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Welcome to the August edition of Manufacturers’ Monthly. In this issue’s Manufacturer Focus, we sat down with Richard Petterson, director of Tindo Solar, to learn how the company continues to thrive as Australia’s only solar panel manufacturer. Discover the innovative strategies and challenges it faces in maintaining its position in the market. Later in this edition, we speak with the LightForce Group about its ongoing collaboration with the Australian Defence Force, shedding light on the critical role its technologies play in national security. Finally, in this month’s Engineering Focus, explore the cuttingedge development of self-healing composites. These materials are revolutionising submarine technology by autonomously responding to microcracks, enhancing durability and safety. Happy reading!
Leading the charge in Australia’s manufacturing and renewable future
Dear Readers,
As we navigate the ever-evolving landscape of Australia’s manufacturing and renewable energy sectors, it is with enthusiasm that I share some compelling developments shaping our nation’s future. These stories not only highlight advancements but also underscore the dynamic interplay between innovation, sustainability, and economic growth.
Western Australia is making strides towards becoming a leader in the renewable energy sector with the approval of the first project under the State Government’s pioneering Green Energy Approvals Initiative. This initiative, managed by the Department of Water and Environmental Regulation’s green energy directorate, aims to streamline regulatory processes and expedite approvals for renewable energy projects.
In a landmark achievement, the Yindjibarndi Energy Corporation (YEC), in collaboration with ACEN Australia, has secured environmental clearance for its inaugural solar venture. This project, located within the Yindjibarndi Native Title Determination Area in the Pilbara region, is set to generate up to 150 megawatts of clean energy. It marks the beginning of YEC’s ambitious plan to develop three gigawatts of renewable energy capacity, encompassing solar, wind, and storage technologies. This initiative not only accelerates the transition to clean energy but also promises job creation and economic growth, particularly benefiting Indigenous communities in the Pilbara. Environment and Climate Action Minister, Reece
Whitby, emphasised the transformative potential of these projects, highlighting their role in reducing carbon emissions, fostering Aboriginal employment opportunities, and supporting renewable energy adoption. Pilbara MLA Kevin Michel echoed these sentiments, recognising the project’s significance for the region’s sustainable future.
In another leap towards a sustainable future, the first electric bus manufactured under a joint $250 million initiative by the Australian and Western Australian Governments has been completed. Built at the Volgren facility in Malaga, this bus is the first of 18 electric buses set to transform the CBD CAT bus routes in Perth.
Federal Member for Perth, Patrick Gorman, praised the initiative for its contribution to building a cleaner and more sustainable community. The investment, which includes $125 million from both the Australian and Western Australian Governments, encompasses not only the acquisition of electric buses but also the development of essential charging infrastructure and upgrades to manufacturing facilities. This initiative supports more than 100 local jobs, including apprenticeships, and represents a crucial step towards reducing emissions and fostering local industry growth.
Another issue of note is that the Federal Government has commenced construction on the first Hunter Class Frigate, marking a milestone in enhancing Australia’s naval capabilities. This project, part of a broader commitment to build six Hunter Class Frigates in South Australia, underscores the importance of continuous naval
shipbuilding for national security and economic prosperity.
The construction of these frigates at the Osborne Naval Shipyard is expected to create thousands of direct and indirect jobs, bolstering the state’s workforce and industrial infrastructure. Premier
Peter Malinauskas highlighted the importance of this initiative for South Australia’s future, ensuring a pipeline of secure, well-paid jobs for generations to come.
Finally, the Federal Government has granted approval for Senex Energy’s $1 billion expansion of its Atlas and Roma North projects in Queensland. This expansion is poised to deliver 60 PJ of natural gas per year from 2025, meeting more than 10 per cent of annual east coast domestic gas requirements. The project is set to create 900 jobs during expansion, with 200 ongoing roles, bolstering Queensland’s economy and domestic gas supply.
Resources and Critical Minerals Minister, Scott Stewart, underscored the crucial role of gas in Australia’s energy transition, supporting both households and the manufacturing industry. The Queensland Energy and Jobs Plan further identifies the importance of renewable energy, with a goal of 80 per cent renewable electricity by 2035.
These stories collectively paint a vibrant picture of Australia’s journey towards a sustainable, innovative, and economically robust future. As we continue to support and celebrate these advancements, let us remain committed to fostering growth and sustainability within our manufacturing and renewable energy sectors.
COMMENT
Worker shortage barrier to nuclear ambitions
Opposition leader Peter Dutton recently announced seven sites for reactors, unveiling his long-awaited policy for nuclear power with the claim that operations could start in the 2030s.
Federal opposition leader Peter Dutton’s proposed nuclear reactor sites are former or current coal plants that possess the necessary technical attributes, including transmission infrastructure, cooling water capacity, and –apparently – the skilled workforce required.
Nuclear technology has been in existence for decades, supplying a large amount of zero-emission power to a number of developed countries across Europe and North America. However, the majority of these nuclear power plants were built in the 1970s and 1980s, and have largely been abandoned in favour of other power supply options.
Last year, just five new nuclear reactors were opened, and the same number were closed, according to the World Nuclear Industry Status Report. This trend is on par with the past two decades, which has seen 102 reactors opening globally while 104 have shut down. Out of the 416 active nuclear reactors, the average age is 32 years. While the Coalition claims its reactors will operate for 80 to 100 years, the world has yet to see a 60-yearold nuclear reactor.
What’s more, there is a critical shortage of welders
needed for the nuclear power plant program. This deficiency in highly skilled tradespeople poses a threat to the successful execution of this national energy initiative.
High costs to build
The reason why the nuclear renaissance of the 2000s never eventuated has less to do with public opposition and fears around nuclear meltdowns, than it does with cost. Nuclear power plants are expensive to construct, operate, and maintain: many nuclear programs of the 1970s and 1980s severely underestimated these costs. The subsequent budget blowouts meant that almost no new nuclear power plants were built in Europe and North America until the late 2000s.
An Oxford Professor’s study of 16,000 major construction projects found that nuclear reactors have the third-highest rate of budget and time blowouts. One of the two project types that ranked above nuclear power plants is radioactive waste repositories, which Australia would also need to build to support the Coalition’s proposed nuclear program.
The CSIRO estimates that each 1-gigawatt nuclear
plant could cost well over $8 billion, and warns that the real-world costs may double in a country that has never built a nuclear reactor before, given the high start-up costs. The 15-to-20-year timeline given by the CSIRO for building each plant is contrary to the Coalition’s plans for full operationality before 2040.
In the United States, some nuclear projects have even been abandoned prior to completion due to billions of dollars in cost blowouts, such as Virgil C Summer, which had already expended almost $14bn on the failed project. The Coalition’s nuclear project also draws parallels with the UK’s Hinkley Point C nuclear power plant project, which has experienced a three-year delay and an £8 billion cost overrun. A major factor in this project is the shortage of skilled engineers and steelworkers with no robust strategy to address this workforce gap.
The lack of skilled workforce
The proposed nuclear power plant program, alongside increased activities in defence shipbuilding, critical minerals mining and processing, hydrogen plants and renewable energy infrastructure projects, will exacerbate the
COMMENT
GEOFF CRITTENDEN, CEO, WELD AUSTRALIA
existing shortage of welders from 70,000 to nearly 100,000. In fact, of the 67,000 welders identified in the last census, fewer than 5,000 possess the expertise to weld to the highest standards required for nuclear power plants, submarines, and other critical infrastructure. And of those 5,000 welders, approximately one third are nearing retirement, further compounding the issue.
If Australia were to shift its energy policy yet again, we might see a slight decrease in demand for welders assuming we halt the production of wind towers, refrain from extending the grid, and cancel hydrogen and green steel projects. Given that wind and transmission tower production can be significantly automated, let’s optimistically estimate a reduction of 20,000 welders.
However, if we decide to build two nuclear power plants simultaneously while maintaining all existing coal-fired power stations indefinitely, the demand for highly skilled welders will be immense. Welding for nuclear power plants requires expert welders who can handle all positions and processes with the highest accuracy and quality. Those same welders are also essential for maintaining coal-fired power stations, building submarines and frigates, and developing hydrogen and mineral processing plants. Coming back to Hinkley Point C, Managing Director Stuart Crooks has said that restarting the nuclear construction industry in Britain after a 20-year pause
do it, just, with some sensible policy settings. But it’s impossible to imagine where we would find the engineers and tradesmen to build one nuclear power station, let alone seven.
We cannot rely on immigration. The global shortfall in welders is evident, with the US experiencing a deficit of 480,000 before its recent manufacturing boom and Japan reporting a shortage of 250,000 welders. The demographic shift away from trades has created a global crisis that Australia is not insulated from.
Additional barriers to nuclear
Even if the Coalition was somehow able to fill the worker shortage, there are additional legal hurdles to overcome. Australia implemented a nuclear ban in 1988, which PM John Howard tried and failed to remove in the run-up to the 2007 election.
If Dutton is hoping for a different outcome in the Federal Election, in the event that the Coalition is unable to form a majority government, they will be relying on independents to support lifting the ban in Parliament, since Labor and the Greens are opposed to such a move. Queensland, Victoria and New South Wales also have a ban on nuclear power; as the Coalition’s planned development includes a reactor in every mainland state, state governments would also need to favour lifting the ban, which seems unlikely under Labor Governments.
governments will need to find a permanent solution for radioactive waste, regardless of whether they adopt nuclear power. Until that time, he has suggested storing waste on-site until the end of life of the power plant, which is not considered to be the safest, long-term management option by regulator ARPANSA (Australia’s Radiation, Protection and Nuclear Safety Agency).
A need for immediate, decisive action
Despite the claims of the Coalition, the likely result will be much higher electricity bills for consumers, with the price of wholesale power at least tripling to recover the costs of building the nuclear plant. As energy retailers will pass these costs on to consumers, the average household could see an increase of $1,000 a year in their power bill.
The Coalition’s plan to go nuclear will impact the lives of every Australian at a time when costs of living are skyrocketing. It will also place increased pressure on the steel industry and skilled workers. Australia’s energy transition is already struggling, and adding the monumental task of building nuclear power plants without a sufficient workforce is impractical.
We are barely able to meet our current commitments, let alone embark on new nuclear projects. The situation necessitates a multi-faceted
Dutton’s plan to repurpose coal plant sites for nuclear reactors needs skilled workforce despite some of the infrastructure already being in place.
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Green energy initiative approved in WA
Western Australia has given its first approval of a project under the State Government’s pioneering Green Energy Approvals Initiative.
Managed by the Department of Water and Environmental Regulation’s green energy directorate, the Green Energy Approvals Initiative streamlines regulatory processes across governmental agencies, expediting approvals for renewable energy projects.
Yindjibarndi Energy Corporation (YEC), in collaboration with ACEN Australia, has secured environmental clearance for its inaugural solar venture.
The approved solar project, slated to generate up to 150 megawatts of clean energy, will be situated within the Yindjibarndi Native Title Determination Area, spanning 13,000 square kilometres in the Pilbara region.
The Green Energy Approvals Initiative aims to attract investment in diverse sectors including wind and solar power generation, renewable hydrogen production, and the manufacturing of essential renewable energy components.
This milestone is part of YEC’s plans to develop a total of three gigawatts of renewable energy capacity.
It accelerates the transition to clean energy
communities
into a renewable energy powerhouse.
“By reducing carbon emissions, fostering Aboriginal employment opportunities, and supporting renewable energy adoption in the Pilbara, these projects will play a pivotal role in our
monumental step forward for the Pilbara region.
“Not only will it help decarbonise our energy systems, but it will also create sustainable jobs and deliver substantial benefits for our community and environment,” said Michel.
Stakeholders anticipate the groundwork laid for YEC’s transformative projects will set a benchmark for future developments across the state.
in the Pilbara. Environment and Climate Action minister Reece Whitby said he is committed to transforming WA
The newly approved solar project will be situated in the Pilbara region of WA.
Electric bus ready to hit the roads for testing
The first electric bus to be manufactured as part of a joint $250 million Australian and Western Australian Government initiative has now been completed.
The inaugural electric bus was built and manufactured locally at the Volgren facility in Malaga, Perth. It will be one of 18 electric buses
used on the CBD CAT bus routes.
Western Australian premier Roger Cook said this is an important step in building WA’s clean energy future.
“It means we’re cutting emissions, busting congestion, and providing affordable public transport
Senex Energy expansion approved
while creating local jobs and building our skilled workforce for the future,” said Cook.
As part of the initiative, the Australian Government has committed $125 million toward electric bus charging infrastructure in Perth.
This investment is combined with a $125 million commitment from the Western Australian Government to acquire 130 locally manufactured electric buses.
The investment will foster the installation of charging infrastructure at key depots and upgrades to manufacturing facilities that produce the electric buses.
The inaugural bus, expected to enter service later this year, is undergoing testing and commissioning.
Staff have also undertaken specialised high-voltage technical training in recent weeks to prepare them for the growing electric bus fleet.
Recently, a $1.65 million contract was awarded to JET Charge to install charging infrastructure at the Elizabeth Quay Bus Station.
The investment to deliver the new electric bus fleet in Western Australia directly supports more than 100 local jobs, including nine apprenticeships.
All 18 new electric CAT buses are expected to be in service by the middle of 2025, with each bus able to travel up to 300 kilometres on a single charge.
The final approval for Senex Energy’s $1 billion expansion of its Atlas and Roma North projects to boost domestic gas supply has been granted by the Federal Government.
The project is expected to deliver 60 PJ of natural gas per year from 2025, representing more than
10 per cent of annual east coast domestic gas requirements.
During the expansion, 900 Queensland jobs, including 200 ongoing jobs in sectors such as manufacturing, are expected to be created.
Resources and Critical Minerals Minister Scott
Stewart said the approval of the project is an example of how Queensland continues to contribute significantly to the domestic supply of renewable gas.
“Unlocking more gas and supplying it to the domestic market is critical for both households and our manufacturing industry,” said Stewart.
More than 20,000 kilometres of land has been released to shore up Australian gas supply since 2017 in Queensland.
Renewable energy backed up by up to 3GW of hydrogen-ready gas generation, will help reduce electricity emissions by 96 per cent by 2040.
Senex has already secured eight long-term supply agreements for the project with Australian manufacturers like CSR to support the expansion.
The Queensland Energy and Jobs Plan identifies up to 3GW of low to zero emissions hydrogen-ready gas generation to provide backup as Queensland builds a renewable electricity grid.
Renewable energy is set to provide 80 per cent of electricity needs by 2035, with long-duration hydro energy storage storing enough energy to end reliance on coal generators.
The first electric bus was built at the Volgren facility in Malaga, Perth.
The project is expected to deliver 60 PJ of natural gas per year.
DroneShield awarded $4.7 million contract
DroneShield has received an order of $4.7 million from a Swiss international customer to provide multiple vehicle-based counter-drone (C-UxS) systems.
The vehicle-based solution will offer a rapidly deployable C-UxS platform that can be operated in both static and on-the-move (OTM) missions for convoy and mobile VIP protection.
Payments are expected to be received throughout 2024, with the final payment expected in Q1 2025.
The product will incorporate DroneShield’s radio frequency detection and mitigation, radar, and electro-optical sensors into a single vehicle-based platform.
The system will be powered by the DroneSentry-C2 command-and-control system, including its proprietary AI-based sensor fusion engine.
DroneShield CEO, Oleg Vornik, said the company is excited to have the new customer on board.
“This order highlights DroneShield’s expertise not only as a maker of cutting-edge AI-based C-UAS sensor and effector technologies, but also as a system integrator for demanding applications that involve multiple sensor and effector modalities, operating in tough conditions,” said Vornik.
“We are excited to have this new customer on board and look forward to doing more work with them over the coming years.”
The system will be powered by the DroneSentry-C2 commandand-control system.
ADF tests first energy-directed weapon
Image: CPL Jacob Joseph / Australian Government Defence
The Australian Defence Force’s first directed-energy weapon, the Fractl Portable High Energy Laser, has been developed and is now in its testing phase.
Corporal Patrick Flanagan was given a ‘soldier’s five’ before he successfully shot down a drone.
“You push a button to track the drone and the computer takes over, then you push another button to ‘pull the trigger’ just like a video game,” said Flanagan.
device, and hundreds of metres away, a drone falls out of the sky in a tiny puff of smoke.
Melbourne company AIM Defence designed the suitcase-sized laser that works like a blowtorch travelling at the speed of light.
At the Puckapunyal demonstration, the team ‘hard killed’ a drone at 500m with a deployable prototype.
While the laser’s strength is limited by power supply, AIM Defence has successfully engaged drones at 1km in past tests.
Robotic and Autonomous Systems
Implementation and Coordination Office’s warrant officer class two, Eli Lea, said the device could be one of many emerging weapons on future battlefields.
The Fractl Portable High Energy Laser is powerful enough to burn through steel and can track objects as small as a 10-cent piece travelling at 100km/h a kilometre away.
It’s silent, virtually motionless, and soldiers can be taught to use it in minutes.
Last month, the weapon system was put through its paces for senior officers looking to expand the ADF’s counter-unmanned aerial system arsenal.
“With your index finger, you can quickly change your aim between the drone’s video camera, centre mass, or one of the propellers.
“It only takes seconds to knock out the camera and two or three seconds to disable the rotor.”
A soldier presses a button on a small handheld
“Drones come in all shapes and sizes, and you need a variety of tools to defeat the threat,” said Lea.
“Shooting small multi-rotor UAS out of the sky is particularly challenging. A directed-energy weapon that can detect, track, and engage those types of targets is a part of that toolset.”
Directed-energy weapons are one way Defence is embracing emerging technology to counter off-theshelf small multi-rotor uncrewed aerial vehicles.
State Budget unveils investment into TAFE NSW
Manufacturing is among the industries that will receive monies from a $2.5 billion investment into TAFE NSW as detailed in the 2024-25 NSW Budget.
The skills sector is essential for delivering the homes NSW needs, facilitating a renewable energy future, and reinvigorating the State’s domestic manufacturing sector.
A strong TAFE allows us to up-skill the next generation of apprentices and trainees and re-skill existing workers.
The state Government is investing up to $16.3 million to continue fully subsidised training for all apprentices and trainees.
This initiative has the potential to remove barriers for employers and those seeking employment and addresses the cost-of-living pressures facing the emerging skilled workforce.
The demand for trained workers continues to grow, with NSW needing thousands of skilled professionals across healthcare, hospitality, construction, renewable energy.
This investment will ensure that anyone who wants to access vocational education and training can afford to do so.
The funding also targets the skills shortages facing the State by ensuring talented teachers are enticed and retained in NSW TAFEs.
The 2024-25 NSW Budget also includes an $83.1 million boost to support the conversion of 500 casual teachers to permanent employment.
The Budget will also address infrastructure needs to ensure teachers and learners have access to modern facilities and teaching equipment.
This includes $190 million to undertake repairs at campuses across the State, upgrade 5,000 digital devices, and improve Wi-Fi at 40 campuses.
The investment has the potential to enable TAFE NSW to better support the needs of industry and the community.
AIM Defence designed the weapon that works like a blowtorch travelling at the speed of light.
The new TAFE funding is set to up-skill the next generation of apprentices and trainees.
Becoming Australia’s only solar panel manufacturer
Manufacturers’ Monthly spoke with Richard Petterson, CEO of Tindo, to learn more about his company’s journey in becoming Australia’s only solar panel manufacturer.
Tindo, an Adelaide-based company in South Australia, specialises in manufacturing high-quality solar panels for residential and commercial use.
Founded in 2010 by Adrian Ferraretto, the company was named after the Kaurna Aboriginal word for “sun.”
Currently, Tindo is Australia’s exclusive solar panel manufacturer.
“We’re privileged to currently be Australia’s only solar panel manufacturer,” said Tindo CEO, Richard Petterson.
Tindo’s unique position as the sole solar panel manufacturer in Australia is a result of its history of persevering through challenges posed by global competitors.
The technology used in most contemporary solar
panels was developed in Australia, when a group Australian researchers pioneered solar photovoltaic technology, converting sunlight directly into electricity.
Martin Green and his team at UNSW invented the Passivated Emitter and Rear Cell (PERC) in 1983, which now powers around 90 percent of global solar panels.
Despite the technology being developed in Australia, free trade has since hindered local production of panels due to cheaper imported products.
China strategically invested in solar manufacturing utilising this technology and now dominates the global supply, producing around 90 percent of the world’s solar panels.
“The solar industry’s development has been
heavily subsidised by governments underpinning rapid growth,” Petterson said.
“There was 20 years of investment in China.”
Petterson said that Tindo has survived in the face of immense global competition due to its unique value proposition.
“Tindo remains successful because we focus on delivering a high-quality product with long-term performance,” he said.
Petterson explained that Tindo’s direct relationship with end-users contributed to the company’s success and survival.
“Our direct sales approach in South Australia has been crucial, allowing us to deeply understand customer needs,” he said.
This direct connection with customers has helped Tindo better understand it’s client’s needs
Richard Petterson (right) oversees production at Tindo’s Adelaide facility, Australia’s only solar panel manufacturer.
Image: Tindo Solar
and apply this knowledge effectively in their manufacturing process.
“We believe in understanding the end product and customer needs better and how they are applied. We don’t just make solar panels; we design solutions for people as well,” said Petterson.
Materials come first
While also grappling with the challenges of global competition, Tindo faced challenges in accessing the appropriate materials, particularly as the industry trended offshore.
“At Tindo Solar, we’ve confronted daily challenges, particularly in securing the right materials and adapting to offshore trends since our inception 15 years ago,” said Petterson.
“We must ensure that we source materials that meet our standards to create high-value, highperforming products.”
Quality control is crucial, not just during manufacturing but also throughout the supply chain.
Tindo also faced significant design challenges, such as identifying and addressing weak points and underperformance issues.
However, these early learnings allowed Tindo to ultimately improve its design and manufacturing processes.
“We faced design and performance hurdles, but these experiences shaped our rigorous quality standards and improved manufacturing processes today,” said Petterson.
“Quality control is paramount, both in production and throughout our supply chain. Training our workforce from scratch has been a continuous effort, given the lack of a local solar panel industry in Australia.”
Another key challenge is training their workforce. Since there’s very little industry in Australia, specifically for solar panel manufacturing, they must train their workers from scratch.
Making high-quality solar panels is a specific skill that can only be learned on the job with Tindo, through their training and hands-on experience.
“There aren’t similar industries to draw from. Making a high-quality, reliable panel requires very specific skills that can only be learned through hands-on experience and Tindo’s training,” said Petterson.
“Currently, we boast a strong engineering team, many of whom have been with the company for over 11 years.”
Petterson explained that their current workforce of 65 people could scale up to around 300 if they achieve their production goals.
The processes
By 2017, Tindo underwent a change in ownership, with Glenn Morelli assuming ownership.
Since then, Tindo has enhanced its manufacturing capabilities with a state-of-the-art facility, pioneering advancements in solar panel production in Australia.
Currently, Tindo’s facility in Adelaide has the capacity to manufacture 150 megawatts of solar panels.
Technicians oversee precision manufacturing at Tindo’s cutting-edge solar panel facility in Adelaide.
MANUFACTURER FOCUS
Their future objective is to eventually scale up their production even further to 1000 megawatts, which is equivalent to 1 gigawatt.
Tindo journey has the potential to be significantly bolstered by the new strategic Government support and funding initiatives, as well as research and development initiatives.
“We continuously invest in research and development to innovate and introduce new products,” said Petterson.
The Australian Government has played a crucial role in fostering the country’s renewable energy sector. However, support for local renewables manufacturers has been limited, with Tindo only receiving one grant since its inception.
Thankfully this is changing and a shift in government thinking to recognise the importance and value of domestic manufacturing capabilities is bringing Tindo closer to achieving its goal.
“We’ve been actively collaborating with various levels of Government to stimulate Australia’s renewable manufacturing sector,” Petterson said.
“Currently, Australia installs between five to six gigawatts annually across residential, commercial, and utility sectors.
“The Government aims to produce 20 per cent of future solar panel demand domestically, which seems achievable given the scale needed to meet ongoing requirements over the coming decades.”
These new initiatives mark a turning point in Australian manufacturing, with governments increasingly supporting industries shifting towards sustainable practices.
Petterson said that while Australia historically relied on abundant fossil fuels like coal and gas for energy security, the nation is now shifting towards renewables like solar, wind, and green hydrogen.
“Australia has been fortunate to possess abundant fossil fuel historically sufficient to meet its energy needs for a prolonged period,” said Petterson.
“However, we are now transitioning away from these resources towards a renewable energy future.”
This transition underscores the significance of strengthening domestic manufacturing capabilities to secure supply chains.
As Petterson emphasises, it also presents an opportunity for Tindo to expand its production capacity.
Tindo aims to scale production to 1000 megawatts, enhancing Australia’s renewable energy capacity.
However, the company has encountered challenges stemming from supply chain issues and limited access to local suppliers.
“I think that it’s a real opportunity for us right now, because we are the only ones who are in a great position to be able to work with the Government around a solid SunShot programme,” said Petterson.
Navigating the complexities of global supply chains has thus been a pivotal challenge for Tindo.
Despite Australia’s abundant solar resources, the lack of local suppliers for critical components means Tindo must look elsewhere in the short term.
Petterson explained that Tindo is often compelled to rely on international supply chain due to limited local options in Australia for components such as aluminium frames and glass.
Tindo is actively working to change this landscape by engaging in ongoing discussions with local suppliers.
Its aim is to establish domestic sources for these materials and even explore opportunities for local production of essential components such as silicon and wafers.
“Strategically, it makes a lot of sense for Australia
to start thinking differently about that element,” said Petterson.
“As we know, it doesn’t take much of a disruption in the global supply chain to significantly impact key drivers, as seen with the COVID pandemic and the war in Ukraine.
“This includes not only making solar panels but also producing the essential components like cells and silicon to balance the supply chain.”
“We are in discussions with local suppliers to potentially source these materials domestically, and there are ongoing conversations about establishing silicone and wafer manufacturing locally,” said Petterson.
Petterson continued to explain that Australia’s manufacturing sector has declined from 25 per cent of GDP in 1985 to 6 per cent today, and its economic complexity has also decreased.
He said that the country needs to rebuild its capabilities and develop a more robust economy.
“Australia needs to plan over a 10 to 30-year horizon, rather than relying solely on a free market approach, which is no longer realistic given what other countries and their governments are doing in terms of industrial policy,” said Petterson.
Petterson believes that Tindo could potentially
meet 20 per cent of the nation’s solar energy demands within the next five years, but that ultimately hinges on Government support.
“The remainder of the supply chain might take a bit longer to scale, depending on how well the Government positions itself,” he said.
“With the right support from the Government, it is certainly achievable. This requires a longer-term view.”
Petterson expressed optimism about Tindo’s role in shaping Australia’s renewable energy future, advocating for long-term planning and sustainable development practices to drive meaningful change across the industry.
Apart from Government initiatives, Tindo has many strong partnerships to work through, including several educational institutions such as the University of New South Wales, the University of Adelaide, and the University of South Australia, where they are located.
The primary goal of these partnerships is to catalyse innovation within the renewable energy sector and subsequently commercialise those advancements.
“Our existing collaborations create a space for innovation and industry to take their ideas to the
Tindo’s workforce of 65 could potentially expand to 300 to meet future production goals.
MANUFACTURER FOCUS
transparently and proactively,” said Petterson.
“If we discover a problem with a product, we collaborate with them to conduct root cause analysis.
“We then transparently report back to our customer about what happened and what we’ve done to rectify the issue.”
The company aims to meet 20 per cent of Australia’s solar energy demand with proper government support.
RENEWABLE ENERGY
A vision for decarbonisation with renewable gases
Manufacturers’ Monthly spoke with Mike Davis, managing director of Optimal Renewable Gas,
to discuss the
potential usage of renewable gas in manufacturing sectors.
Renewable gas is the umbrella term now used globally to describe gases produced from renewable energy sources, such as biomethane and hydrogen.
Optimal Renewable Gas (ORG) is an Australianbased company that provides renewable gas solutions for businesses.
It advocates for the usage of sustainable gases such as biomethane.
Biomethane is derived from organic waste through anaerobic digestion and is upgraded to a quality akin to natural gas.
It is touted for its potential to reduce emissions by converting waste into usable methane for various energy applications.
Leading the charge
ORG’s mission is to deliver renewable gas directly to consumers via existing gas networks – whether through pipelines or virtual pipelines – offering a straightforward, eco-friendly, and cost-effective alternative to traditional fossil fuel natural gas.
“We are a large-scale developer of anaerobic digestion facilities, primarily focused on producing biomethane for injection into the gas grid,” said Mike Davis, managing director of ORG.
“We’re based in New South Wales and our major shareholder is Optimal Group, an industrial and energy solutions business headquartered in Melbourne.”
Davis explained the company is planning to develop large-scale “bio hubs” within the next decade.
“We have a national focus, planning to develop 10 large-scale bio hubs across the east coast of Australia by 2030 in Tasmania, Victoria, South Australia, New South Wales, and Queensland,” he said.
Biomethane injection to the energy grid can provide an array of benefits for business and industry, large and small.
A sustainable solution
For example, in manufacturing, biomethane provides reliable, continuous energy without infrastructure changes.
It has the potential to reduce costs, support sustainability goals with minimal emissions, and offers byproducts like biogenic CO2 for renewable
fuels and industrial use and nutrient-rich digestate for agricultural use.
“First, our approach establishes a circular economy at scale by focusing on biomethane for the grid,” said Davis.
“By aggregating feedstocks to acheive scale, we can additionally commercialise by-products like biogenic CO2 and digestate.
“A renewable molecule like biomethane has intrinsic value for meeting energy demand, distinct from intermittent sources like wind and solar, due to inherent storage in the gas infrastructure supply chain.”
Collaborating with Jemena
ORG has signed an MoU with the energy asset owner and network operator, Jemena, to deliver projects across the NSW gas distribution network.
“We’ve entered into an MOU to deliver three projects around the NSW gas distribution network. This agreement enables us, as developers, to integrate feedstocks, logistics, technology, and financing to bring these projects to fruition,” said Davis.
“The MOU facilitates close cooperation during the early assessment and development phases of these projects.”
Jemena owns and manages $12.4 billion of critical gas and electricity assets across Australia’s Eastern Seaboard.
The company provides essential services to millions of households and businesses daily.
The Jemena network distributes natural gas
to over 1.5 million residential, business, and industrial customers across Sydney, Newcastle, the Central Coast, and Wollongong, as well as to more than 20 other regional centres. These include the Central West, Central Tablelands, Southern Tablelands, Riverina, and Southern Highlands regions.
Davis explained gas infrastructure partners like Jemena are essential for ensuring a dependable connection and proper injection.
“Collaboration with the gas infrastructure is crucial to ensure reliable connection and injection of gas into their network,” said Davis.
He expects the three collaborative projects with Jemena to be delivered late this decade and anticipates many more projects will be delivered over the next five years as the industry scales up, with many more projects expected.
“Our first major project is scheduled to deliver first gas by 2027. Following this milestone, we aim for a staggered progression of project deliveries approximately every six months thereafter,” said Davis.
“Our focus initially is on navigating the approval process for the first project, with plans to replicate this success in other regions.”
The potential for decarbonisation
By replacing these traditional energy sources like natural gas, biomethane can contribute to a reduction in greenhouse gas emissions and other pollutants.
Davis explained that even relative to other
Image: Jemena
Jemena’s biomethane injection plant, located in Malabar, NSW.
sustainable choices, like hydrogen, biomethane would generally be more beneficial.
“At the moment renewable hydrogen is too expensive for Australian manufacturing,” he said.
“To keep domestic manufacturing industries competitive we need to establish alternative decarbonisation pathways for industrial heat, noting not all industrial demand can be easily or affordably electrified.
Davis envisions that a portion of Australia’s gas usage could be from biomethane.
“Based on our analysis of accessible feedstocks near gas infrastructure, we believe around 30 per cent of Australia’s current domestic gas use could be met by biomethane,” he said.
“There are reports suggesting it could be much higher. For instance, the Race for 2030 report indicates that 371 petajoules are available in terms of accessible feedstocks, while other reports estimate over 1000 petajoules.”
Barriers for biomethane
What’s stopping biomethane from becoming more widely used? Davis thinks that the State and Federal Governments could have a more technology agnostic approach that would help make biomethane more accessible for industrial users.
“In my background, spanning over 15 years
in the gas and energy industry, I’ve worked extensively in gas infrastructure including, natural gas, hydrogen and biomethane as well as commercial and industrial solar.
“My conclusion is that biomethane is the lowest cost renewable gas that can be readily supplied to existing industrial users”
Davis raised concerns over the recent federal budget, as allocations overwhelmingly prioritised hydrogen development and future manufacturing.
“The federal government has strongly emphasised gas’s future role, highlighting biomethane and hydrogen,” he said.
“In my discussions with industrial users, there’s concern about the lack of policy support for existing businesses to access lower-cost renewable gas, particularly biomethane.
“Compared to renewable hydrogen, biomethane is a complete “drop-in” replacement for natural gas, it offers lower development costs, lower technology risks, and utilises proven technology that is being used extensively across Asia, US and Europe, and allows customers to use existing appliances and equipment without modifications.”
Davis explained that hydrogen is likely to play an important future role but there are initial challenges relating to the capital cost of plants and accessing sufficient low-cost renewable electricity to viably produce renewable hydrogen.
The compact integrated system for safety gate monitoring
“I think it’s related to this narrative that assumes how cheap renewable electricity is without fully accounting for the entire supply chain costs – from production to storage, utilisation, and market integration,” said Davis.
“There has been a prevailing idea that you can capture sunlight and export it, but honestly, I don’t think people have done the maths.
“With hydrogen, there are many assumptions that sound like a silver bullet. This isn’t to downplay hydrogen’s importance in the future energy mix, but I question the current level of investment in it.”
In a statement to the industry, Davis said to reach decarbonisation goals effectively, Australia should become more open-minded and not favour one specific source of energy over another.
“It’s crucial to recognise that renewable gas solutions, such as biomethane and other biogenic fuels, play a significant role that shouldn’t be overlooked,” he said.
“The focus on hydrogen, while important, currently poses cost challenges for Australian manufacturing.
“To keep these industries competitive and achieve effective decarbonisation, we must also address industrial heating needs.”
Safety gate monitoring, safe interlocking, guard locking and control elements in a compact system.
Electromechanical
Safe interlocking and guard locking up to PL e, CAT 4
Compact: 40 x 65 x 238 mm
Rapid diagnosis with 4 LEDs and diagnostics output
Holding force up to 7500 N
Optimising manufacturing with HMI panels
SIMATIC HMI Unified Basic Panels set a new standard in industrial automation, streamlining data communication and visualisation.
SIMATIC HMI (Human-Machine Interface)
Unified Basic Panels, manufactured in Europe by Siemens, enables users to streamline data communication between machines and humans.
The panel, distributed by APS Industrial, is part of a family of ‘unified panels’ manufactured by Siemens.
These panels are part of the Siemens’ Human Machine Interface (HMI) portfolio, designed for monitoring, control and visualisation in industrial automation applications.
The interfaces are used to monitor and manage machines and systems effectively.
“Siemens has created a unified landscape for all HMIs, enabling us to access and visualise better data faster and more efficiently,” said Matthew Buser, product manager for factory automation products at APS Industrial.
“In today’s digitalisation space, this capability is essential.”
In manufacturing, HMI panels enable operators to quickly respond to issues, subsequently improving
operational efficiency and ensuring consistent product quality.
The SIMATIC Unified Basic Panels fully integrate with the Siemens family of factory automation products, including S7-1500 controllers and SINAMICS G220 variable frequency drives. This ensures seamless visualisation of data to empower operators to make informed and effective decisions.
Data visualisations can effectively simplify complex data into visual formats, making patterns and trends easier to identify and understand, thus aiding in informed decision-making and effective communication of insights.
This can all be done in real-time with Siemens Unified Basic Panels.
These panels not only simplify data interpretation but also enhance accessibility to vital information through their intuitive touchscreen interface.
“Typically, engineers can create their own graphics to display data specific to their applications,” said Buser.
“These panels come with standard objects that can be used to design these graphics, however engineers can customise these visuals based on the specific process data they want to display.
Siemens, through its master distributor in Australia, APS Industrial, offers an HMI solution for every application.
Siemens Unified Basic Panels come with various mounting options, certifications, and device variations, which allows for use in all environmental conditions.
Available in four display sizes from 4” to 12”, all models have the same performance, the same number of hardware interfaces and the same functionality.
Information from these panels can also be accessed remotely through standard consumer devices like smartphones and tablets.
The maintenance-free web client offers flexible remote access to the visualisation, independent of on-site device operation.
Images: APS Industrial
This is all accessible through a web browser, with no additional software required.
“In production environments today, there’s a significant shift towards edge technology, allowing for remote access across different plants and locations,” said Buser.
“This connectivity underpins Industry 4.0 advancements across industries, enabling seamless communication and operations management from afar.
“This means businesses can efficiently monitor and control processes across their operations remotely, improving overall efficiency and responsiveness.”
Addressing cybersecurity concerns
Naturally, with connected devices, there are inherent security concerns, considering the device has access to important information.
Buser explained that Siemens, with its experience in manufacturing, has established itself as a global leader in cybersecurity management.
“Siemens is at the top of the tree in terms of cybersecurity management,” he said.
“They are market leaders globally, both within their own organisation and in the products they sell.
“Buzzwords like ‘digitalisation journey’ and
‘Industry 4.0’ were coined with their influence.”
Buser said that Siemens understands that for businesses to be successful in a digitalised world, processes need to be safe and secure.
“While nothing is ever 100 per cent secure, choosing Siemens gives you the best chance to mitigate those risks.”
Victoria’s Big Build with Siemens and APS
Siemens HMI panels are being utilised in the construction of concrete tunnel segments meant for the Northeast Link, one of Victoria’s largest infrastructure projects.
The Northeast Link represents the largest investment in Melbourne’s northeast, transforming how people navigate the city.
As part of Victoria’s Big Build, it encompasses three major road projects.
The 6.5km Northeast Link tunnels, stretching from Watsonia to Bulleen, will address a critical gap in Melbourne’s freeway network, removing 15,000 trucks from local roads daily and reducing travel times by up to 35 minutes.
Additionally, the project includes upgrades to the Eastern Freeway and M80 Ring Road, featuring new lanes, smart technology, and a seamless connection to the Northeast Link tunnels.
This program is meticulously planned to ensure
the projects open in 2028, integrating all components of the Northeast Link.
The tunnel segments are being manufactured at the LS Precast site, which was revamped with Siemens products, with the assistance of APS Industrial.
“The large concrete batching plant here on-site previously had two different SCADA systems running on two different PLC networks,” said Steve Bleijswijk, director at Deacam.
“We had to design the static mould vibration system from scratch, where we leaned heavily on Siemens and APS to provide us with variable speed drives, motor protection circuit breakers, and other panel accessories.”
All of which, can be interfaced with Unified Basic Panels.
As Bleijswijk explained, APS doesn’t just provide Deacam with access to high standard automation equipment from Siemens; it also provides a great service.
“APS provides us with world-class technology, along with product support for that same technology,” he said.
“Without those guys, we really wouldn’t have ended up with the solution that we’ve got here.
“We’ve got a great relationship with them, and they’re invested in our outcomes.”
Siemens SIMATIC HMI Unified Basic Panel enhances efficiency with intuitive touchscreens, customisable visualisations, and remote access.
Airshow set to showcase aviation excellence
The Avalon Airshow 2025 returns to Victoria’s Avalon Airport, featuring a six-day lineup of exhibitions, air displays, and cutting-edge conferences in both civil and military aviation.
The Avalon Australian International Airshow, Australia’s largest aerospace and defence industry event, will return to Avalon Airport in Victoria in March 2025, in a six-day program of displays, exhibition and conferences across the spectrum of civil and military aviation.
Held every two years, Avalon is Australia’s equivalent of the legendary Paris and Farnborough airshows, with numbers to match: Avalon 2023 saw 794 participating exhibitor companies, around 280 official industry, government and scientific delegations from more than 30 countries, 59 conferences and more than 300 aircraft on display in the air or on the ground, from homebuilt light aircraft to heavies such as the Boeing C-17. There were more than 48,000 attendees across the event’s industryonly days, with the weekend public airshow swelling total attendances to around a quarter of a million. The flying display was a celebration of Australian and international expertise, featuring Australian F-35 Lightning and transport aircraft, the Republic of Korea Air Force Black Eagles display team in its first Australian appearance, and the final display flight of the official US Air Force display pilot tasked with demonstrating the Lockheed Martin F-22
Raptor fighter aircraft’s capability, before handing over to his successor.
The first three days are industry-only exhibition days, devoted to the business of aerospace. Day four becomes a hybrid business and public day, with gates opening to the general public in anticipation of the world-famous Friday Night Alight evening airshow. This is followed by two weekend days of
public airshow, with vintage and veteran, warbird, and modern military aircraft sharing the display with civil aerobatics teams, parachutists and gliders. And it’s growing. Exhibition space sold out in 2023, so the exhibition footprint has grown by a third for Avalon 2025, with the addition of a fourth exhibition hall. This will be complemented by updates to external exhibition spaces, a new Executive Business
The C-17 Globemaster III’s flight demonstration at the Avalon Airshow showcased its remarkable capabilities.
Industry comes to the Avalon Airshow to sell, to learn and to network.
Unit product for industry and a repositioned corporate chalet line to improve links to the industry exhibition halls.
This is Australia’s signature aerospace industry event, renowned for the engagement opportunities created by the sheer concentration of industry, government, defence and academia.
With the latest military aircraft, business jets, commercial aircraft, helicopters and light aircraft displayed on the flight line, industry promotes its products and services in the exhibition halls and external display areas. International household names exhibit alongside SMEs and start-ups, offering industry at all levels an opportunity to connect with customers, suppliers and partners.
This is where conversations can, and have led to, multi-million-dollar contracts and the smart small company can be noticed by the big end of town.
Avalon is an industry melting pot for sales, product launches, customer relationship development and market research, for seeking out potential suppliers and for studying major competitors.
And it’s not just industry that sees the benefit.
Avalon provides a unique interface between defence and industry, with international delegations and dignitaries from air forces around the world interacting with the Royal Australian Air Force on
programs that improve mutual communication with our allies and international partners.
“International relations are built on trust, and it’s the personal connections that you make at events such as Avalon that allow you to pick up a phone and resolve an issue before it becomes a crisis,” said then Australian Chief of Air Force, Air Marshal Robert Chipman, AM, CSC, at Avalon 2023.
The industry exhibition is complemented with a conference program on a range of issues across industry, defence and government. The 2023 program included presentations from the Australian Chief of Air Force, Australian Association for Uncrewed Systems (AAUS), Australian Space Agency, Austrade, Royal Aeronautical Society, Department of Defence, CSIRO, Aviation Australia, United States Commercial Service, Royal Australian Air Force and Air bp, and more than 50 other organisations from airport design companies to flight test and engineering societies.
Avalon celebrates the breadth of flight, from private aircraft to space and military. Avalon 2023 celebrated the centenary of the first flight of the autogyro, with a contingent of autogyro aircraft from Australian clubs and associations.
Avalon 2025 will mark the centenary of the first flight of the De Havilland Moth series of aircraft in
February 1925. The later DH-82 Tiger Moth served Australia in a variety of civil and military roles through and beyond World War Two and is still making a living today across various scenic flight operations around the country.
Avalon also contributes to finding and encouraging the next generation of products and people. The showcase will include a $100,000 Innovation Awards program and formal Careers and Skills events connecting industry with students of all ages to encourage STEM study and careers pathways.
“The week of Avalon has a special atmosphere, a feeling of being involved in something quite out of the ordinary,” said Justin Giddings, CEO of Avalon Airshow organiser AMDA Foundation.
“There’s a sense that the entire aviation community, including the Royal Australian Air Force, major aviation-related government departments, support organisations and industry associations are in residence at Avalon for that week. People are of course promoting their own aircraft, products and services, but there’s also a collegiate community atmosphere, with Avalon acting as a barometer for the health and future of the whole industry.
“All this happens with regular flying displays demonstrating some of the most advanced civil and military aircraft in the world.”
The 53rd Air Demonstration Group, known as the Black Eagles, represents the flight display team of the Republic of Korea Air Force.
Ciltech and Capral forge a path towards sustainable jetty systems
Ciltech, a jetty and pontoon manufacturing specialist, relies on sustainably produced aluminium from their supplier, Capral Aluminium. Manufacturers’ Monthly reports.
Ciltech, a West Australian company, specialises in delivering products and services to the marine, mining, and construction industries. Their core expertise lies in designing, manufacturing, and constructing floating jetty systems for government, residential, and commercial applications.
Ciltech initially focused on importing and exporting high-quality steel and high-density polyethylene (HDPE) products to marine and mining businesses. In 2017, under the Global Trade Sales (GTS) banner, the company expanded into marine consultancy and steel manufacturing, collaborating with ACH Global on the design and construction of
an offshore conveyor jetty for Metro Mining’s Bauxite Project in Queensland.
Returning to their origins in 2019, under GTS, Ciltech refocused on developing and manufacturing jetty systems, or more specifically, pontoons.
Eventually, GTS transitioned/merged into Ciltech when Leno Cilia and Mason Cilia partnered following their tenure at GTS.
“It actually began in 2022 and was a sort of a transition merger of an associated entity called Global Trade Sale,” said Cilia.
“Ciltech was a realignment of that to better represent what our product and services are because we don’t want to just be any company.
“We want to be a brand of products which are purpose fit for the marine industry.”
Now, both Leno and Mason Cilia co-direct Ciltech, each bringing a set of unique skills to the company.
Leno brings over 30 years of experience as a successful businessman and Director, showcasing a high level of professionalism.
Mason Cilia is a dedicated professional engineer with more than five years of maintenance engineering experience in the rail and mining industries, and over eight years of design and engineering expertise in jetties and marine systems.
The Cilias both have extensive family history and experience in marina manufacturing.
From design to delivery, Ciltech ensures precision and quality at every step.
Images: Capral
Mason, speaking on his earliest experiences with his father and brother, he said: “Even at a young age—maybe around 11 or 12—I was involved in boat shows, helping out with cleats and other tasks, like assisting in their construction.”
“The Royal Perth Yacht Club stands out as one of the major projects we’ve undertaken in the past.
“I must have been around 15 years old at the time, assisting my brother in constructing the marina. It’s a project that holds a lot of memories for me.”
Since the establishment of Ciltech, the company has seen two major developments in their manufacturing process.
“One of the two biggest developments is probably putting more emphasis on sustainability and reducing carbon on the aluminium aspect and the HTPE side,” he said.
“Just using something like Carpal’s LowerCarbon Aluminium (LocAl), we can reduce carbon emissions up to 76 per cent in our framework, that’s a lot of reduction of CO2. We’re also exploring the use of more environmentally friendly materials to replace polystyrene and foams, prompted by events like the Queensland flood which caused polystyrene pollution.”
The jetties
Ciltech manufactures jetties in standard sizes of 8m, 10m, and 12m lengths, with widths ranging from 2m to 3.5m.
These dimensions cater to typical requirements,
but, as Cilia explained, custom sizes can also be tailored to meet unique customer needs.
All jetties consist of an aluminium framework, HDPE floats, and FRP decking.
The jetty design incorporates floats underneath, enabling it to adjust with varying tide heights.
This flexibility is complemented by secure fastening using piles and/or moorings, ensuring stability in diverse marine environments.
For Ciltech, an important aspect of the manufacturing process is their commitment to sustainability.
Recently, the company’s efforts are being concentrated on promoting sustainable products primarily to government clients.
“Sustainability is something that we all should work on because, unfortunately, as humanity, we’re always going to be consuming,” said Cilia.
“We need to come up with more sustainable approaches. The marine industry, unfortunately, has predominantly used polystyrene, even though Australian standards are now pushing for more sustainable materials.”
This industry shift towards sustainability necessitated Ciltech’s decision to partner with Capral.
“Capral provided us with all the information on their LocAl materials, and we were quite interested because it aligns well with our product.”
“It made sense to approach and see if the Department of Transportation (DOT), for example, would get into it, and they seemed keen.
“Hopefully, the next project, estimated to involve 18 tonnes of aluminium, will include our entire product range.”
As Cilia explained, he wanted the supply chain to be mostly Australia-based.
“Our previous products are widespread across Australia, but our latest innovations are primarily focused on the WA market currently,” he said.
“However, we are eager to expand nationwide and are actively seeking opportunities to do so, with a strong emphasis on Australian and locally based products.”
Cilia expressed that the most rewarding aspect of producing jetties and pontoons lies in the design and engineering facets of the manufacturing process.
“A couple of things: I genuinely enjoy the design and engineering aspects, working with our fantastic team, and being part of this community,” he said.
“I have a real passion for our products, which drives our continuous investment and innovation.”
Ciltech’s projects
When it comes to ambitious and large-scale marine projects, Ciltech’s recent undertakings at Fremantle Fishing Boat Harbour and Hillary’s Boat Harbour stand out.
“In the past two years, our most significant projects have been Fremantle Fishing Boat Harbour and Hillary’s Boat Harbour for the WA DOT, said Cilia.
“At Hillary’s, we used approximately 55 tonnes of aluminium for frames and pontoons across a total area of about 2,500 square meters of jetties.
Ciltech’s core expertise lies in the design, manufacture, and construction of floating jetty systems for government, residential, and commercial applications.
ALUMINIUM
“Fremantle Fishing Boat Harbour, while slightly smaller, was still a substantial endeavour.”
Cilia explained that DOT consistently returns to Ciltech because their products are always of high quality.
“We’ve been doing a lot of work for the Department of Transport for quite some time through the previous director, Lene Ocilia, who’s been working with the department for about 20odd years at this point,” he said.
“They keep coming back to us because we consistently deliver high-quality products, and they love our service.”
Cilia said that he often hears positive feedback from residential and commercial customers.
“We’ve received numerous compliments on our projects. For example, at Hillary’s, penholders loved the new Marina and floating jetties compared to the old ones,” he said.
“Upgraded systems are clearly beneficial, especially for those renting pens.
“We frequently get positive feedback from residential customers as well. Recently, a customer in Pinjarra called to express their satisfaction with their new system.”
Jetty manufacturing
The manufacturing team at Ciltech comprises four to six personnel in the workshop, staffing levels are adjusted according to current labour needs.
As Cilia explained, before the manufacturing process begins, the customer will approach the company and initiate the design phase.
The company offers standard systems and sizes, but customers often want to customise their desired products.
“We offer a standard set of systems and sizes
The manufacturing team adjusts staffing based on labour needs and manages everything from customer design to material procurement and assembly.
LIGHT MANUFACTURING
Lightforce Group supplies Theon Sensors night vision equipment to the ADF
Force Ordnance, a division of Lightforce Group, has partnered with Theon Sensors S.A. to supply binocular night-vision devices to the Australian Defence Force’s Dismounted Combat Program.
Lightforce Group’s defence arm, Force Ordnance, has leveraged its partnership with the world-leader in customisable night vision and thermal imaging systems, Theon Sensors S.A, to supply 120 advanced binocular night-vision devices to the ADF’s Dismounted Combat Program, Army Headquarters.
Force Ordnance personnel delivered ‘train-thetrainer’ instruction, qualifying ADF instructors at both the Royal Military College, Duntroon and the School of Infantry, Singleton in the use of
the equipment. The non-ITAR restricted nightvision devices allow sharing of technology and collaboration with Australia’s regional strategic partners.
Lightforce signed an exclusive agreement with Theon Sensors in 2018, paving the way to manufacture, assemble, test, distribute and provide through-life support and maintenance of Theon Sensors products at its Adelaide manufacturing facility.
The Royal Military College and School of Infantry
now fields the latest generation night vision devices, superseding the current in-service ITAR regulated device.
Force Ordnance’s Defence Programs Manager, Paul Mason, said that the agreement with Theon has opened the door for the ADF to access the latest technology in night vision and thermal imaging without the restrictions and complexities of the ITAR controls.
“Theon night vision and thermal devices are currently in service with a host of militaries
Advanced binocular night-vision devices supplied to the ADF’s Dismounted Combat Program by Force Ordnance and Theon Sensors S.A.
“ ”
Theon Sensors is deeply committed to the Australian Industry Capability (AIC), ensuring that our partnership with Lightforce not only meets but exceeds the expectations.
throughout the world. Specialising in electro optic products, Theon Sensors provides innovative solutions allowing users a battlefield advantage across a range of environmental conditions and when offered with through-life support provided by Lightforce, the Theon night vision and thermal
International, which will have a presence at this year’s Land Forces International Land Defence Exposition, said:
“Theon Sensors is deeply committed to the Australian Industry Capability (AIC), ensuring that our partnership with Lightforce not only meets but exceeds the expectations of the Australian Defence Force, now and in the future.”
“This partnership has been instrumental in advancing THEON’s NYX Product Family of Night Vision Binoculars and providing the Australian Defence Forces with state-of-the-art MIL STD products that enhance their operational capabilities. We take pride in our role in supporting the ADF’s mission with reliable, high-performance equipment and further contributing to the security and technological advancement of the Oceania region,” added Kolotos.
Force Ordnance, as part of the iconic Australianowned Lightforce Group has provided sovereign defence capability since 2017. Offering organic brands such as Nightforce Optics, Horus Vision Reticle Systems and the Klondyke Range Complex,
defence market came in 2017 when a large one-off purchase of the first fleet of Nightforce Optics was conducted. Force Ordnance has continued to support their use in the ADF prior to the latest big win in 2022, when it was selected to provide its world-leading Nightforce precision rifle scopes to the ADF as part of the Sniper Systems component of LAND 159 Tranche 1.
Providing ADF snipers the ability to rapidly and effectively engage the enemy, the Nightforce ATACR 7-35x56 F1 rifle scopes with the Tremor 3 reticle are already in service and trusted by many Five-Eyes nations militaries.
Recently, Lightforce has advanced its credibility as a designer, manufacturer and supplier of solutions for military and law enforcement clients and trusted provider of specialist advice, having been selected on the Australian Federal Police’s munition’s panel, providing ammunition to the AFP and wider law enforcement community of Australia.
As a systems integrator, Force Ordnance brings together the Lightforce group’s own brands:
Providing training instruction to the ADF for the Theon NYX Night Vision Device.
EVENTS: WOMEN IN INDUSTRY AWARDS 2024
Women in Industry Awards
The finalists for the 2024 Women in Industry Awards have been announced, recognising exceptional female leaders across various industrial sectors.
The 11th annual Women in Industry Awards were held at the Dolton House, Hyde Park, Sydney, recognising the achievements of exceptional women across various industries.
The event celebrates outstanding women working across mining, transport, manufacturing, engineering, logistics, bulk handling, waste management, rail, and construction and infrastructure.
The gala dinner was opened by MC, Samantha Lane, an award-winning broadcast journalist and& author.
Lane announced the first winner gong of the night in thewas for Business Development Success of the Year Award, which: “Recognises those who have created new growth opportunities and allow their organisation to expand and generate greater revenue.”
This award was won by Sandra Robinson from United Rentals.
“In the first six months of this role, Sandra exceeded her sales targets by a whopping 252 per cent,” said Lane.
“I had to double check that there wasn’t a typo in the script.”
Possibly the biggest highlight of the night was Derelle Mitchell taking home the Woman of the Year award, which is chosen from the winners of the other Awards categories.
Speaking on her win, Mitchell said: “I started this company (Health Focus Manufacturing), from very humble beginnings,” said Mitchell.
“I’ve provided jobs to single mums, as well as mums who have never worked before, giving them a chance.
“I find the most enjoyment in my job from giving people a chance and helping them secure employment. I truly love what I do.”
Mitchell was also awarded the Excellence in Manufacturing Award, which recognises an individual
who has thought ‘outside the box’ to implement an outstanding personal contribution to their manufacturing business and the wider manufacturing community.
Mitchell founded Health Focus Manufacturers in November 2011 after purchasing the assets of a closing cosmetic manufacturing company.
Starting with just three staff, a basic commercial property, and a small office space converted into a lab, she built the business into a $10 billion enterprise.
Now, on the cusp of launching a state-of-the-art manufacturing facility, Mitchell has surrounded herself with industry experts.
She has taken a hands-on approach, focusing on processes, quality products, and collaborative customer relationships to create a world-class brand.
“To receive this award, I’m way out of my safety zone here, I’m used to wearing my safety vest and steel caps,” Mitchell remarked.
“I may have won this award alone, but I’ve surrounded myself with some very special people who work with me.
“As I mentioned, we started with three people, and now I’ve networked to 60 staff, with 80 per cent being women.
“I have a wonderful family who has supported me all the way. My wonderful son nominated me for this award, so I’ll talk to him after this. I’m very humbled and thank you so much.”
Other notable winners include Allyson Woodford, from the APA Group, who received the Excellence in Engineering Award.
Throughout her acceptance speech, Woodford credited her former boss, her grandmother, her mother, and her father.
“I’m very proud to be here tonight with my peers from ADA. We are a business looking to the future, working with both young engineers and seasoned professionals on the energy transition,” said Woodford.
“There are a few people I need to thank. First, my grandmother, who passed away at the end of last year and was a significant role model for me.
“My mother, who found opportunities for me, including getting me into a science camp, and my father, who was an exceptional role model.
“Thank you very much. I am incredibly proud and grateful for this award,”
Continuing the celebration of remarkable talent, the Women in Industry Awards also honoured several other outstanding individuals for their contributions across various sectors.
Other winners of this year’s awards included Kate Leone from UGL, who was named Rising Star of the Year for her work on the M6 Stage 1 Project, and Steph Gee from CM & SM Gee Electrical, recognised with the Industry Advocacy Award, represented by Steph Andrade. Kirstin Reblin from Opal Packaging won Mentor of the Year, while Anne Modderno from Swietelsky received the Excellence in Transport award.
Sinead Booth from Fortescuee, represented by Sophie Davies, won Excellence in Mining, and Sinead Redmond from GeelongPort was awarded Excellence in Construction.
Finally, Vesna Olles from BOC Limited won the Excellence in Energy award, which recognises contributions to the renewable, electricity, pipeline, or oil and gas industries.
Sponsors
The Women in Industry Awards showcased a diverse range of sponsors committed to excellence and innovation across various sectors. This event owes much of its success to the generous support of its sponsors.
PACCAR Australia, with its rich 50-year history, celebrateds milestones in manufacturing trucks
tailored for Australian conditions.
Atlas Copco emphasises diversity and innovation, supporting the Rising Star of the Year category to advance gender balance in industry.
Komatsu advocates for corporate social responsibility, aligning its business values with community support through sustainable solutions, sponsoring the Industry Advocacy Award.
SEW-EURODRIVE, a global leader in power transmission systems, backed Excellence in Engineering, while Fulton Hogan, renowned for its work in infrastructure excellence, supportes the
of the Year
Kenter, a woman-owned freight forwarding company, sponsors the Excellence in Transport award, highlighting its commitment to tailored logistics and exceptional service.
Fulton Hogan, a large infrastructure construction company based in New Zealand and Australia. They specialise in constructing and maintaining transport, water, energy, mining, and land development infrastructure.
These sponsorships underscore dedication to industry advancement, innovation, and community impact.
Woman
Award.
Sports journalist Samantha Jane Lane was the emcee at the awards night.
Derelle Mitchell, pictured (right) with her Excellence in Manufacturing Award.
EVENTS MEGATRANS2024
Industry professionals gather at MEGATRANS2024, Australia’s largest logistics conference and exhibition.
Driving Australia’s logistics towards sustainable warehouses
MEGATRANS2024 represents a significant milestone for Australia’s logistics and manufacturing sectors, focusing on the theme of sustainable supply chains and warehouses.
As Australia’s largest integrated conference and exhibition dedicated to the logistics industry, the MEGATRANS2024 event will gather industry professionals, companies, and innovators to discuss and showcase advancements in achieving zero-carbon footprints in warehouse operations.
Achieving a net-zero carbon footprint in warehouses involves balancing emitted greenhouse gases with equivalent reductions or offsets, ensuring no net increase in carbon dioxide levels.
This goal reflects a growing commitment across industries to environmental stewardship and sustainability in manufacturing processes.
Innovation in sustainable warehousing
Among the exhibitors, Nexobot stands out as an example of innovation in modular warehouse robotics. The company specialises in systems designed to meet the evolving demands of warehousing and logistics sectors.
Its robotic solutions, such as efficient parcel sorting mechanisms adaptable to cold supply chains, demonstrate practical applications aligned with sustainable practices.
Dominic Lindsay, co-founder and CEO of Nexobot, emphasises its approach to overcoming industry challenges through innovative, sustainable solutions, underscoring the role of platforms like
MEGATRANS2024 in showcasing transformative technologies.
“MEGATRANS is perfect for us because we’re primarily focused on working with people who are doing any sort of horizontal movement through a facility, and predominantly the moment in parcel sorting, which is exactly where MEGATRANS is focused,” said Lindsay.
Industry insights and best practices
The conference component features speakers from prominent companies and organisations like ANL, Toll Group, and the Victorian Government.
Speakers will share insights on current trends, best practices, and future strategies in sustainable logistics and warehouse management.
Their participation underscores MEGATRANS2024 as a knowledge-sharing hub for industry professionals seeking to drive sustainable change.
MEGATRANS2024 also includes prestigious awards ceremonies such as the Mercury Awards and the MHD Sustainable Warehouse Award, recognising excellence and innovation in logistics and warehouse management.
These awards celebrate achievements and inspire further advancements in eco-friendly technologies and strategies.
The expo experience
The expo’s interactive format welcomes exhibitors of varying sizes, fostering a diverse showcase of technologies and solutions.
This inclusivity encourages collaboration and partnership opportunities essential for advancing sustainable logistics practices.
MEGATRANS2024 provides attendees with valuable networking opportunities, enabling professionals to forge connections, explore collaborations, and stay updated on technological developments.
The event’s focus on sustainable warehouses and supply chains aligns with global efforts to mitigate climate change and reduce environmental impact. It will ultimately serve as a pivotal platform for driving innovation and sustainability in Australia’s logistics and manufacturing sectors.
By convening industry leaders, innovators, and stakeholders, the expo facilitates critical discussions and collaborations aimed at shaping a sustainable future.
As companies increasingly prioritise environmental responsibility, events like MEGATRANS2024 play a crucial role in accelerating the adoption of sustainable practices and technologies in warehouse management and logistics operations.
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Cracking down on microcracking
A new carbon fibre composite has the potential to selfidentify and heal fatal microcracks in submarines.
Composite materials form essential structural components that are crucial for ensuring the integrity of many products. In high-pressure environments where warcraft like submarines operate, any structural compromise could result in fatalities.
This was exemplified by the OceanGate Titan, a manned submarine that imploded off the coast of Canada on June 18th, 2023, supposedly due to a microcrack forming in its carbon fibre composite hull.
Manufacturers’ Monthly sat down with Dr. Nisa Salim from Swinburne University of Technology’s School of Engineering, who has applied prior research into a new carbon fibre composite to the maritime sector. Research suggests that the composite has the potential to heal a microcrack.
“The structure would have the ability to self-sense any defects and report them in real time,” said Salim.
“Our research focus on materials that could selfrepair such micro-cracks. This means materials can behave like a living organism and can sense, respond and adapt in a matter of time.
“We need such autonomous materials to stop catastrophic accidents from happening. It’s not science fiction, it’s the future of technology and innovation.”
Early research and development of new composite material
Salim’s preliminary research into the new composite material began during her completion of a PhD.
“We created hexagonal ordered nanostructures using polymers, and that is something very hard to do because polymers are soft, and typically form less ordered structures. It’s not like a normal crystalline metallic material,” she said.
This research into developing nanostructures
with polymers was successful, leading Salim to experiment with high-end applications for the designs. These included using the polymer nanostructures to make materials such as epoxies less brittle.
After completing her PhD, Salim continued her research, shifting her focus to carbon fibres and composites. Utilising the experience with brittle epoxies, Salim aimed to tackle microcracking, something she referred to as the ‘Achilles heel’ of all industries that utilise carbon fibre reinforced composites.
“Sometimes there’s cracking happening [in composites] and once there is a microcracking, what happens is this cracking nucleates towards the bigger structural issues,” said Salim.
Salim’s initial project was focused on researching the internal structure of carbon fibres and what caused cracking in composites. She would spend
Research suggests that a new carbon-fibre composite has the potential to heal a microcrack.
five years on carbon fibre research to deepen the narrow range of information on the material.
“At this stage, my research was about moving from nano to micro level, (carbon fibre is several micrometers in diameter). I spent half a decade learning about, the precursor science… they were very in-depth and intense studies on carbon fibre production process.”
Salim’s lifetime of research would collide as she moved to Swinburne University, where she began combining the research of polymers with that of carbon fibres. She has been working at the university since 2019. While combining this research, she noticed a potential path to making multi-functional materials.
“I found out we can make materials that can deliver more than one functionality. I started with carbon fibres because we did some modification on them,” said Salim.
Salim noted that a recurring issue faced in developing multifunctional carbon fibres was the interface problems caused by blending materials that are non-carbon in nature.
“Traditional approach is to apply metal-based oxides on to the top of carbon fibres to utilise the functional applications of carbon fibres – for example energy storage. But there is a problem. Because we are dealing with non-carbon materials there will be interface issues,” said Salim.
experiment with the “wonder material” known as graphene.
and thermal stability are beneficial for the functionalities that we are aiming for,” said Salim.
When identifying graphene suitability to compliment carbon-fibre, Salim and her team then planned to develop a coating material that could be applied to any surface. To the benefit of Salim and her team, graphene wasn’t in short supply with Swinburne university having the capability to scale up graphene materials.
Self-identify capabilities of new composite
Because of the advantageous nature of graphene, Salim and her team have begun combining graphene with polymer systems to formulate coating materials on carbon fibres. The research led to a discovery that the material would act as a sensor and can give continuous information about the health of the composite.
“When we tested it, we are not compromising the mechanical properties, yet we were at the same time getting extra features out of it,” said Salim.
“We were applying this on to the carbon fibre fabric and were getting continuous real time data every time.
Self-healing
capabilities of composite
Salim’s research also found that the composite material can heal itself before they nucleate into a substantial problem. While researching how
inherently brittle material. To initiate the reaction, we add a secondary component into it, and we apply a little bit of heat,” said Salim.
“But while we were doing that, we found that when we modified the reaction part it showed selfhealing behaviour.
“Our specialised polymer system can therefore heal microcracks itself by breaking and reforming chemical bonds via exchange reactions.”
Applications to submarines and other industries
Salim first introduced the multifunctional composite prototype to the maritime industry at a global industry exhibition that occurred last year. The Indo Pacific International Maritime Exposition took place in Sydney, Australia, where Salim highlighted the advantages that the new multifunctional composites can bring to the structural integrity of submarines. There, she pitched the concept, relating it to how in a structural entity, these abilities will be vital in ensuring that an event such as the OceanGate Titan never occurs again. Different industries, especially defence, showed interest in the composite.
“At Indo Pacific I pitched about this concept because the tragedy (OceanGate) had just happened a couple of months before,” said Salim.
Dr. Salim’s team from Swinburne University is one of the largest groups in the mechanical engineering department.
Image:
Nisa Salim
ENGINEERING FOCUS
few microns in size.
“So, we need technologies that can identify microcracks early enough… And then a submarine can rectify the situation by itself. That’s an advantage.”
The application of these composites can extend further than the maritime sector.
“Whether it is a submarine, a wind turbine blade, or a spacecraft… we need a system where it can give regular, real-time data. It can detect that kind of cracking or defect problem then we know that the structure’s got an issue and we need to rectify it,” said Salim.
Future of new composite in Australia
Salim believes that Australia is very well advanced in composites research.
“At Swinburne, we are doing very advanced research.
Interest from the defence sector has given Salim faith that co-development and implementation of these composites will occur sooner rather than later. She acknowledges that she cannot take full credit for the work that has now progressed significantly.
“I would say I have a large team in the mechanical engineering Department who are excellent in demonstrating their skill set at various fronts,” she said.
Salim and her team will continue to work with both the government, industry and defence players to strengthen and implement this research.
Dr. Nisa Salim from Swinburne University of Technology’s School of Engineering has years of experience researching composite materials, epoxies and polymers.
In high-pressure environments where warcraft like submarines operate, microcracks could result in fatalities.
Image: Nisa Salim
Choosing Australia’s first lunar rover SPACE MANUFACTURING
The ELO2 Consortium, short for EPE and Lunar Outpost Oceania, is pioneering the development of designs for Australia’s first lunar rover.
As part of its mission in establishing infrastructure on the Moon, NASA signed an agreement with the Australian Space Agency to establish lunar operations.
The agreement, which is named the Trailblazer Mission, has the Australian Space Agency agreeing to aid an Australian consortium that will produce a semi-autonomous lunar rover for NASA’s Artemis Program.
This program aims to return humans to the Moon with the goal of establishing a sustainable presence and preparing for future missions to Mars.
One of the two Australian consortiums competing to manufacture said lunar rover is the ELO 2 Consortium.
Manufacturers’ Monthly spoke to Joseph Kenrick, the program manager at Lunar Outpost Oceania, and the ELO 2 Consortium technical director, to learn more about its efforts.
“For the Trailblazer mission, the Australian Space Agency acts as a liaison with NASA. Through the Space Act Agreement, they have partnered with
NASA, which provides the rocket and the lander,” said Kenrick.
“In turn, the Australian Space Agency supplies the rover. For this mission, the consortium works with NASA through the Australian Space Agency.”
“It’s been a huge honour and exciting to work on this lunar rover project,” said Kenrick.
“I’ve previously worked on various rovers, but this one is the most impactful. I came from the US to join this mission from its inception.
“My team is entirely Australian, and it’s thrilling to see them in action.”
The Australian Space Agency’s Moon to Mars initiative has involved a $150 million investment over five years.
The Trailblazer program, a flagship element of this initiative, allocates up to $50 million to grantees, Australian businesses, and researchers.
Initial funding stages, announced on March 20, 2023, allocated $4 million each to the ELO 2 Consortium and another consortium to develop lunar rover prototypes.
“Together with Brisbane-based co-lead, EPE Oceania, we have assembled a consortium specifically for this mission, with expert scientists and engineers from Australia’s leading universities and industry and have received grant funding from the Australian Space Agency,” said Kenrick.
“Lunar Outpost is involved in other missions, but all the funding for this mission is channelled through the ELO 2 Consortium.”
The consortium is a group of 16 different entities, all working towards the same goal of designing and manufacturing Australia’s first lunar rover.
“For us this is a national mission which will have impact in industry and research here in Australia,” said Kenrick.
“Our consortium partners are from across the country and the Trailblazer program helps to advance Australia’s capabilities in extreme environment robotics and all the technical aspects that go into designing a lunar rover that have application here on Earth.”
Currently, as part of phase one of the Artemis
Australia’s first Moon rover, Roover, was named by public vote, receiving 35 per cent of votes.
Program, ELO 2 is competing against another consortium, called AROSE, based in Western Australia.
Both consortiums are designing their own prototype rovers, aiming to eventually be selected by the Australian Space Agency as the prime candidate.
The winner will move on to phase two of the program, which entails the manufacture of a flight rover that will then be sent to space.
Establishing lunar presence
“The Artemis campaign is led by NASA, but it is a multinational effort,” Kenrick said.
“Many nations have signed on to the Artemis Accords, which outline the vision and agreements for conducting this next phase of lunar settlement and exploration, similar to the Apollo program.
“The Trailblazer mission will support the Artemis campaign and help inform where the Artemis astronauts might land.”
The primary objective of the lunar rovers is to collect and sample lunar regolith, which is a layer of loose, heterogeneous material covering solid rock. It includes dust, soil, and broken rock.
The lunar regolith contains oxygen bound in chemical compounds with elements such as iron and silicon.
The rover’s task requires it to survey the environment, locate and collect the regolith, and transport it to the designated delivery zone.
Kenrick explained that the delivery zone will most likely be the lander, which is a spacecraft designed to land on the surface of an astronomical body.
“The lander is the typical route for rovers like this, with expectations for the lander to survive,” he said.
“While there are potential direct Earth options, the standard procedure involves the rover being deployed from and communicating through the lander”
Independence from earth is ultimately critical for the astronauts that will eventually return the Moon, as resource utilisation is critical for Moon colonisation as it ensures sustainability by reducing dependence on Earth for supplies.
This is in-turn critical for establishing a long-term presence on the Moon, in theory, which will enable NASA to travel to Mars.
Another important aspect of establishing human presence on the Moon and Mars, is by establishing a cislunar economy.
Kenrick explained that with technology becoming cheaper to produce, there is no better time for humans to return to space.
“Advancing technology and the advent of reusable, commercially made rockets have drastically reduced the cost of space access, creating a domino effect that makes Earth orbit and lunar missions economically feasible,” he said.
“We have some fully funded commercial lunar
missions that will happen before this mission, without any government funding. This is the main driver in creating a cislunar economy.
“This will make Mars exploration more achievable and cost-effective, as the Moon can serve as a pit stop.”
Manufacturing and engineering
The manufacturing of the rover for the Trailblazer mission involves various materials such as aluminium, titanium, and specialised alloys, utilising manufacturing methods like sheet metal, CNC cutting, and additive metal 3D printing.
To develop specific parts for the lunar rover, ELO 2 is partnering with universities.
“We tested various wheel and scoop designs with
RMIT in their Advanced Manufacturing Precinct; they’re our main partner for manufacturing,” said Kenrick.
“Additionally, Titomic brings advanced capabilities to the project. Smaller components are supplied by other partners such as Melbourne Space Lab at the University of Melbourne.”
For ELO 2, one of their goals is to ensure that all materials are sourced locally during the manufacturing process.
“There may be some niche, smaller components that could require sourcing internationally if local options aren’t available,” said Kenrick.
“Specific decisions on materials are pending as we finalise the design. Overall, most materials can be readily sourced locally for the project.”
Images: ELO 2 Consortium
Joseph Kenrick, the program manager at Lunar Outpost Oceania, and the ELO2 Consortium technical director.
SPACE MANUFACTURING
Prior to sending the rover to moon, it must be ready to endure the conditions space. This necessitates rigorous testing.
Testing lunar regolith for oxygen is essential for a moon habitat because it supports life support, water production, rocket fuel, and construction, enabling a sustainable lunar presence.
Kenrick explained that there are two primary testing categories; functional and environmental testing.
Functional testing, which focuses on verifying operational capabilities remotely and ensuring mobility over lunar terrain, addresses challenges like time-delayed remote operation and extreme lighting conditions.
“In functional testing, we remotely operated the prototype from our control centre in the US while the rover was in Australia, proving our capability to run the mission solely through the rover’s cameras,” said Kenrick.
“Managing operations with a seven-second time delay can pose challenges, and it highlights
the complexities of remote operation under such conditions.”
Kenrick said the tests are a critical and intensive phase throughout the program’s lifecycle.
“In environmental testing, the rover undergoes simulation in a thermal vacuum chamber to replicate space conditions, adjusting pressures and temperatures,” he said.
“This ensures that thermal management systems keep internal components within safe operating limits.
“Vibration and shock tests replicate launch stresses, including high-frequency vibrations and significant G-forces experienced during rocket detachment.”
The Artemis mission requires a maximum sixmonth transfer phase to the Moon, which is the most challenging part after launch.
The mission plans to use a yet to be selected Commercial Lunar Payload Services (CLPS) lander, of which each provider has varying transit times.
“The longest and most challenging part of the
mission occurs upon launch,” said Kenrick.
“The longest transit time is six months, while most are expected to range from one to two weeks.
“Once landed, the mission’s minimum viable duration is just under two weeks, equivalent to a lunar day, during which all mission objectives must be achieved within 14 Earth days.”
Kenrick explained that lunar technology being developed by ELO 2 offers dual-use capabilities for both space and Earth applications. Particularly in industries like mining and defence.
“Consider underground mines – dark, dangerous environments with no GPS, poor lighting, and high temperatures, similar to the lunar south pole with some differences,” he said.
“This niche technology developed for the moon finds applications in resource-centric missions and defence, addressing extreme remote environments and unstructured terrain.
“BHP, one of our key partners, underscores our focus on these capabilities.”
Several ELO2 rover prototypes.
Challenges
The mission faces challenges in balancing tight budgets and timelines, navigating high-risk classifications, and proving technical reliability through prototype testing, all while aiming for cost reductions compared to previous NASA projects.
“This mission is under a fixed-duration, fixed-cost contract, classified as a Class D mission by NASA, which indicates a higher risk tolerance,” said Kenrick.
“Unlike Class A missions involving humans or budgets exceeding billions, where failure is not an option, Class D missions prioritise cost and schedule over technical success.”
Kenrick highlighted that Australia’s pioneering rover mission has placed considerable pressure on the ELO 2 team.
“Given the national prestige attached to Australia’s first moon mission, it’s a flagship endeavour demanding a delicate balance between cost, schedule, and technical prowess,” he said
“Prototypes have been crucial in validating our endto-end supply chains and team capabilities, though working within fixed resources poses challenges.
“It’s a continual process of trade-offs and risk management.”
Despite these challenges, the team remain passionate to be involved in such a program.
“Several of our team members graduated shortly before this program began, having pursued degrees and extracurricular activities focused on building lunar rovers, despite such opportunities not being available in Australia until now,” said Kenrick.
“It’s amazing to witness their dedication to a dream they’ve nurtured for over 20 years, now finally coming to fruition with this real opportunity to work on lunar rovers.”
ELO 2 ’s future projects
Kenrick explained that the formation of the ELO 2 Consortium for the Trailblazer mission has fostered a collaborative environment, enabling the team to synergise.
“It’s been a valuable partnership where we’ve learned a lot about each other’s strengths and weaknesses, and how we complement each other,” he said.
ELO 2 members are now seeking other opportunities within the Artemis mission, particularly with manufacturing lunar vehicles.
“We’re exploring additional opportunities; our US team at Lunar Outpost leads the Lunar Dawn team, which won a contract for the next lunar terrain vehicle,” said Kenrick.
“This mirrors the competitive process for an upcoming NASA Artemis mission, potentially worth up to $4 billion.
“We’ve issued an RFI to Australian industry for critical technologies and are looking into ELO 2 Consortium’s involvement.”
The flight rover will semi-autonomously explore the lunar surface, identifying and gathering lunar regolith.
ASSOCIATION
COMMENT DR
RANYA SIMONS, CSIRO GROUP LEADER
Innovative materials for a circular economy
Global demand for raw materials has skyrocketed to 100 billion tonnes each year. This appetite is putting immense strain on our planet’s resources, leading to depletion, pollution and waste.
The future holds incredible potential, but first we need to rethink our relationship with materials. The traditional linear model of material use – often described as ‘take, make, dispose’ – must be replaced with a circular approach that emphasises keeping resources in use for as long as possible. Australia’s current circularity rate is only around 4 per cent according to a recent CSIRO report. This means we use a mere 4 per cent of materials in a closed loop, with the rest ending up as waste. We need a fundamental shift.
The good news is that some innovative solutions are emerging in the field of materials science. Here at CSIRO, we’re at the forefront of developing
sustainable materials for a circular economy. As leader of the Hybrid Materials Group at the national science organisation, I’ve been incredibly proud to be part of this journey. We’re tackling the challenge from two key angles: downstream recycling and deconstruction of waste created from current materials, and upstream redesign of materials for circularity.
Giving waste a second life
Mechanical recycling reprocesses waste streams without altering them chemically. While it’s often the simplest and cheapest method, there is usually a limit to how many times a material, especially plastic, can be mechanically recycled
due to degradation. It can also be difficult, or even impossible, to mechanically recycle mixtures, hybrid or composite materials.
Downstream deconstruction, also known as advanced recycling, goes beyond simple mechanical recycling. It focuses on uncovering hidden potential within complex waste materials, transforming them into valuable resources.
At our MUSE (Materials Upcycling and Sustainability Exploration) labs, we’re pioneering advanced recycling techniques. Take waste expanded polystyrene (EPS), which is currently difficult to recycle. Being mostly air, it is expensive, inefficient and cost prohibitive to transport it for recycling. We’re developing a portable reactor that returns it
The team is using mobile technologies to turn bulky expanded polystyrene into reusable styrene monomer onsite.
to styrene monomer – the essential building block for many products like food packaging, insulation materials, and even car parts. This mobile reactor will eliminate bulky waste transportation.
Used cooking oil gets a new lease on life, too. Our research explores using special catalysts to convert it into useful products like biodiesel fuel and industrial chemicals, which can then be used in everything from powering vehicles to creating everyday cleaning products. This not only diverts waste from landfills but also reduces reliance on virgin resources.
But deconstruction isn’t limited to single materials. We’re developing a new method that uses a special solution to dissolve PVC from mixed waste streams, like old electrical cable covers. This recovered PVC is then purified to be as good as virgin PVC, allowing it to be seamlessly reintroduced into the production cycle.
CSIRO is also investigating other advanced plastic recycling techniques. This includes chemical depolymerisation, which breaks down waste plastics to their original building blocks, or transforms them into valuable chemicals. The idea is to create entirely new materials from what was once destined for landfill. Importantly, chemical depolymerisation does not have a limit on how many times a material can be recycled, unlike traditional mechanical recycling.
However, recycling isn’t a one-size-fits-all solution. Sometimes, the most sustainable, lowest energy option involves combining waste streams to make brand new materials with useful properties, known as ‘upcycling’. At CSIRO we have worked with industry to create new composites from mixed waste streams for a range of applications such as footwear, furniture, sporting goods, in the construction space, and for the food industry. An example is our collaboration with Worn Up. We helped them test and refine their innovative process for creating high-quality furniture from 100 per cent recycled composite material made from discarded uniforms. This gives used textiles a valuable second life while reducing demand for virgin resources in furniture production.
Metals aren’t left out either. CSIRO is exploring the development of high entropy alloys, formed by combining multiple recycled metal powders in unique proportions. The resulting alloys possess exceptional properties that could revolutionise various industries.
Another CSIRO initiative, for ‘TiWi’ or titanium wire, tackles the challenge of transforming recycled titanium – a valuable but often underutilised metal – into a roll of continuous wire for additive manufacturing. This can then be used for a range of applications in everything from medical implants to high-performance sporting equipment.
We’re also investigating the use of recycled titanium powders to create protective coatings for
steel structures in acidic environments. Imagine extending the lifespan of bridges and buildings by essentially giving steel a suit of armour made from recycled materials!
Engineering sustainability from scratch Recycling is crucial, but wouldn’t it be better to create materials that are inherently sustainable? This is where upstream design comes in. This involves re-engineering materials from the ground up, with features like recyclability and biodegradability built in.
CSIRO is at the forefront of this approach. We’re working on innovative creations like 100 per cent biodegradable shipping pallets, bioplastic composites and coatings, bioderived polymers from microalgae, and home-compostable materials made from food and agricultural waste. These biomaterial solutions offer a game-changing alternative to traditional plastics, as they reduce the strain on resources and ease the burden of waste management.
Some materials do not currently have sustainable pathways for waste disposal and can only go to landfill or be incinerated at their end of life. Thermoset polymers are an example of difficult-torecycle materials because they contain irreversible bonds, which means they cannot be thermally processed or mechanically recycled like traditional plastics. That’s why we’re developing “recyclableby-design” polymers, which will have a significant impact in reducing such wastes. These innovative materials are essentially pre-programmed for efficient recycling, compostability, or re-use at the end of their lifespan.
We’re developing innovative coatings, composites, sealants and adhesives. This includes creating special reversible chemical groups for epoxies and polyurethanes to allow end of (first) life reprocessing. We are even redesigning synthetic polymers so that they can be digested by insects at their end of life.
In another exciting project we’re developing a sprayable, biodegradable mulch film for broadacre agriculture. Traditional plastic mulch films used on farms create a major microplastics issue.
Our solution offers a sustainable alternative that helps farmers retain soil moisture, increase crop yield, and suppress weeds while minimising environmental impact.
Supporting Australian manufacturers on the road to sustainability
Transitioning to a circular economy offers significant environmental and financial benefits to Australian manufacturers. But navigating this shift can be a complex challenge.
We’ve collaborated with numerous Australian companies, helping them implement circular economy principles and often realising substantial cost savings.
Whether you’re looking to integrate recycled materials, explore bio-based alternatives, develop advanced or modular and portable recycling technologies, or design products with efficient end-of-life solutions in mind, our world-class scientists can partner with you on the journey.
If you’re looking to reduce your environmental impact and create a more sustainable future for your company, get in touch.
The CSIRO MUSE lab is collaborating with industry leaders and researchers on sustainable upcycling processes and developing autonomous chemical processing systems.
IO-Link Safety: Pilz Master PDP 67 IOLS
IO-Link Safety satisfies the wish for flexible automation. How, you ask? It’s quite simple: with the safe, standardised point-to-point communication IO-Link Safety, you can integrate sensors up to field level – quickly and conveniently. At the same time, IO-Link Safety offers new possibilities for data diagnostics, therefore helping to optimise your processes.
• S afe point-to-point communication from the controller to the sensor in the field.
• Standardised worldwide in IEC 61139-2.
• Maximum safety up to PL e of EN ISO 13849-1 (SIL 3 of IEC 61508/62061).
• Fieldbus-independent.
Pilz offers a system with master and sensors and supports users with the integration of IO-
Link Safety into their application.
As the interface to the safety controller, the IO-Link Safety Master enables point-to-point communication up to field level. With the Pilz Master PDP 67 IOLS, users can also connect IO-Link sensors and classic safety sensors alongside the IO-Link Safety devices.
Key features:
• Profinet/Profisafe device (slave);
• 4x 2FDIO --> eight failsafe digital inputs and outputs (configurable: two inputs or two outputs on one port);
• 4x IOLS --> four Type A - IOL safety ports;
• 25 Byte FS Input and 25 Byte FS output data each port (IOL-S spec);
• sensor and actuator connection: M12, 5-pin ports;
• protection class: IP67/IP69K;
• ambient temperature: -30°C to +70°C;
• operating voltage: 24 V DC; and
• functional safety: PLe/SIL3.
IO-Link Safety Master PDP 67 IOLS offers advantages such as:
• C onnection of safety sensors with IO-Link Safety and safety sensors with OSSD outputs.
• Inputs and outputs can be configured.
• Standard IO-Link sensors can also be connected.
• C onnection to Standard sensors is also possible.
Company: Pilz Australia
Phone: 1300 723 334
Website: www.pilz.com.au
Resources have served the NT well – time to grow further
As a resident of the Top End, I, like many Territorians, am acutely aware of the economic impact from the mining and energy sectors on our way of life.
More than a quarter of the Territory’s wealth is derived from mining and energy. These sectors are critically important, and we often miss out on many opportunities and economic dividends by not fully value-adding to these abundant resources.
If you have been around long enough, you will know that one of the challenges with mining and energy is their high volatility. Prices can fluctuate enormously, impacting whether we have enough skilled workers, housing, or even the foresight to meet industry needs. This volatility makes economic forecasting very difficult for a resource concentrated region like ours.
It was this thinking that influenced the final report of the Territory Economic Reconstruction Commission in 2020, which recommended that the NT should focus on growing its manufacturing base to enhance its capabilities and economic contribution. Doing so would add an additional layer of resilience to the NT economy while also creating highly skilled, well-paid jobs.
In 2020, manufacturing accounted for just 4.1 per cent of the NT’s total economic output. Today, despite the challenges of COVID and national skills shortages, manufacturing’s contribution remains fairly stable. In contrast, mining has declined by two
per cent over the same period resulting in billions in lost revenue for the region.
Given these challenges and recent geopolitical disturbances, it would be wise to build on our strong mining and energy base and invest in developing advanced manufacturing capabilities for the NT. This would create a more balanced, reliable, and stable economy. By doing so, we can shift towards trading on the value of products rather than their cost. Crucially, this would increase the complexity of our products and expand job opportunities for future generations of Territorians – keeping our smarts here.
Arctic Installations’ roof panels in production.
At some point, we must acknowledge that our luck may run out and demand for our raw commodities will falter. Therefore, we must use prosperous times to prepare for future challenges. The Northern Territory Government recognises that tomorrow’s economy will not mirror today’s, hence it is expanding efforts to diversify the region’s economy through initiatives like the Advanced Manufacturing Ecosystem Fund (AMEF).
In collaboration with the Advanced Manufacturing Growth Centre (AMGC), the NT Government was one of the first jurisdictions in the country to focus on growing our manufacturing capabilities. Better still, the program seeks to leverage our knowledge economy, spur cooperation and have manufacturers create globally relevant products and services. It is not about replacing mining or energy operations but leveraging them further to boost the diversification of the region and the
Index (ECI), which ranks countries based on the diversity and sophistication of their exports. At 93rd place among 133 countries, Australia lags Uganda and Pakistan, ranking lowest among OECD nations. We can and must do better.
Fortunately, manufacturing offers a solution.
The AMEF, spearheaded by the Northern Territory Government, has already supported local manufacturers in commercialising innovative products, enhancing local capabilities, and fostering cross-border collaboration to solve valuable commercial and complex problems.
For instance, Arctic Installations has developed specialised roofing and insulation panels tailored for hot, humid, and cyclonic conditions in collaboration with James Cook University, MDI Systems, and Rapid Engineering. This initiative has led to new jobs, products, processes, and a sovereign capability for the Territory – displacing
in Alice Springs, which has scaled up production of the world’s first pneumatic side-tipping haulage trailer, reducing costs and enhancing efficiency. Collectively, AMEF participants are set to create 195 new jobs and contribute $99.8 million to the NT economy, from a mere $4.3 million in co-investment to date. These success stories highlight how leveraging existing knowledge and capabilities can boost economic contribution –and we have funding available for like-minded manufacturers.
The potential for our region to add value to its natural resources and elevate economic complexity is immense. It is my hope that we recognise our strengths and proactively embrace manufacturing to secure a larger share of the NT economic pie. AMGC, in partnership with the NT Government, stands ready to support this endeavour. So, if you are a Territory-based manufacturer seeking to
L-R AMGC MD Dr. Jens Goennemann, Arctic Installations founder Garry Burns, AMGC NT director Charmaine Phillips.
THE LAST WORD
Enter Weld Australia’s 2024 Welding Excellence Awards now
Weld Australia’s Welding Excellence Awards are one of the most prestigious events on the welding industry calendar.
Wquality and professionalism. The awards are an opportunity for welders, fabricators and educators across Australia to showcase their people and their operations.
Why enter the Welding Excellence Awards?
An industry award win can act as a third-party endorsement for your business. A win can give a seal of approval to your activities and is a sign of quality for potential customers.
Business awards can be an overlooked tool in your marketing toolbox. Make sure you maximise PR exposure and update your marketing materials. Winning an industry award can open doors to getting contracts, finding new supply channels and breaking into new markets.
Welding Excellence Awards categories COMPANY OF THE YEAR
The Company of the Year Award recognises superior performance across a range of business metrics. There are three sub-categories: Fabrication Company, Supplier, and Indigenous Company of the Year.
and fabrication industry. The individual should demonstrate a high level of skill, knowledge or craftsmanship.
PROJECT OF THE YEAR
The Project of the Year Award recognises excellence in welding and fabrication projects, with a focus on exceptional craftsmanship, a commitment to Australian and International Standards, as well as environmental sustainability and innovation.
HEALTH AND SAFETY IN WELDING
This Award recognises organisations that are leading the way in encouraging and promoting health and safety and ensuring the health and safety of their own team. Organisations will be judged on criteria such as design and implementation of innovative programs or initiatives.
TRADES PERSON OF THE YEAR
This Award recognises tradespeople who are making a valuable contribution to the welding and fabrication industry. The individual should demonstrate a high level of skill and have professional development plans in place. There are three sub-categories: Young
TRAINING AND EDUCATION AWARD –ORGANISATION
The Training and Education Award recognises the outstanding achievements of a STEM or VET provider or program. Entrants may include secondary education and tertiary education providers. Criteria include delivery of quality, innovative training programs, involvement with industry, recruitment and retention of students.
TRAINING AND EDUCATION AWARD –INDIVIDUAL TEACHER
This Award recognises the outstanding achievements of a STEM or VET teacher. Entrants will be judged on quality of delivery, innovation, knowledge, strong links with students, and dedication.
How to enter the Welding Excellence Awards
Entries must be submitted via the specific online form for each category by 23 August 2024. These forms can be found via the Weld Australia website. weldaustralia.com.au/2024-weldingexcellence-awards/
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