulations across the world,” he says. By adopting this rigorous approach, the facility ensures it meets (or surpasses) safety and standards regulations, reinforcing its commitment to operational excellence and the well-being of its employees.
When starting to design a facility like this, “you have to think of the future.”
Lutzen also emphasizes the importance of sustainability in the design and operation of the facility, aligning with their global sustainability initiative—Planet Care—which aims for net-zero emissions by 2045.
A key part of this initiative is incorporating energy-efficient design elements to reduce the facility’s carbon footprint. “We have incorporated LED lighting and motion sensors, as well as heat recovery systems to minimize energy use and recapture heat,” he explains. This commitment to sustainability is also reflected in the facility’s certifications, as it meets ISO 14001 and 50001 standards, ensuring a continuous improvement loop in environmental and energy management.
Another sustainability feature is the facility’s wastewater treatment and reuse plant, which lets them capture and reduce water consumption by 20 per cent. Additionally, the facility has
invested in efficient boilers to service its needs, further contributing to the reduction of energy consumption and overall environmental impact.
To ensure everything functions as designed, the facility is currently undergoing a comprehensive commissioning and qualification process. This includes in-field verification, where each circuit
and loop undergo function testing. By conducting thorough testing, Lutzen and his team can confidently confirm that the system is operating correctly, maintaining the high standards required for a fully automated, closed manufacturing environment.
But he is excited about the process so far. “We’re so proud of this facility, that we as a team at Sanofi were able to do this.” |DE
intelligence is also making it easier to use machine vision in more applications.
The latest trends in machine vision are helping manufacturers make faster decisions and optimize their designs.
BY ANDRÉ VOSHART
Machine vision is vital in manufacturing to enhance precision, efficiency and quality control. By using cameras and sensors, these systems inspect products, detect defects and guide robots, reducing human error and ensuring consistent output.
Increasingly, smart cameras with built-in intelligence are helping manufacturers make faster decisions and allowing engineers to optimize their designs. Design Engineering spoke with several machine vision technology providers to explore current trends and innovations for machine builders and design engineers.
In the industrial sector, there is a notable trend toward high-speed interfaces to meet the demands of real-time data processing and high-resolution imaging.
“Interfaces such as Ethernet, CXP and CLHS have gained prominence for their ability to deliver robust connectivity and high bandwidth, essential for industrial automation and quality control applications,” says Riana Sartori, director of product management with Teledyne FLIR IIS. “Moreover, the standards are developing toward new Ethernet standards like RDMA over Converged Ethernet (RoCE), which
25 Gpbs, but increasing demand for higher bandwidths results in potentially latency and CPU usage concerns,” he says.
RoCE (originally developed for high-bandwidth transfer in data centres) enables direct memory access from a device to a computer without involving the operating system. “RoCEv2 ensures seamless integration and compatibility within Ethernet networks while enhancing overall functionality,” Goffin says. “For vision applications, RoCEv2 reduces CPU involvement in the data transfer process ensures that system resources are freed up, allowing them to be utilized for other tasks such as image processing while scaling up to 400 Gbps.” To enhance reliability, the networking technology delegates error detection and recovery tasks to dedicated hardware to ensures a smoother and more consistent data transfer while supporting low latency.
offer enhanced performance and reliability, particularly in mission-critical environments.”
Along these lines, Ed Goffin, Pleora’s vice-president of product marketing, says the next major release of the GigE Vision standard— version 3.0—integrates RoCEv2 for data streaming as additional functionality.
GigE Vision is a global camera interface standard that allows for fast image transfer using low-cost standard cables over very long lengths and helps hardware and software from different vendors to interoperate seamlessly.
“The GigE Vision standard has supported the evolution of machine vision from 1 to
“As the next version of the GigE Vision standard is released, designers can anticipate interface solutions that integrated higher bandwidth, lower CPU usage enabled by RoCEv2,” Goffin says.
Matt Moschner, senior vice-president of platform technology with Cognex, says artificial intelligence (AI) is making it easier to use machine vision in more applications. “Because AI simplifies the training and maintenance of machine vision systems, many applications can be set up by end customers without third-party help. That reduces costs and lets manufacturers apply vision solution to applications they hadn’t considered previously.”
He says designers should challenge their preconceived notions around what applications can see positive ROI from vision applications. “Try some proofsof-concept to evaluate what those costs really are,” he says, “and to evaluate the ease of use provided by modern AI tools.”
Instead of treating all input information equally, attention-based vision models prioritize certain areas based on their importance to the task—like how humans concentrate on important details—which enhances the accuracy and efficiency of tasks like object detection, segmentation and classification.
“These can potentially improve vision systems that use deep learning algorithms,” says Mathias Winther Madsen, senior machine learning research engineer at Micropsi Industries. “Given recent successes with attention-based vision models for text prediction, a lot of research efforts have gone into atten tion-based vision models.”
But he warns that these models can be inherently poor at expressing and estimating precise locations, which is important in manufacturing. “We are continuing to watch any indication that these models have matured beyond these limitations,” he says.
Tom Busher, Mouser Electronics’ se nior vice-president of global sales and service, says that while machine vision stands as a cornerstone of industrial automation the rapidly expanding role of data is driving the next phase of trans formation.
“Despite some inflated expecta tions around AI, industry adoption of machine vision is progressing steadily within the broader context of Industry 4.0,” he says. “This phase has primarily focused on data capture, but we’re still scratching the surface when it comes to deep data utilization. As industries adopt more advanced data storage and management solutions, we’re on the brink of leveraging this data more effectively, promising deeper insights and practical applications.”
(IT) closer together. “Historically, machine vision operated in real time, driving decisions at discrete points during the manufacturing process. That information was gone as soon as it was used. Now, there’s a growing recognition that machine vision systems can fuel higher-level decision making and operational improvements. At the same time, IT infrastructure is improving, with better bandwidth and storage capacities to
capture and store the images and data from machine vision operations.”
He says the opportunity here is for design engineers and machine builders to provide additional value beyond point-in-time decision making. The technology and protocols for data sharing are available out-of-the-box and can provide trend information about line speed, defect distribution, waste rates and more.
Cognex’s Moschner says machine vision systems are bringing operational technology and information technology
Cognex’s In-Sight 3800 system enables automated quality control in high-speed manufacturing environments.
“The continuing development of new interfaces standards, primarily for devices designed for consumer, smartphone and automotive types of applications, are now finding new uses in machine vision systems,” Pleora’s Goffin says.
Most commonly, MIPI and SLVS sensors are being designed into smallform-factor, lower-power embedded imaging and sensor devices in combination with edge processing for machine vision applications requiring local decision-making, such as robotics and IoT systems. Similarly, FPD-Link and GMSL provide an interface option for machine vision applications targeting the automotive market.
Another continuing trend is the integration of machine vision technologies into new markets. “A significant market for machine vision is security and defence where designers are now more actively embracing commercial off-the-shelf technologies in the design and retrofit of systems,” Goffin says.
In particular, he says machine vision technology is being designed into
retrofit projects to digitize legacy imaging systems.
“For example, closed hatch driving systems allow commanders and drivers to maneuver, locate and identify without having to exit the vehicle by networking cameras and sensors to provide a complete field of view that is presented on display screens inside the vehicle,” he says.
“Converting the video feed from a legacy analog interface to GigE Vision enables the use of extended reach, more flexible cabling to reduce complexity and weight in the vehicle while supporting multicasting to multiple displays in the vehicle.”
Teledyne FLIR IIS’s Sartori adds that technology trends in machine vision reflect the evolving needs and applications of both industrial and non-industrial markets.
“While industrial customers prioritize performance and reliability in high-speed interfaces, non-industrial customers seek flexibility and versatility in an optimized package with low size, weight and power for their specific use cases.”
There’s a growing recognition machine vision can fuel higher-level decision making and operational improvements.
Process monitoring is another emerging application area. “While current systems excel at guiding industrial processes, detecting flaws and measuring components, they still heavily rely on human oversight for comprehensive process monitoring,” Mouser Electronics’ Busher says.
He adds that the future will see AI tools and devices capable of autonomously analyzing process data, identifying anomalies and providing actionable insights—much like how humans currently monitor plant floors.
A neural radiation field is a technique in computer graphics and machine learning that uses neural networks to represent and render 3D scenes with realistic lighting and detail. It works by learning a continuous volumetric scene function from 2D images, which allows the generation of new views of the scene from arbitrary camera angles.
“There has been a lot of progress in the reconstruction of 3D scenes from photographs thanks to neural radiance fields,” Micropsi’s Madsen says. “These neural networks originally took hours to fit to a particular scene, but a lot of research has gone into optimizing them faster. We may see this technology becoming less expensive, leaner and more easily available. Current methods for
Light is focused through a microlens array onto the micro-ring in the optical parallel computational array chip test system.
industrial 3D representations are hindered by high implementation expenses and a dependency on manual input for precise 3D modelling.
“To address these issues, neural radiation fields have emerged as a promising solution for learning 3D scene representations from given 2D training images.”
Mouser Electronics’ Busher says the evolution of machine vision in industrial automation will continue to redefine operational efficiency and autonomy.
“AI-driven advancements will allow for more sophisticated applications, like autonomous mobile robots and automated guided vehicles, streamlining logistics and material handling,” he says. “The adoption of edge computing will further enhance machine vision capabilities by reducing latency and improving response times.”
Researchers are also pushing the boundaries of what machine vision can do. At Tsinghua University in China, researchers have demonstrated a new intelligent photonic sensing-computing chip that can process, transmit and reconstruct images of a scene within nanoseconds. This advance opens the door to extremely high-speed image processing that could benefit edge intelligence for applications like autonomous driving, industrial inspection and robotic vision.
Edge computing, which performs intensive computing tasks like image processing and analysis on local devices, is evolving into edge intelligence by adding AI-driven analysis and decision-making.
In the Optica journal, the researchers describe the new chip, which they call an optical parallel computational array (OPCA) chip. They show that the OPCA has a processing bandwidth of
up to one hundred billion pixels and a response time of just six nanoseconds, which is about six orders of magnitude faster than current methods.
“Capturing, processing and analyzing images for edge-based tasks such as autonomous driving is currently limited to millisecond-level speeds due to the necessity of optical-to-electronic conversions,” research team leader Lu Fang says. |DE
How a Thales-led project is shaping the future of autonomous flight through industry-wide collaboration.
BY ANDRÉ VOSHART
Over the past 40 years, aircraft have become increasingly reliant on automated functions to simplify tasks for aircrew and improve flight safety—but new forms of mobility such as future air taxis and fully autonomous drones herald the arrival of a new paradigm.
The Consortium for Research and Innovation in Aerospace in Quebec (CRIAQ) recently released a progress update on its Autonomy of Future Air Mobility (AMAF) project led by Thales, with partners Presagis (now CAE) and Université Laval.
The project aims to propose a structured framework for the increasing autonomy of vehicles involved in advanced air mobility—a fast-developing segment of the aerospace market that is attracting very high levels of research and development investments worldwide.
The key innovation goal of the project is to develop and test the technology needed for an air vehicle to fly safely and fully autonomously along a previously defined flight path. Project partners Thales, Université Laval and CAE are combining their expertise in digital technologies, artificial intelligence (AI), critical systems and simulation to design the components needed for the autonomous aerospace of the future.
The AMAF project’s goal is not only to revolutionize air mobility but to also create a framework that integrates new technologies safely and sustainably across industries.
Design Engineering spoke with JeanFrançois Gagnon, director of the Thales Research and Technology facility in Canada, about the complexity of the task ahead.
Gagnon explains that air mobility will impact the entire aerospace ecosystem, from the regulatory environment to new technology integration. Thales is leading efforts to develop not only the technical standards but also the language and operational context necessary for integrating autonomous systems into airspaces, while addressing challenges in safety and energy efficiency.
He says autonomous systems like drones will require advancements in sensor technology and machine learning to navigate airspace safely. He also notes that the aerospace industry is relatively conservative, especially when you bring machine learning and AI into an avionics solution. “In the aerospace industry, you have to think of AI innovation differently because safety is always the number one priority,” he says. The project’s primary focus is on maintaining safety of flight, more complex in the context of autonomous detection and recognition of obstacles in flight paths.
A major challenge lies in creating AI algorithms that guarantee obstacle detection even when unforeseen objects are encountered. For example, unmanned aerial vehicles (UAVs) conducting infrastructure inspections will need to avoid pylons or birds, making AI algorithms reliability crucial to maintain safety.
Aircraft with the ability to operate autonomously in critical moments will help make air travel more secure.
Certifying these technologies is another complex issue—and Gagnon stresses that it cannot be done alone. A collaborative approach, involving various partners, is essential for ensuring regulatory compliance and building trust in AI-based systems.
Beyond safety, the AMAF project is also heavily focused on environmental sustainability. He explains that optimizing energy usage within fleets of hybrid propulsion aircraft, whether electric or fuel powered, is a major challenge. In this respect, the Université Laval team’s contributions have been valuable. For instance, while fuel is more effective during climbs, electricity can be more efficient during other phases of flight. Balancing these variables across the full spectrum of operations involves intricate mathematical optimization. The project also considers how to deploy infrastructure for refuelling and recharging aircraft, striving to make air mobility greener while still meeting operational constraints and demands. Thales is consistently focused on pursuing disruptive innovations, especially in fields like air mobility. “I would say that this is in our DNA,” Gagnon says, adding that projects like AMAF serve as experimental grounds to test new concepts and evaluate their feasibility in real-world applications.
The goal isn’t necessarily to implement all findings directly into future systems but to identify potential opportunities, risks and areas that need further development. By addressing these questions, Thales remains at the forefront of innovation, assessing both market value and technical readiness for emerging technologies. This iterative process is embedded in the company’s core innovation strategy.
Thales excels in designing high-end sensors such as radars, sonars and optronics, which are core to their business. Gagnon highlights that the real value of these sensors is maximized through their integration with AI, particularly in obstacle detection and vision systems. He says that what sets Thales apart is its TrUE AI framework—transparent, understandable and explainable AI. This framework is essential for ensuring trust in AI, especially for safety-critical environments. Thales aims to qualify AI systems in these domains, addressing the rigorous demands of safety and reliability.
The Thales UAS100 is a key example of how autonomous technology is advancing in air mobility, specifically within the context of Thales’ project. Gagnon emphasized the UAS100’s role as the preliminary target for developments in obstacle detection and navigation path optimization, making it a critical focus of this initiative. Designed for security, defense, and civilian operations, it offers real-time, high-resolution imaging and can operate up to 100 kilometers from its base. Equipped with advanced sensors and secure communications, the UAS100 is ideal for tasks such as border patrol, infrastructure monitoring and disaster management. Its innovative design allows for autonomous operations, ensuring minimal human intervention while maintaining safety and compliance with aviation regulations. The drone is a scalable solution for enhanced situational awareness in various environments. Thales was able to collaborate with the CED (Unmanned Aerial System Centre of Excellence in Quebec) for in-flight trials.
A significant challenge was the limited amount of data available for training AI models, especially in comparison to the vast array of potential airborne scenarios, as the diversity of potential scenarios far exceeds the available data. “Even if we had one billion images, it’s still nothing compared to the amount of possibilities of things that we could see in the air space,” Gagnon says.
The team needed to ensure that algorithms trained on existing data could accurately identify new, unseen objects, such as pylons or other airborne hazards. This critical technical hurdle requires advanced algorithm development to ensure safety and reliability in diverse conditions.
The collaboration with CAE is helping to mitigate this issue. CAE was tasked with creating a digital twin of the airspace environment to support real-world implementation of innovative perception and navigation functions developed as part of this project, and to provide training for users of these new systems. A virtual test bench will be created to analyse interactions between the real world and an entirely simulated environment.
Beyond this challenge, the project is always evolving. Since the beginning, project hypotheses have evolved, refining their understanding of potential system users and optimizing deployment strategies, underscoring the project’s iterative and adaptive nature.
While the technological capabilities for autonomous flight may be within reach sooner than expected, the challenges extend beyond just innovation. The regulatory landscape, integration with legacy systems and industry-wide coordination will need time to adapt.
In the near future, the possibilities for autonomous flight seem promising, particularly in enhancing safety and efficiency. Regardless of the type of aircraft—whether business jets or air taxis—the integration of autonomous systems will likely progress. Collaborative autonomy, where AI works alongside human pilots, will improve safety, especially in situations where human factors such as fatigue or incapacitation come into play. “I see Canada is well positioned to contribute to this,” Gagnon says. “We have a very strong aerospace industry. We see investment in this area every year.”
Aircraft with the ability to operate autonomously in critical moments will help make air travel more secure, potentially reducing accidents caused by human error.
While fully autonomous flight may not become mainstream anytime soon, projects like AMAF are helping to lay the groundwork. “It’s not going to happen within the next five years,” Gagnon says. “But it’s time to work on it nevertheless, because it will come.”
He also emphasized the long-term impact of the project in cultivating the next generation of engineers given the number of people they’re training on these emerging topics. “We did one thing I’m always proud of these kinds of projects: We’re building the future of Canada for engineers that will work on these real things in the future. In the next 20 years, they’ll be leading the show. So that’s the thing that’s most important for me.” |DE
Saskatchewan’s PAMI revitalizes agricultural machinery by designing custom parts and modern control systems. BY
ANDRÉ VOSHART
Who says old machinery can’t learn new tricks? At PAMI—the Prairie Agricultural Machinery Institute—legacy equipment gets a second chance at life.
PAMI specializes in helping clients maintain the viability of legacy equipment by designing and building replacement parts such as transmission controllers and wiring harnesses. Equipped with cutting-edge tools for electro-hydraulic control integration, custom harness prototypes and assembly testing, PAMI serves both new machinery and retrofit projects.
Many fleet operators and customers come to PAMI looking for solutions for obsolete equipment. They need help developing new setups that integrate modern automation and control systems, allowing the equipment to function more efficiently than originally designed.
“How do you come up with a new a new setup that allows us maybe some further level of automation control beyond something that was originally designed?” asks Bryan Lung, PAMI’s director operations. He says their small but mighty team specializes in retrofitting these machines, providing updated, reliable solutions that extend their lifespan and enhance their operational capabilities while addressing the lack of available original components.
Humboldt, Sask.-based PAMI’s Electronics Lab and Cable Shop offers a full suite of capabilities for designing, assembling and
When designing wire harnesses, PAMI emphasizes the importance of breaking them into smaller, manageable sections for ease of assembly and serviceability.
testing advanced electrical and electronic systems. Specializing in schematic and harness design, the lab plays a crucial role in developing control system components for various industries.
When a customer encounters an issue, the PAMI team starts by reviewing existing schematics and documentation of the product. “We’ll round up whatever information we can find on the existing product,” technical team lead Derek Schultz says. “So existing schematics, drawings, things like that.”
Then from there, using CAD modelling and other tools, they design a new solution that often improves upon the original functionality, sometimes adding automation or control upgrades.
The cable shop uses advanced computer-aided manufacturing to ensure precision and efficiency in building wire harnesses.
Engineers design these machines using SolidWorks and Creo, generating 3D harness routing for accurate assembly.
When designing wire harnesses, they emphasize the importance of breaking them into smaller, manageable sections for ease of assembly and serviceability. Using Zuken’s Harness Builder for E3.series software, the team generates accurate form board layouts, bills of materials and wire cut lists, which are then fed into a Schleuniger cutter that measures, cuts and labels wires to precise specifications. Once the wires are prepared, they are laid out, assembled and undergo rigorous testing through an MPT tester, which checks for electrical continuity, insulation strength and proper function.
This modular approach reduces costs and complexity while ensuring that parts are easier to
replace, especially in rugged industries like agriculture and mining.
Following testing, the harnesses are braided for added durability using temperature- and abrasion-resistant yarn. This braiding is performed using two specialized machines—a 36-carrier machine for larger cables and a 16-carrier for smaller ones. Once the components are braided for durability, they undergo a final round of testing before being added to inventory or installed in machines.
Once validated, the parts can be manufactured in small or large production runs. This process ensures that clients can extend the life of their machinery without needing to replace entire fleets, providing a cost-effective solution while ensuring that updated equipment performs reliably.
According to Schultz, this streamlined approach drastically reduces troubleshooting time, making the machinery operational within hours instead of weeks. This streamlined process allows them to produce fully functional harnesses efficiently, transforming a complex production task into a well-structured, quality-controlled operation.
The Big Bud tractor project revolved around reviving outdated machinery by designing a new transmission controller, as the original replacement parts were no longer available. And what’s more, the owners of Big Bud tractors have a strong attachment to these machines.
“The people that have Big Bud tractors are kind of like people that have Harley’s— they love their machines,” Lung explains. “They’ll put all kinds of love labour into
keeping their tractors rolling. It’s a piece of history, and in their minds, it’s the ultimate machine. So there’s definitely a desire that goes beyond just patching it to make it work.”
PAMI was tasked with developing a solution that would extend the life of these tractors while ensuring operational reliability. The team had to navigate technical challenges like integrating with existing systems, determining which components needed replacement and choosing materials that would endure harsh agricultural environments.
To ensure the design’s success, they collaborated closely with the client to identify key requirements, including forward and reverse compatibility, service conditions and projected production volumes. Factors like the longevity of materials, corrosion resistance and ease of serviceability were considered essential in the design process, especially given the tough conditions Big Bud tractors often operate in. The team had to make decisions on component types, from plastic versus metal connectors to the environmental impact of materials.
Ultimately, they created a solution that not only
solved the immediate issue of finding replacement parts but also improved the functionality of the tractors. This process included considering future maintenance and ease of service, making the new system both user-friendly and robust enough to extend
the tractor’s operational life significantly. The successful development led to offering retrofit kits to other Big Bud tractor owners, ensuring that these machines could continue to operate reliably in agricultural environments.
“We’ll let the requirements drive the process,” technical sales director Lorne Grieger says. “It is understanding what the requirements are for the equipment and the conditions that it’ll be operated in once it leaves our facility.” So they take the time to work with the client to understand all those details up front.
“And sometimes the clients don’t really know what they want either,” Schultz adds. “So they’re relying on our guidance and experience to steer them in the right direction with the product design.” |DE
BY KEVIN NICHOLDS
Applications are growing in metal additive manufacturing (AM), particularly in laser powder bed fusion (L-PBF), among the most mature metal 3D-printing technologies. Metal AM is now cost-competitive with casting in some applications, and earning the confidence of automotive, aerospace and industrial suppliers.
Arguments against metal AM are falling like dominoes. The industry has figured out how to use very high-powered lasers to deliver economical build rates, how to get a better surface finish while enhancing build speed, how to optimize process control software and how to collaborate on materials databases to speed up qualification. These breakthroughs are courtesy of materials
The industry has embraced the need for consistency and repeatability.
suppliers, equipment suppliers and end users working together from the earliest stage of part design and material development through to post-processing and part qualification.
AM offers some unique capabilities (i.e. conformal channels for cooling, structural/weight optimization and parts consolidation), but cost is still king in manufacturing. No production technology can become a mainstream option unless it can make the grade based
about 20–30 cm 3/hr was considered standard, with some machines capable of going faster using multiple lasers. In 2024, build rates on modern production units are reaching around 400 cm3/hr—about 40 times the speed of printers just eight years ago.
Cutting-edge manufacturers, with the right combination of equipment and materials, are developing capabilities to produce parts even faster. Eaton Corp., working with Equispheres and Aconity3D, has demonstrated a method for producing valve bodies using a very high-power laser system that will roughly triple production rates again. Once integrated into production systems, this technology will achieve part costs roughly 50 per cent lower than even the best production systems today.
on productivity, quality and cost.
The industry has rallied to achieve substantial gains in these three metrics. For aluminum parts, some printer/ powder combinations can match the economics of casting for low- and medium-volume production applications.
Productivity varies according to part geometry, but the upward trend in the past few years is remarkable. The industry standard build rate for a single laser, powder-bed fusion printer in 2016 was only 10–15 cm3/hr. In 2020,
The evolution of L-PBF is headed in a direction that will be familiar to most manufacturing engineers. At the intersection of the new generation of lasers, engineered metal powders, and sophisticated control software is a process that looks a lot like CNC machining. L-PBF can now produce larger sections at high build rates and then switch to lower speeds and finer resolution for thinner features and better surface finish, similar to roughing and finishing cycles.
Collaboration can help maximize productivity and part quality for production applications. The industry has learned from successful additively manufactured production parts that the customer-supplier relationship is critical to optimize serial production.
Engineers, designers and managers accustomed to
Productivity and design freedom go together in modern metal additive manufacturing. This production part for a 3D printer illustrates the capabilities of laser powder bed fusion.
more traditional manufacturing methods may be surprised to learn how much influence material selection and key process variables can have on the final part costs when using additive technologies. For L-PBF of aluminum, for example, even within the same alloy, the choice of one powder over another can affect print time by 50 per cent.
The interaction among powder, printer and process parameters defines:
• average and statistical mechanical properties
• dimensional accuracy
• surface roughness
• heat treatability
• throughput rate
As an example of the effect of powder selection and process parameters, consider TRUMPF’s experience with Equispheres’ powders. This global equipment supplier has qualified Equispheres AlSi10Mg powders for its TruPrint 3000 series of 3D printing systems. The qualification process confirmed that Equispheres’ advanced aluminum materials could achieve up to a 33-per-cent faster build rate on the TruPrint system than a
end-use application. Depending on your materials supplier, some powder features—like microstructure, particle dynamics (flow, packing), surface chemistry, shape and size range—can be fine-tuned for specific applications. It has been shown that metal powders designed specifically for AM impart a more controlled melt pool and are more suited to highspeed processing.
Consistency is as important as productivity as AM enters the mainstream.
and standards.
The industry has embraced the need for consistency and repeatability throughout the supply chain, starting with materials and the printing equipment.
standard aluminum powder. TRUMPF’s development achieved laser-melting rates of 164 cm³/h on a dual-laser system.
With early and open collaboration, powder characteristics can be optimized to achieve design performance targets, maximize productivity and ensure repeatable results.
One major difference between AM and subtractive methods is that in L-PBF and many other additive technologies, you recreate the material as you form the part. L-PBF is, at its heart, a process of stacking many very tiny welds. It modifies the raw material as the piece is being built.
Because of this, decisions made about the build process strongly influence mechanical properties by defining the part density and microstructure of the material coming out of the printer.
Once an alloy is selected, powder selection (in some cases, custom powder design) is necessary to align the material input with the additive process and the
Speaking about the AM Forward program, Brian Baughman, chief engineer of additive manufacturing at Honeywell Aerospace, said the industry needs consistency from parts suppliers so that users and certifying agencies can be confident the parts meet the requirements
Metal AM can deliver both design freedom and high speed, making it cost-competitive without compromising material properties and performance. And the economics of modern L-PBF processes elevate metal AM to be a contender in many design and production discussions. Multi-mode lasers, high-performance metal powders and readily available, standardized engineering data are taking metal AM from a consideration to a necessity. |DE
Kevin Nicholds is the CEO of Ottawa-based Equispheres.
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BY RALPH GRABOWSKI
Generative design software isn’t as popular as it could be. In today’s green-aware environment, minimizing resources in manufacturing ought to be a no-brainer, a task at which generative design excels.
And yet here are reasons for the reluctance to deploy generative design:
It has been expensive. Autodesk at one time charged US$8,000 per year per seat, though now it’s much less
2. It’s an extra step in the manufacturing process. After the design phase, there’s the generative optimization process, followed by simulation and then machining.
3. Its organic outputs may create compatibility issues. The designs often consist of meshes or NURBS (non-uniform rational B-splines), which are difficult for traditional mechanical CAD (MCAD) software to edit or manipulate. This can create
compatibility issues with existing software solutions, limiting its practical usability.
Its use of bone-growth algorithms results in spindly knobby-looking shapes filled with lattice holes.While these forms are well-suited for 3D printing, they are much harder to manufacture using conventional CNC machining tools, which can be much cheaper to run and more commonly found.
The aim is for generative design to automate design and manufacturing to the point that some CAD vendors have taken to calling theirs “artificial intelligence.” The idea: once designers specify constraints, the generative design software output optimized parts, which are manufactured by 3D printers—all automatically. Constraints include the volume in which the parts must fit, connection points with other
parts, allowable stresses and acceptable materials.
Legacy generative design software needs new thinking. I’ve come across two companies—InfinitForm and Hyperganic—that are doing the rethinking by making the claim that designing for additive manufacturing (AM) is too difficult and too expensive as compared with subtractive manufacturing, such as using CNC machines. InfinitForm figures that generative design software could eventually do 99 per cent of the work—from design to manufacturing.
Each firm has written its own generative design software and works toward algorithmic design—but with opposite results. For InfinitForm, the solution is to have generative software output prismatic shapes, which are suitable for subtractive manufacturing. For Hyperganic, the solution is to drive down the cost of design.
After getting a PhD in topology optimization, Michael Bogomolny founded (and then sold to Carbon 3D) his first generative design firm. In CogniCAD, he had found a way to more accurately emulate microstructures of artificial bones by having lattice-grain bias in the direction of force.
In an interview with Design Engineering, Bogomolny says that after leaving CogniCAD, he wondered if it might be possible to get prismatic parts out of generative design software. Prismatic parts, with their flat sides and round arcs, would be editable in 3D MCAD software and easier to machine with CNC tools than the organic shapes usually produced by generative design.
He targeted CNC machines because he says they are cheaper to run than 3D printers and, once set up, are
ideal for mass production. He notes that prismatic shapes benefit from being more accurate to measure with coordinate measuring machines than organic shapes. Working with solid materials like aluminum ingot means you know what’s inside the material, which is not necessarily the case with 3D-printed materials, he argues, and so 3D-printed ones are not used for critical parts, such as in aerospace.
In May 2024, his company came out of stealth mode with a closed beta. The software figures out the best compromise between least material and greatest manufacturability and then adjusts surfaces to be prismatic: flat faces with round arcs. Fillets assume the radius of cutting tools, while narrow webs and slots are made wide enough to be machined. No gnarly, bone-like structures.
I asked him how he gets those flat sides out of generative design. “It is our secret sauce,” he says. My guess: InfinitForm runs something like a civil engineer’s cut-andfill operation for road construction: removing material from one area to add it to another, all the while repeatedly checking that the parts still meet the constraints.
Being prismatic, parts can be brought into 3D MCAD programs to adjust the design, such as unnecessary features InfinitForm might have left in. For example, in a demo I watched, there were some shallow dimples in the final result, which would need to be edited out.
InfinitForm claims it reduces the design-to-manufacturing process from weeks to minutes. A part typically takes four to 20 minutes to process, depending on its complexity and whether organic and prismatic outputs are wanted.
To start off, the kernel was OpenCASCADE, but the program is now being ported to Parasolid, allowing InfinitForm to run inside MCAD programs like SolidWorks. For now, it’s based on CUDA with Amazon’s cloud, using NVIDIA’s massively parallel GPUs for speed. The plan is to eventually let it run on desktops, also on a GPU.
As the software is still in closed beta, no pricing is set, but the plan is to ship in Q4 this year.
Lin Kayser, co-founder of Hyperganic, agrees with Bogomolny that 3D printers
are too costly. Manufacturers hand-make their products, and they “are sold like luxury cars, one by one,” charging “outrageous” amounts for materials, he says.
But he disagrees with Bogomolny over how parts should be manufactured. He feels CNC machines are too limiting, as they can be set up to mass produce only one kind of part at a time; to mass-produce the next part requires expensive changeovers. By their nature, 3D printers effortlessly switch between producing different parts. His solution is to drop of the price of 3D printers by mass producing them with 3D-printer farms.
The problem is that the price drop is only an idea: Kayser doesn’t own a 3D printer company. So his former firm (he is no longer with Hyperganic) is tackling the other side. HyDesign’s expertise is generating the 3D parts quickly, and then exporting a file that is not too large but of good quality to the 3D printer. The kernel in this generative design software has some Assembly-code optimizations for speed, and it runs on the cloud.
Users can define lattices in HyDesign using the TPMS
(triply periodic minimal surface) feature, in which algorithms determine if there ought to be material or space in each point of the part, or else users can access the UltraSim lattice library from BASF’s Forward AM to explore materials and their properties.
Hyperganic wants to become a one-stop shop (from engineering to manufacturing), so it acquired DirectFEM, which deploys a quasi-mesh-less method to work directly with HyDesign’s voxel data model—no meshing needed. Users can evaluate algorithmically engineered objects quickly.
Currently, HyDesign imports STL (from MCAD) and OBJ files (from industrial design), as well as places PNG raster images to define features. The roadmap plans import of native CAD formats in the future. Product manager Weijie Zhao says that there is no export to native CAD formats at this time because there is no practical mathematical approach to generate a CAD boundary representation from an arbitrary voxel geometry representation, echoing InfinitForm’s point. But you can export models to the 3MF format, which is optimized for AM.
In 2021, Hyperganic received $7.8 million from HV Capital and other investors, in addition to earlier undisclosed funding. Pricing for the software starts at e25/ month (about CA$37), about a sixth of Autodesk’s fee for accessing generative design. A free tryout is available at hyperganic.com/pricing |DE
Ralph Grabowski writes on the CAD industry on his WorldCAD Access blog and has authored numerous articles and books on CAD and other design software.
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Gearboxes are vital components in industrial applications, driving productivity across sectors such as manufacturing and automation. As industries demand more energy-efficient, high-performance and durable equipment, engineers and product developers must refine gearbox configurations to meet these expectations.
We’ll go over practical strategies and insights into boosting gearbox efficiency by improving system performance, minimizing energy use and extending equipment lifespan.
Before we dive into advanced technologies or complex optimizations, it’s essential to understand the foundational elements that impact performance:
Load capacity: Gearboxes must be engineered to handle the specific load requirements of an application. Miscalculating load capacity can cause premature failure or inefficiency. Conducting a thorough load analysis helps tailor a system that operates effectively without wasting energy or resources.
Gear type selection: Choosing the right gear type is key for balancing efficiency, noise reduction and load management, and each one offers distinct advantages:
Helical: Known for quieter operation and superior load distribution, making them ideal for high-speed scenarios requiring smooth motion.
Worm: Capable of generating
high torque at low speeds, though they usually have reduced efficiency due to frictional losses. These gears are beneficial when space is limited or self-locking capabilities are needed.
Spur: Simple and cost effective, these gears are suitable for applications with moderate speed and torque needs. They tend to be more efficient than worm gears but produce more noise.
Bevel: Best suited for changing the direction of torque and speed at an angle, often 90 degrees. Bevel gears provide precision and high efficiency, making them a preferred option when directional changes with minimal energy loss are required.
Material selection: Advanced materials such as lightweight alloys or composites reduce weight and friction, while high-strength steel increases load-bearing capacity. Factors such as heat dissipation, strength-to-weight ratio, and material compatibility all contribute to a more durable and efficient system.
Modern advancements have revolutionized how engineers approach gearbox optimization, providing powerful tools to enhance functionality and reduce energy consumption.
Precision manufacturing: Precision manufacturing techniques—including CNC machining and additive manufacturing—enable tighter tolerances and more accurate gear meshing.
Gearboxes are vital components in industrial applications, and reducing energy usage is a central objective when developing modern gearbox systems.
This reduces friction and wear. These methods also allow for more complex geometries that distribute loads better and minimize mechanical losses.
Gear tooth profile optimization: Fine-tuning the tooth profile can increase the effectiveness of gear systems. Asymmetric designs, for instance, reduce sliding friction and enhance contact patterns. Engineers can employ CAD and finite element analysis tools to model gear interactions and refine profiles to match specific load and speed demands.
Lubrication: Proper lubrication is the key to minimizing friction and wear. Advanced alternatives like oil mist or nano-lubricants deliver consistent lubrication even under high loads and speeds.
Once fundamental principles and modern technologies are applied, the following steps can help further optimize gearbox operation: Comprehensive load analysis: Begin with a detailed analysis of the loads the system will encounter. Simulating load variations accounts for both peak and typical operational conditions. This approach allows for optimal performance during
routine operations while maintaining robustness under peak loads.
Optimizing gear ratios: Adjusting the gear ratio according to speed and torque needs is essential. Poorly selected ratios lead to unnecessary energy consumption. Careful analysis helps fine-tune the ratio to balance speed reduction with torque output. For applications with fluctuating loads, variable ratios can yield significant efficiency improvements.
Predictive maintenance systems: Real-time monitoring of system health through predictive maintenance tools like IoT-based sensors helps engineers detect wear, overheating or lubrication issues before they result in failures.
Thermal management: Excessive heat degrades lubricants and weakens materials. Installing cooling systems or using materials with high thermal conductivity helps dissipate heat efficiently and maintain energy performance.
Lightweight gearbox solutions: In mobile or rotating systems, the weight of components directly affects overall efficiency. Using lightweight materials—such as titanium alloys or composites—can reduce mass without compromising strength or reliability.
Streamlined production: Streamlining production processes helps eliminate inconsistencies that may hinder performance down the line. For example, controlling heat treatments during production results in uniform material properties, reducing the risk of failure.
Reducing energy usage is a central objective when developing modern gearbox systems.
Minimizing friction losses: Friction is a significant contributor to energy waste. Improving surface finishes and using high-performance lubricants can lower friction. Additionally, advanced coatings like diamond-like carbon (DLC) enhance meshing by reducing friction, leading to greater efficiency.
High-quality sealing: Sealing prevents lubricant leakage and protects against external contamination, both of which can increase friction and reduce efficiency. High-quality seals preserve the internal integrity of the system, minimizing wear and energy loss.
Backlash reduction: Backlash— small gaps between gears—leads to inefficiencies and can reduce precision. Reducing this backlash is critical, particularly in high-precision applications. Advanced gear-cutting techniques and precise assembly allow for tighter tolerances, minimizing energy loss.
Maximizing longevity: Efficiency not only enhances performance but also extends the lifespan of equipment by reducing wear and tear.
Thorough testing protocols: Extensive testing during the development phase helps identify potential weaknesses and allows for refinement. Accelerated life testing simulates various operational conditions, providing insights into expected lifespans and guiding further adjustments.
Built for simplified maintenance: Building systems with accessible lubrication points, modular components and quick-release housings simplifies maintenance. This approach promotes longer-lasting, reliable equipment. |DE
Visit design-engineering.com to read the full feature, including more on NEMA standards and noise and vibration control.
MAXXDRIVE industrial gear units from NORD DRIVESYSTEMS are designed to handle heavy-duty applications such as bucket elevators, agitators, conveyor belt drives, mixers, mills, drums, crushers, and more. The product family is available in a parallel shaft design as well as a right-angle design. As a standard, the gear units are equipped with an efficient NBR or FKM sealing system that is suitable for many environments.
Ruland Manufacturing has expanded its jaw coupling line for high-torque applications, offering bore sizes up to 1-3/4 in. and torque capacities of 2,655 in.-lbs. (300 Nm) through RotoPrecision. They’re designed for use in precision systems with high deceleration and acceleration curves like in semiconductor, solar, conveyor and warehouse automation applications. With zero backlash, misalignment capabilities and a design that reduces vibration at speeds up to 8,000 rpm, they deliver optimal performance for demanding environments.
IKO International has introduced its CFL Series cam follower that boasts a space-saving outer ring design and polymer layer that exceeds the capabilities of conventional resin-type cam followers. They incorporate a polymer layer that is molded directly onto the IKO exclusive thin-walled steel outer ring and are available in a self-lubricating type and a shock-absorbing type. These units are suited for use in high-tech equipment or as part of conveyance mechanisms in precision machines that includes direct product contact.
Zero-Max has added the new ServoClass-HSN coupling to its ServoClass Flexible Shaft
Coupling line to address noise and vibration issues in certain high gain, high speed stepper/ servo motor applications. They are designed for maximum damping and performance. The zero-backlash design features an optimal torsional stiffness to provide low hysteresis and ensure accurate positioning in applications requiring increased damping properties.
Schneider Electric has launched its the new ultra-compact Lexium SCARA (selective compliance assembly robot arm), a high-speed industrial robot. Deployable across several industries including battery manufacturing, electronics, warehousing and consumer packaging goods, the Lexium SCARA offers quick and accurate movements. This makes it ideal for use in manufacturing and assembly processes including machine loading and unloading, pick-and-place, packaging and material handling applications.
Rethink Robotics has unveiled its Rethink Reacher line of collaborative robots (cobots). The Reacher cobot line includes seven new cobot models (RE 07, 09, 13, 16, 21, 30, and 30L), handling payloads ranging from 7 to 30 kg (15–66 pounds). In addition to the cobots’ improved design, their robust hardware delivers increased precision, speed, and durability, enhancing their capabilities for industrial use, supported by an IP65 rating for use in wet and dusty environments.
Electromate has announced the new Harmonic Drive HPF Series for engineers requiring hightorque solutions in compact spaces. Its precision gearing and versatility make it ideal for robotics, automation and other high-performance applications that require exact motion control. In robotics, it’s used in robotic arms and precision movement systems, where space-saving designs and torque output are critical. It’s also ideal for medical devices, particularly in robotic surgery and diagnostic machines, where high accuracy is essential.
Premier Tech has introduced its new TOMA product line. The first product under the TOMA brand is a palletizing solution featuring the most advanced interface on the market, bringing together industrial robustness and user-friendliness with collaborative robotics. Thanks to its seamless integration requiring no coding, no engineering and no programming, both small and large manufacturers can access the benefits of automation, setting a new standard for efficiency and ease of use.
Clippard has releases its EHS series electronic valves, precision-engineered to deliver robust performance in higher pressure (up to 1,000 psig) applications. It incorporates key features like substantial cross-sectional O-rings, proven poppet designs and strategic placement of mounting hardware outside the flow path. It’s the preferred choice for high-pressure applications that demand lasting, low-leak performance.
Danfoss Power Solutions has expanded its Vickers by Danfoss portfolio of proportional valves with the launch of the KBFRG4-5 valve. The new single-stage, four-way hydraulic valve features a round solenoid design and delivers high power capacity and superior durability. It is designed for a range of industrial applications, including wind turbines, machine tools, plastic molding, metal forming, pulp and paper processing, and more.
The idea behind Axtion Independence Mobility’s RAYMEX Lift began when co-founder Raymond McGillivray started experiencing falls—which highlighted a lack of solutions that help preserve independence for seniors.
“While there were lift devices available in the market, they were not a practical solution for those who want to maintain their independence,” says Tracey McGillivray, co-founder and CEO of Wolfville, N.S.based Axtion Independence Mobility.
“They were heavy and/ or came in multiple pieces that needed to be brought, assembled and operated by an able-bodied companion or caregiver and, in some cases, two people,” she adds. “We set out to create a device that was easy to use independently or with the help of a companion who may have limited abilities.”
One in four people aged 65-plus fall annually, and that doubles to one in two for those over 80. Falls can have a devastating impact—from cessation of activities that put people at risk of falls to significant injury, hospitalizations, long-term care and death.
The standout feature of the RAYMEX Lift is a powered elevating seat that descends to the floor and raises up to 24 inches—and stops anywhere in between.
Once this was proven, the addition of rotating handles/ arms and a rotating seat made the device as much
about fall prevention as fall recovery.
The device now supports four functions: lift, transfer aid, multi-purpose mobility aid and a rehabilitative tool for standardized sit-to-stand exercises.
From the outset, the Axtion Independence Mobility team followed the principles of user-centred design, guided by Clifton Johnston, professor and NSERC chair in design engineering in the department of mechanical engineering at Dalhousie
University and the academic director of the Emera ideaHUB.
“We began with rapid prototyping, creating four different design approaches using wood, disassembled car jacks and disassembled drills to test the various designs,” McGillivray says.
After landing on the best approach, the team produced five functional prototypes with step-change improvements at each iteration.
“With each version, we had formal workshops,
evaluations and feedback sessions with users, healthcare providers, clinicians and caregivers, most led by independent university researchers to ensure we received candid feedback and inputs,” she adds.
Their fifth prototype, now nearly market-ready, is undergoing real-world trials with 20 participants, led by Dr. Caitlin McArthur in the School of Physiotherapy at Dalhousie University.
One significant design challenge was ensuring the seat maintained level positioning throughout its vertical travel, regardless of how weight shifted. Another was integrating a folding frame for easy transport while maintaining the seat’s rigidity.
“The seat and frame needed to be rigid independently of each other, whereas traditional rollators can combine the seat into the frame,” McGillivray says.
On its most recent prototypes, Axtion Independence Mobility has been working with a contract design manufacturer and an experienced industrial designer to help them refine the design with a holistic Design for Excellence approach, focusing on Design for Manufacture/ Assembly, Design for Safety, Design for Reliability and Design for Serviceability/ Maintenance. |DE
Axtion Independence Mobility is part of the first cohort of the Mobility Unlimited Hub. Read more mobility technology profiles from the hub on Page 6
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