Lisa Hanschu, Sr. Account executive lisa@indmacdig.com 785-965-9159 | Fax: 785-965-7199
William c. Strickland III, National Sales 205-903-9178 | fax 866-826-5918
Susan Strickland, Accounting susan@indmacdig.com 205-542-1098 | Fax: 866-826-5918
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As the holiday season envelops us with its warmth and festive cheer, I find myself reflecting on the remarkable year we've had in the manufacturing and industrial sector. It has been a year of resilience, innovation, and growth. In every challenge, our industry has found a way to evolve, proving once again the indomitable spirit of the manufacturing community.
In this issue of Industrial Machinery Digest, we celebrate the groundbreaking advancements and steadfast dedication that define our industry. From Wauseon machine’s comprehensive machining and fabrication services to the unveiling of Vogelsang’s eP Series rotary lobe pumps tailored for extreme conditions, these stories showcase the passion and ingenuity driving progress. each innovation highlighted in this issue is a testament to what we can achieve when technology meets expertise.
As we look toward the future, education and workforce development remain central to our mission. This issue also delves into how companies like moduleWorks and Universal robots are bridging the skills gap, ensuring the next generation is prepared to meet the demands of Industry 4.0. It's inspiring to see these collaborations between academia and industry, paving the way for a brighter, more inclusive manufacturing landscape.
The holiday season also reminds us of the importance of connection—whether it's connecting parts in a production line, processes in a factory, or people in our workplaces. The latest trends in automation, digitalization, and collaborative technologies showcased in this issue reinforce the value of working together to achieve a common goal.
As we decorate our homes, gather with loved ones, and reflect on the year gone by, let us also take a moment to appreciate the community we’ve built within the pages of this magazine. It’s your ideas, stories, and achievements that bring Industrial machinery Digest to life.
Here’s to celebrating the successes of 2024 and to embracing the opportunities of 2025 with renewed energy and optimism. From everyone here at Industrial Machinery Digest, we wish you a joyous holiday season filled with peace, prosperity, and plenty of inspiration for the year ahead.
Warm regards,
William Strickland
William Strickland, Publisher, ImD
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Flex machine Tools to Hold Open House on December 5th
Flex machine Tools invites manufacturing professionals to its Open House at its Wapakoneta, Ohio, headquarters on December 5, 2024, from 9:00 a.m. to 4:00 p.m. Additional appointment slots are available on December 6. The event highlights innovative technologies designed to enhance productivity in metal fabrication.
INDUSTRY NEWS
Attendees will experience live demonstrations of the FlexJet FLX waterjet cutting system, featuring IG emS technology and an advanced 5-axis cutting head. The versatile FlexcNc c-series long-bed machining center will showcase its capabilities for high-speed drilling, milling, and tapping, including thermal drilling and milling keyways. The newly developed Flexible Tapping center will demonstrate streamlined operations for drilling, tapping, and countersinking in sheet metal applications.
Participants will also explore a range of pneumatic, electric, and hydraulic tapping solutions with FlexerGO Arms, emphasizing safe and ergonomic operations. Hands-on experience with the FlexArm Tapping Arm will allow attendees to see its ease of use firsthand. Additionally, a guided tour of the company’s expansive 115,000 sq. ft. facility will provide a behind-the-scenes look at its advanced manufacturing processes.
This complimentary event is an excellent opportunity for professionals to gain insights into cutting-edge machining solutions that drive operational efficiency. registration is required to attend.
For more information, visit www.flexmachinetools.com
Advanced materials Shaping the Future of carbon capture carbon capture technology is vital in addressing emissions challenges in industries like power generation, steel, and chemicals. Greene Tweed leads innovation in this field, offering advanced materials that enhance the durability and efficiency of carbon capture infrastructure and equipment.
The company addresses challenges across four major carbon capture technologies: post-combustion, pre-combustion, oxyfuel combustion, and Direct Air c apture (DAc). For post-combustion processes, Greene Tweed’s chemraz® 541 O-rings and Wr® 600 composite bearings excel in high-temperature and corrosive environments, such as those encountered with aminebased solvents. Pre-combustion technologies benefit from Wr 650® materials, which withstand high-pressure cycles and bi-directional gas flows.
Oxyfuel combustion applications, which operate under extreme temperatures, require materials like Arlon 3000XT® cross-linked PeeK, capable of resisting degradation in harsh conditions. meanwhile, DAc
processes use chemraz® 541 components for improved reliability and extended equipment life.
Greene Tweed’s innovations are pivotal in reducing maintenance needs and improving the longevity of critical equipment, including pumps, valves, and absorbers. by providing reliable, high-performance materials, the company empowers industries to meet emissions goals and adopt sustainable practices.
Greene Tweed’s commercial and engineering team offers customized solutions to tackle specific carbon capture challenges, helping industries transition to a more sustainable future.
For more information, visit www.gtweed.com
Laser Photonics Welcomes John T. Armstrong as executive VP
Laser Photonics corporation has appointed John T. Armstrong as executive Vice President to strengthen its leadership team and accelerate business growth. Armstrong brings over 30 years of experience in operations, strategic planning, and human resources, having held leadership positions at boeing and Astronics Test Systems.
At LP c , Armstrong will focus on advancing the company’s influence in laser cleaning and material processing. His expertise in enterprise-wide project management and developing operational efficiencies aligns with LP c ’s goals of innovation and industry leadership.
“John’s leadership will be crucial as we develop strategies to fuel our growth and maintain excellence in laser solutions,” said Wayne Tupuola, LP c ’s ceO. Armstrong is equally enthusiastic, expressing his commitment to helping LP c cement its role as a key player in material processing.
Armstrong’s educational background includes an mbA and a master’s in management Systems from Webster University, along with a b .S. in mechanical engineering from Villanova University. His extensive experience in b2b environments positions him to guide LP c ’s next growth phase.
This appointment reflects LP c ’s commitment to investing in strong leadership to drive innovation and expand its global footprint.
mastercam Appoints Oscar elizaga as Global VP of Sales
mastercam has appointed Oscar elizaga as Vice President of Global Sales and Services to lead its commercial operations and drive market growth. With more than 30 years of experience in high-tech and software industries, elizaga is recognized for building high-performing global sales teams and fostering customer-centric cultures.
In his new role, elizaga will focus on optimizing sales strategies, increasing market penetration, and strengthening mastercam’s partnerships worldwide. He aims to align mastercam’s innovative solutions with
customer needs, ensuring exceptional value delivery across industries.
“I’m honored to join mastercam during this pivotal time,” elizaga said. “mastercam’s dedication to innovation and customer success inspires me, and I’m excited to contribute to its global expansion.”
Susan brandt, President of mastercam, expressed confidence in elizaga’s leadership. “Oscar’s strategic vision and extensive experience are invaluable as we expand our sales operations and continue to deliver industryleading solutions.”
As part of the Sandvik manufacturing Solutions organization, mastercam remains committed to innovation and customer success, with elizaga’s appointment reflecting its strategic focus on growth and excellence.
For more information, visit www.mastercam.com
Kenton county Honors mazak corporation’s 50th Anniversary mazak corporation celebrated its 50th anniversary with recognition from the Kenton county Fiscal court of Kentucky, declaring October 31, 2024, as mazak corporation’s 50th Anniversary celebration Day. This honor highlights mazak’s contributions to innovation and economic growth in Northern Kentucky since establishing its Florence facility in 1974.
Over the past 50 years, mazak’s Florence-based iSm ArT Factory™ has expanded to 20 times its original size, employing over 600 workers and producing more than 70 advanced machining solutions. The company’s commitment to technological excellence and customer collaboration stems from the vision of its founder, Teruyuki Yamazaki, who emphasized staying ahead of industry advancements while maintaining strong relationships with customers.
Dan Janka, President of mazak corporation, expressed pride in the company’s legacy and its impact on the local community. “We’re honored to call Kentucky home and contribute to the state’s economic vitality. This proclamation reinforces our commitment to innovation and sustained growth.”
mazak’s continued focus on advanced manufacturing technologies and workforce development ensures its
Mastercam Appoints Oscar Elizaga as Global VP of Sales
Kenton County Honors Mazak Corporation’s 50th Anniversary
leadership in the machine tool industry, supporting industries worldwide. The anniversary celebration underscores its enduring contributions to global manufacturing and local economic development.
For more information, visit www.mazakusa.com
meI rigging & crating expands Industrial Storage capacity
meI rigging & crating has achieved a significant milestone by expanding its industrial storage capacity to over 4 million square feet. recent facility expansions in Virginia, Texas, and california have bolstered meI’s ability to meet diverse storage needs across industries like automotive, data centers, and food processing.
Key highlights include the addition of 175,000 square feet in richmond, Virginia; 50,000 square feet of climate-controlled storage in Fort Worth, Texas; and 450,000 square feet of secured storage in Los Angeles. meI’s nationwide network now spans 50 facilities across 14 states, complemented by over 90 acres of outdoor storage space.
These facilities offer state-of-the-art services such as automated shipment notifications, inventory reporting, and on-site power for equipment testing and demonstrations. The expansion reflects meI’s commitment to providing tailored solutions for short- and long-term storage needs
in response to trends like modular construction and prefabrication.
beyond storage, meI provides comprehensive services, including rigging, machinery moving, crating, and installation. These capabilities make meI a trusted partner for industries requiring specialized handling and storage of critical equipment.
With its expanded footprint, meI continues to lead in providing innovative solutions to address modern industrial storage and logistics challenges.
For more information, visit www.meiriggingcrating.com
meI rigging & crating Helps Deliver LunarOrbit Habitat
meI rigging & crating showcased its expertise in complex logistics by transporting a 5,000-pound lunar-orbit habitat module to Space center Houston. This mockup, part of NASA’s NextSTeP-2 program, was originally built by Northrop Grumman as a prototype for the Artemis Gateway project.
The module, measuring 14.5 feet wide by 21 feet long, required precise handling due to its size and fragility. meI’s team used specialized equipment, including a 25/35 Versa-Lift and trolleys, to carefully maneuver the habitat through a narrow 14.8-foot-wide entrance. Floor protection measures ensured the facility’s interior
remained undamaged during the process.
Now on public display at Space center Houston, the module allows visitors to explore what life aboard a lunar orbit platform might entail. Guests can walk through the habitat and experience a “day in the life” simulation, gaining insights into the potential of space exploration.
This project highlights meI’s ability to manage intricate rigging operations and contribute to groundbreaking initiatives in industries like aerospace. meI’s involvement underscores its reputation as a leader in handling and transporting high-value, sensitive equipment.
For more information, visit www.meiriggingcrating.com
meI
expands rigging and machinery Operations with coast Acquisition
meI rigging & crating, LLc , a leading national provider of rigging and industrial services, has announced its acquisition of coast rigging and machinery moving, based in charlotte, North carolina. coast has served the region for over 25 years, earning a reputation for dependable solutions in rigging and machinery moving. Known for its extensive inventory of specialized equipment, including Versa-Lifts and mobile gantries, coast provides comprehensive services to diverse industries.
This acquisition strengthens meI’s presence in North c arolina and the Southeast, complementing its nationwide network of facilities across 14 states. “We are thrilled to welcome the coast team to the meI family,” said Doug Dayton, ceO of meI. “Their dedication to customer service and safety aligns perfectly with our values.” bob Knosby, former ceO of coast, will remain with the company to support the integration.
by expanding its operations, meI enhances its ability to serve customers with tailored solutions for machinery moving, millwrighting, and industrial storage. The acquisition highlights meI’s commitment to growing its footprint and providing high-quality services across the U.S.
For more information, visit www.meiriggingcrating.com.
motion Promotes eric Gonzalez to Senior Vice President
motion Industries has promoted eric Gonzalez to Senior Vice President of mexico, canada, Industry Segments, and business Development. Gonzalez has been with the company for 26 years, holding roles in sales, fluid power, automation, and corporate leadership. His career began as a corporate Trainee, and he has since become a driving force behind motion’s business growth.
In his new role, Gonzalez will lead operations in mexico and c anada while building teams focused on expanding industry segments and business development. His expertise in sales and field leadership uniquely positions him to optimize operations and foster strategic growth. “ eric’s energy and sales leadership are
exceptional,” said James Howe, President of motion. “I am confident he will elevate motion’s sales growth and orchestrate exciting new synergies.”
motion Industries continues to innovate as a leading distributor of industrial technology solutions, delivering excellence in maintenance, repair, and operations replacement parts.
For more information, visit www.motion.com.
NeTZScH Names Dwight Waters as Industrial Sales Director
Ne TZScH Pumps USA has announced Dwight Waters as its new Industrial Sales Director. Waters joins Ne TZScH with over 30 years of experience in the pump industry, having held executive roles focused on sales growth and business development. In his new role, Waters will lead Ne TZScH’s newly established Industrial Sales team, tasked with expanding the company’s market reach in strategic sectors like mining, shipbuilding, adhesives, and battery production.
Known for its innovative fluid handling solutions, Ne TZScH is the world’s largest manufacturer of progressing cavity pumps, rotary lobe pumps, and screw pumps. The company also offers metering systems and grinders designed for complex industrial processes. Waters will focus on leveraging Ne TZScH’s advanced product line to address customers’ challenges in demanding environments.
Ne TZScH’s commitment to providing cutting-edge solutions for industries like oil and gas, food processing, and municipal services is reflected in this strategic appointment. With Waters’ leadership, the company aims to strengthen its presence in the U.S. market.
For more information, visit www.netzsch.com/us.
Piper Aircraft Achieves AS9100 certification for Aerospace excellence
Piper Aircraft, a renowned name in aviation manufacturing, has earned AS9100 rev D certification, awarded by Dekra certification, Inc. This globally recognized quality management standard highlights Piper’s commitment to excellence in the aerospace industry. The certification strengthens Piper’s capabilities, particularly through its Piper Industrial manufacturing company (PImcO) division, which specializes in high-quality manufacturing for aerospace and defense sectors.
“The AS9100 certification elevates quality across Piper Aircraft, creating a foundation for continuous improvement,” said Stuart mcSorley, Senior Director of Production compliance & Oversight. This milestone
NETZSCH Names Dwight Waters as Industrial Sales Director
positions PImcO to expand into new global markets and forge partnerships within the aerospace industry.
Piper Aircraft’s legacy spans over 88 years of innovation and dedication to safety. The AS9100 certification reinforces its reputation as a leader in aviation manufacturing, paving the way for enhanced production capabilities and international growth opportunities.
For more information, visit www.piper.com.
rOLLON expands Operations with New michigan Facility
rOLLON corp., a leader in linear-motion systems, has expanded its manufacturing footprint with a new 147,000 sq. ft. facility in Norton Shores, michigan, and a new office in New Jersey. The michigan facility will serve as the U.S. hub for producing linear guides, actuators, and robotic transfer units (rTUs). These products are essential for industries like aerospace, logistics, and factory automation.
The new michigan site integrates advanced digital systems and smart manufacturing processes, allowing rOLLON to adapt production in real time to meet customer needs. meanwhile, the New Jersey office consolidates engineering, marketing, and customer service teams, enhancing rOLLON’s operational efficiency.
“ rOLLON is proud to announce this expansion to optimize service for our customers,” said rüdiger Knevels, ceO of rOLLON Group. This growth reflects rOLLON’s commitment to supporting customers in North and South America with high-quality products and solutions.
Founded in 1975, rOLLON has been part of The Timken company’s Industrial motion division since 2018. The expansion underscores Timken’s focus on delivering innovative automation solutions.
For more information, visit www.rollon.com/usa.
Sandvik coromant Appoints Thomas Henry as Vice President of marketing for the Americas
Sandvik coromant has announced Thomas Henry as the new Vice President of marketing for the Americas, effective November 4, 2024. A seasoned leader with over 25 years of experience in metal-cutting and industrial distribution, Henry has a proven track record in driving marketing innovation and digital transformation.
Previously serving as the Global channel marketing manager, Henry spearheaded strategies that enhanced customer engagement and drove sales growth. In his new role, he will focus on achieving strategic sales objectives, optimizing marketing channels, and delivering impactful product launches. His vision centers on providing personalized, resonant customer experiences that align with the Sandvik coromant brand.
Henry's career includes notable achievements, such as developing a global channel partner program and receiving the excellence in Leadership and change management award in 2017. His appointment marks a pivotal step in strengthening the company’s market position and customer connections across the Americas.
“Thomas brings exceptional leadership and an unmatched understanding of manufacturing,” said Veronica messersmith, President of Sandvik coromant Americas. “We are excited to see how his expertise will drive innovation and growth in our industry.”
For more information, visit www.sandvik.coromant.com.
Gulf Wind Technology Accelerates Wind Turbine Design with Stratasys 3D Printing
Gulf Wind Technology is revolutionizing rotor design for wind turbines using Stratasys’ additive manufacturing solutions. b y adopting Stratasys Neo ® stereolithography (SLA) technology, Gulf Wind has cut design iteration cycles from 30–40 days to just 3–4 days. This significant time reduction allows for faster prototyping and the inclusion of advanced features like pressure taps for real-time airflow data, enhancing wind tunnel testing capabilities.
The use of Somos® PerFOrm reflect™ material, known for its high strength and stiffness, enables Gulf Wind to create durable models tailored for rigorous testing. Stratasys’ technology has allowed the company to innovate with greater speed and precision, achieving results previously unattainable through conventional manufacturing methods.
“This technology has transformed our design process, enabling us to iterate faster and with more precision,” said James martin, ceO of Gulf Wind Technology. “It’s opened new opportunities and enhanced our ability to optimize wind turbine performance.”
Inspired by advancements in Formula 1 racing, Gulf Wind Technology’s engineers are using Stratasys solutions to refine airfoil shapes and rotor designs. These innovations are poised to maximize wind energy efficiency, particularly for applications in the Gulf of mexico.
Stratasys c hief b usiness Unit Officer r ich Garrity added, “This collaboration exemplifies how additive manufacturing is expanding its role in industries alongside traditional methods, driving efficiency and innovation.”
For more information, visit www.stratasys.com.
What Manufacturers Need to Know About CYBERATTACKS
By George Thuo – Director of Cloud, Global Shop Solutions
In today’s connected world, the manufacturing sector has increasingly become a target for cybercriminals. As industries embrace digital transformation to enhance productivity, improve supply chain operations, and reduce costs, they simultaneously open themselves up to potential cyber threats. Understanding the risks and implementing proactive strategies are essential steps manufacturers must take to protect their operations and intellectual property.
The Threat Landscape manufacturers are particularly vulnerable due to their reliance on automation, robotics, and other IoT-connected technologies. A cyberattack can compromise systems,
resulting in production downtime, intellectual property theft, or even physical damage to machinery. ransomware, phishing, and malware attacks remain prevalent, but threats like industrial espionage and state-sponsored cyber intrusions are on the rise.
A recent report by cybersecurity experts revealed that manufacturing has overtaken financial services as the most targeted sector. The interconnected nature of supply chains means a single breach can
ripple across multiple organizations, amplifying its impact. Threat actors often exploit outdated software, unpatched systems, or insufficient employee training as entry points.
The cost of a breach
The financial implications of a cyberattack can be devastating. Downtime costs alone can range from thousands to millions of dollars per hour, depending on the scale of operations. In addition to lost revenue, manufacturers face potential lawsuits, regulatory fines, and long-term reputational damage.
Intellectual property theft is another significant concern. Proprietary designs, trade secrets, and manufacturing processes are valuable targets for hackers, particularly those motivated by economic espionage. For manufacturers involved in defense or critical infrastructure, breaches can also pose risks to national security.
best Practices for cybersecurity
To mitigate these risks, manufacturers must adopt a comprehensive cybersecurity approach. Here are key steps to consider:
» conduct a risk Assessment
evaluate all systems and processes to identify vulnerabilities. Focus on critical assets such as proprietary software, IoT devices, and operational technology.
» Implement robust Security measures
Use firewalls, intrusion detection systems, and endpoint protection to secure your network. encrypt sensitive data and ensure secure communication channels.
» Patch and Update Systems regularly
Outdated software is one of the most exploited vulnerabilities. ensure all systems, including IoT devices and industrial control systems, are updated with the latest patches.
» enhance employee Training employees are often the weakest link in cybersecurity. regular training on recognizing phishing attempts, securing passwords, and reporting suspicious activity is essential.
» Develop an Incident response Plan
A well-thought-out plan minimizes downtime and losses during an attack. Include steps for containment, recovery, and communication with stakeholders.
» Partner with cybersecurity e xperts engage third-party cybersecurity firms to conduct regular audits and simulations. e xternal experts can provide valuable insights and identify hidden vulnerabilities.
embracing a culture of Security
cybersecurity is not just the responsibility of IT teams; it must be integrated into the organization’s culture. Leadership should prioritize investments in security tools and training. by fostering a culture that values
cybersecurity, manufacturers can empower employees to become active participants in protecting the organization.
Looking Ahead
As the industry continues to adopt advanced technologies such as artificial intelligence, machine learning, and edge computing, new vulnerabilities will emerge. Staying ahead requires vigilance, investment, and a proactive mindset. manufacturers must view cybersecurity as an ongoing process rather than a one-time effort.
Protecting manufacturing operations from cyberattacks is not just about safeguarding revenue but also ensuring the resilience of entire supply chains and the safety of critical infrastructure. In an era where cyber threats are increasingly sophisticated, a proactive approach to security is the best defense.
ABOUT THE AUTHOR
George Thuo is the Director of cloud erP for Global Shop Solutions. George has a bachelor’s degree of m echanical engineering and a master’s degree in Information Systems management from baylor University along with more than two decades of cloud and technical experience. George is dedicated to helping customers run more efficiently with cloud erP.
motor, valve and reservoir are
for
Large rectangular tubes used at base of machine to give safe, instant portability.
What to Consider When Investing in Tooling for a New CNC Machine
Outfitting a new cNc machine with the right tooling is an essential step for any shop aiming to enhance its capabilities. However, the decisions surrounding tooling go far beyond selecting tool categories and brands. A thorough approach ensures that tooling aligns with the machine’s specifications, integrates with your shop’s workflows, and supports both current and future production goals. Think of your tooling and machine tool as a symbiotic partnership: the performance of one directly influences the other. Here are four key considerations to help you make the most of your investment.
1. Integration with current Processes and Shop culture
The first step is to determine how the new tooling and machine will fit into your existing production environment. Too often, the tooling selection process begins after the machine is already on the shop floor, which can lead to inefficiencies. If operators weren’t involved in the purchase decision, this can create unnecessary hurdles as the team works to integrate the machine into established workflows. consider the familiarity of your crew with the new machine’s brand, category, or control system. machines that match your team’s existing expertise often result in smoother transitions. On the other hand, a new machine provides an opportunity to level up your technology and processes. research the latest tooling enhancements, trends, and capabilities to ensure your decisions reflect advancements in the market. Planning for training and open communication upfront will ensure a successful integration of the new technology into your shop’s culture.
2. Intended Use and Long-Term Goals
What is the primary purpose of the tooling, and how will its role evolve in the next five years? While it’s tempting to stick with familiar options, this is the time to think critically about future needs. For instance, if you’re planning to expand into high-speed or dynamic machining, HSK tool holding systems may be a better fit than traditional cAT systems. HSK solutions excel in high-speed applications and micromachining, offering increased precision and efficiency. Workpiece materials and your approach to metal removal should also guide your decisions. Do you favor fast, high-feed cuts or deep, heavy-duty operations? Your answers will influence spindle and tooling requirements. For example, bIG-PLUS spindles, a dual-contact system available on machines from over 150 manufacturers, offer
increased rigidity and flexibility across various cutting applications. However, to maximize the benefits, you’ll need to pair them with bIG-PLUS tooling instead of standard V-flange tools.
Additionally, cutting applications—whether milling, drilling, or tapping—require specific tooling solutions. Selecting the right tool and holder for each application ensures better performance, reduced wear, and cost savings in the long term.
3. Workpiece Type and Size
The type and size of your workpieces directly impact tooling choices. Aerospace applications, for example, often involve large workpieces but require small, high-precision tools. In these cases, high-speed spindles can lead to faster tool wear, making air-driven spindles or similar solutions ideal for preserving tool life.
Tool rigidity and reach are also critical, especially when dealing with larger machines and smaller tooling. Systems like bIG-PLUS can address these challenges by enhancing stability. Angle heads are another option for applications requiring alternative tool angles, offering machinists the ability to shorten tools while maintaining precision. It’s
essential to consult with your machine tool partner to ensure auxiliary systems, such as angle heads, can be seamlessly integrated into the machine’s design. Accuracy is another key consideration, but it doesn’t rely solely on the machine’s specifications. Workholding repeatability and stability are equally crucial. even the most advanced machine cannot achieve precise tolerances without the right workholding solutions. To ensure success, evaluate tooling and workholding options alongside machine specifications.
4.
customization and Future-Proofing modern cNc machines come with a range of options and customizations to enhance productivity and flexibility. However, these features are best utilized when tooling partners are involved early in the process. For instance,
through-spindle coolant systems are invaluable for high-diameter drilling and boring applications, but their effectiveness depends on compatible tool holders. engaging your tooling partner during the selection process ensures you don’t miss opportunities to optimize machine features.
Automation is another critical consideration for staying competitive. Zero-point clamping systems can enhance repeatability, speed, and accuracy by eliminating the need to unclamp parts during multi-step machining. Presetters can keep spindles running efficiently by taking measurements offline, while intelligent tool management systems integrate with shop floor technologies to streamline operations. Digital tools, meanwhile, enable precise adjustments and data capture, reducing human error and improving overall productivity.
Partnering for Success
Tooling decisions play a vital role in the success of your new cNc machine. by involving a trusted tooling partner early in the process, you can align your tooling choices with machine specifications and production goals, ensuring optimal performance. This collaboration helps you make informed decisions, unlock greater flexibility, and futureproof your investment.
Have questions or need expert guidance? reach out to us today to get started on building the ultimate machine and tooling partnership for your shop.
Forging Greater Productivity with Next Gen PM
Proper maintenance of forging equipment is crucial to prevent costly downtime and repairs. New customizable preventative maintenance program options in partnership with the OEM now enable forgers to minimize downtime while maximizing production, quality, and safety.
By Del Williams
In the realm of metalwork and manufacturing, forging equipment is an invaluable asset that can remain in production for decades. However, the key to ensuring optimal equipment performance and longevity is implementing a systematic preventative maintenance (Pm) program. In this way, forging operations can boost production, reduce downtime, and guarantee a superior return on investment (rOI).
regular preventive maintenance (Pm) on forging equipment offers additional benefits. ensuring the machinery operates without unforeseen failures or malfunctions reduces maintenance needs and lowers repair costs. Furthermore, it decreases the likelihood of producing defective or substandard products. Safety is also improved by minimizing potential hazards and reducing the risk of injuries.
Although many forgers follow routine maintenance guidelines, most continue production until the equipment
breaks down. Given the longevity of certain forging machines in operation since the 1950s and 60s, technicians may lack the knowledge required to troubleshoot problems or recognize worn or failing components, which increases the risk of a major breakdown. Studies have shown that the cost of unplanned maintenance can be three times higher than planned maintenance.
“The purpose of a systematic preventative maintenance program is to identify and address potential issues before they escalate. Pm is designed to optimize machine reliability and performance while saving costs over time by avoiding serious breakdowns,” says bill Goodwin, Vice President of Sales and engineering Ajax/cecO/erie Press (Ace), the largest forging equipment supplier in North America.
Traditionally, Pm is performed by facility personnel who conduct routine inspections, maintenance, and repairs on assets to ensure that they are functioning properly.
However, a growing number of forgers are discovering the value of partnering with equipment Oems for customizable Pm programs that incorporate the industry’s best proactive maintenance practices.
“In essence, the O em becomes an extension of the forger’s maintenance team through best practice Pm , proactive training, and even spare parts programs. The goal is to customize the program to fit within the budget and provide as much, or as little, support as needed,” says Goodwin. Ace , with 145 years of experience in equipment manufacturing and more than 300 years of combined forging knowledge, is the longest-running, most experienced forging company in the world. The O em provides a comprehensive array of forging equipment including upsetters, presses, programmable hammers, forging rolls, and automation solutions for various forging materials such as carbon steels, aluminum, titanium, and super alloys.
The Importance of Forging equipment Pm
Today, Ace is offering the most comprehensive preventative maintenance program in the forming and forging industry. The customized program not only includes training activities and scheduled replacement of consumables, but also develops repeatable maintenance tasks and follows Pm best practices for forging and forming equipment.
In this program, the Oem first conducts a preliminary review of any existing Pm program documentation of what is currently performed. This includes the life cycle of frequently replaced parts.
Next, the Oem conducts a “health check” to determine the equipment’s current condition, running clearance, electrical system, and pump performance. based on the results of the health check, the Oem recommends corrective actions to restore the equipment to its original specifications.
Ace is in a unique position to utilize the full documentation of equipment in its broad portfolio of brands, along with extensive maintenance and repair experience accumulated over many decades. With its core brands founded in the 1800s, the company offers a full line of products, including standard mechanical forging presses, upset forging machines, forging rolls, hydraulic forging, forming, compression molding, cold extrusion, compaction, and roll ring preform presses along with stretch forming and straightening machines, solid die forgers, trim presses, programmable die forgers, and custom-engineered hydraulic presses.
In the next step, a customized preventive maintenance program is created. This can vary, but typically involves following best practices for lubrication; daily visual inspections for signs of wear, leaks, or damage; listening for abnormal vibrations/noises when equipment is running that can indicate underlying issues; monitoring the presence of dirt or other foreign particles that can deteriorate the machinery’s efficiency; regular calibration to avoid misalignment or imbalanced
equipment; and documenting all checks, observations, and maintenance tasks performed.
Goodwin stresses that the extent of the Pm program is based on factors such as the type of equipment, production, onsite support, and desired Pm intervals. “It can be scaled up or down to take into account the maintenance team’s experience, availability, and turnover,” he says.
Although Pm is typically performed on-site, some actions can be completed remotely. Ace utilizes advanced collaboration tools and real-time video communications to connect with technicians so each can see, discuss, annotate, and resolve many situations at hand.
Spare Parts Programs to minimize Downtime
ensuring smooth operations goes beyond just the maintenance of forging equipment. It also entails having essential spare parts available at a moment’s notice to minimize production downtime.
consequently, the Pm program can also include a separate spare parts stocking program that anticipates expected maintenance requirements. by utilizing measurable production rates, Ace can proactively schedule service and replacement of critical parts through an online portal. Potential critical failures can be identified and addressed before occurring.
To ensure the highest production uptime of forging equipment and prevent lengthy unexpected downtime, the stocking program typically not only includes consumables but also essential parts that can traditionally have very long lead times.
“common consumables include friction plates and driving plates for presses and upsetters, or piston heads, rods, rings, and packings for hammers. However, it is even more important to stock main gears, eccentric shafts, and rams to avoid long lead times for replacement,” says Goodwin.
According to Goodwin, with the parts stocking program the forger only pays a percentage of the cost up front and the balance when they take possession of the part – up to 2 years later. With minimal up-front investment, the custom stocking program can eliminate many months of downtime waiting on long lead time parts. express shipping costs are also eliminated since parts are readily available.
even though the high impact nature of forging will eventually take its toll, with proper Pm the equipment can be kept productive for many decades, and potentially for the better part of a century.
“ensuring proper Pm is not merely a task, but an investment in the longevity of your forging equipment, the quality of your products, and the productivity and safety of your workforce. by implementing a proactive Pm program, manufacturers can position themselves to reap the maximum benefits from their equipment for decades to come,” concludes Goodwin.
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Wauseon Machine –Delivering End-to-End Precision Machining and Fabrication Solutions
In today’s competitive manufacturing landscape, the need for comprehensive, high-quality, and efficient solutions is paramount.
Wauseon machine, a trusted industry leader in automation solutions, tube forming technologies, and precision machining, has emerged as a powerhouse of innovation and reliability. celebrating over 40 years of excellence, Wauseon machine offers an extensive suite of machining and fabrication services, designed to address the evolving needs of manufacturers worldwide.
comprehensive capabilities Tailored to Industry challenges
Wauseon machine’s array of services caters to the most complex manufacturing demands, enabling clients to achieve their goals with precision and efficiency. Among its advanced capabilities are Saw cutting, Welding, Heat Treating and Tempering, Laser etching, rapid Prototyping, reverse engineering, and carbinite applications, all backed by the company’s stringent quality control standards.
Advanced machining and Fabrication Processes
At the heart of Wauseon machine’s offerings lies its versatile machining capabilities, crafted to deliver exceptional results across a range of industries:
Saw cutting excellence:
Wauseon machine’s in-house saw cutting capabilities provide precision and adaptability for a variety of manufacturing needs. Whether it’s production or bundle cuts, the company leverages premium raw materials and quick turnaround times to meet diverse project requirements.
robust Welding Solutions:
With extensive mIG and TIG welding expertise, Wauseon machine delivers superior structural integrity and customization for projects. For specialized welding needs, the company taps into its trusted network of partners,
ensuring top-quality outcomes tailored to unique specifications.
Heat Treating and Tempering:
Precision is critical in metals, and Wauseon machine’s heat treating and tempering services refine metal properties to meet exact application demands. Operating furnaces up to 2100°F, the company provides hardening, tempering, and annealing processes, enhancing product durability and performance.
Laser etching with Precision:
Utilizing the Tykma Vereo Fiber Laser marker, Wauseon machine delivers detailed and aesthetically pleasing laser etching on flat and round surfaces. This service supports custom logos, detailed font styles, and even photographic enhancements, combining functionality with branding appeal.
Pioneering Innovation with reverse engineering and rapid Prototyping
Wauseon machine's reverse engineering and rapid Prototyping services provide invaluable solutions for customers aiming to refine or recreate parts with precision. by utilizing cutting-edge tools such as the FArO Arm and metrology lab technology, the company ensures unmatched accuracy in part design and development. This capability supports customers in resolving engineering
challenges, testing fit and functionality, and minimizing manufacturing risks.
enhancing Tool and component Performance with carbinite
Wauseon machine’s carbinite technology, a tungsten carbide applied through electro Spark Deposition, provides enhanced friction, grip, and wear resistance for critical components. by extending the lifespan of tools such as collets and clamp blocks, this service delivers measurable cost savings and operational efficiencies for customers.
Quality control and Assurance: A commitment to excellence
Wauseon machine’s state-of-the-art quality control lab stands as a testament to its unwavering dedication to precision and reliability. equipped with advanced tools such as the FaroArm cmm and coordinate measuring machines with vision capabilities, the lab performs 3D inspections, cAD comparisons, and dimensional analyses, ensuring every product meets or exceeds customer expectations.
From concept to completion: Your manufacturing Partner
With its multi-plant operations in Ohio and South carolina, Wauseon machine exemplifies what it means to be a comprehensive manufacturing partner. by
continuously expanding its service portfolio and investing in advanced technologies, the company empowers manufacturers to overcome complex challenges and deliver exceptional products.
Whether you’re looking to enhance your capabilities with rapid prototyping, refine part designs with reverse engineering, or maximize component performance with carbinite treatments, Wauseon machine has the tools, expertise, and commitment to make it happen.
For more information about Wauseon machine’s capabilities, visit www.wauseonmachine.com or contact their team today.
HOW SIMULATION SOFTWARE POWERS REAL-WORLD EFFICIENCY
By: Aaron Hand, TECH B2B, A3 Contributing Editor
Simulation software is an essential tool in modern manufacturing automation, enabling manufacturers to model, test, and optimize processes in a virtual environment before physical implementation. It can be used to design and test robotic movements, assess production-line efficiency, and model complex interactions among machinery, materials, and operators. It plays a key role in the development of new systems and the ongoing optimization of existing ones — in both greenfield planning and brownfield redesigns.
Simulation has traditionally been used across all stages of design, from early capital expenditure (capex) planning to production routing optimization. That’s still the case today, but simulation models have recently made their way into production planning processes. “We take a simulation model of our production environment and run the order forecast through a few scenarios to make better decisions around worker allocation, WIP [work in progress] strategies and quantities, and even planned downtime for equipment,” says michael Sarvo, digital design business development manager for rockwell Automation. “This is a winning strategy because you can improve your reaction time to constantly changing conditions.”
Simulation differentiates the early adopters from the laggards within various segments and industries, says Iiro esko, industry manager and digital transformation architect for Siemens Digital Industries. "You use simulation through optimization, training, commissioning, acceptance testing, engineering, and in connection with procurement and sustainability planning," he says.
The State of Simulation
While some top-level manufacturers understand the benefits that simulation software offers, not everybody is on board yet. “There’s a massive spectrum of adoption and tech level out there,” Sarvo says. “Some companies are all in and have made simulation and related practices an integral part of how they do business, while others still don’t see
how this kind of technology could possibly be a benefit.”
There are many different types of simulation software, as well as different ways to classify it, notes ravi Aglave, director for chemical and process industry at Siemens. control simulation, for example, relates to how you can achieve control of any given process. molecular-scale simulation illustrates how materials will behave at a molecular level. Structural simulation provides insights into how the structure of a building or a car or an airplane might behave or respond.
Simulation can be defined by its scale — anywhere from molecular to the whole plant — or by the depth of understanding it provides. before considering simulation software, manufacturers first need to understand what they want to get out of it. Is it to optimize costs, quality, or system operation, or to increase profitability? Simulation in automation addresses all of the above: It reduces costs by minimizing trial and error in physical setups, enhances flexibility by allowing rapid adjustments to system designs, and improves product quality through refined control over manufacturing processes.
Sarvo explains the benefits simply: “Simulation tools provide a more efficient and more accurate means of predicting the future. When you have better and earlier predictions, you have more opportunity to plan, design, and execute, resulting in better outcomes.”
Figure 1: Simcenter STAR-CCM+ is a computational fluid dynamics (CFD) simulation software from Siemens. Here, it simulates how oil jet cools an electric motor.
At rockwell Automation’s emulate3D User Group meeting in October, integrator Automation Intelligence explained how it used simulation software to help the second largest distributor of beer, wine, and spirits understand whether it could add 20% new volume without constructing another building.
republic National Distributing company (rNDc) handles more than three million cases per year at its distribution center in morgan Hill, california. but the company faced challenges due to labor shortages, growing demand, new material handling equipment, and resource allocation within a multilevel pick module. The strategy was to replace manual processes and storage areas with high-tech automation and control systems. but such significant upgrades bring their own risks.
“Think about it — you must shut down existing production, install new, unfamiliar systems, and train engineers, operators, and maintenance personnel,” Sarvo says. rNDc used emulate3D to model its production environment to understand how the new automation could be used to meet production demands. “ because of the way emulate3D software works, they were also able to test and debug their new control systems against the model before the real system was built, and they were able to train their people on the new processes and equipment, so they were ready for production as soon as the new system was online.”
In production, rNDc continues to use the hybrid simulation/digital twin models to run forecast data and optimize daily production schedules.
How the Digital Twin Fits In
At its core, simulation software creates digital twins of production systems, machines, and workflows, allowing manufacturers to explore a wide range of scenarios without the cost and risk of real-world experimentation.
For Siemens, a digital twin is the digital representation of theoretically all different types of simulation, says Andrea Sassetti, innovation manager, Siemens Digital enterprise Lab at mxD. “We are able to cover many different aspects
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Figure 2: Modeling its operations with Emulate3D, RNDC made key decisions about how to add volume to its distribution center without constructing another building.
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— molecular fluid dynamics, mechanic, kinematic — and also simulate a sensor and see how it performs in a digital space,” he explains. “All those types of things are possible using simulation tools that are capable of converting the simulated activity for the behavior of standard equipment or device or valve or motor in a digital point of view.”
In partnership with the U.S. Department of Defense, mxD in chicago is an ecosystem designed to solve critical manufacturing challenges. There, the Siemens Digital enterprise Lab provides a live mock manufacturing environment to demonstrate Industry 4.0 technologies with the merging of virtual and physical worlds.
At mxD, Siemens partnered with collaborative robot (cobot) manufacturer Universal robots (Ur) to create a palletizing cell, for example, to simulate the robot. “We are able to simulate all the behavior of the equipment — pick the parts, drop on the pallet, open and close the gripper, and do many cycles based on position,” Sassetti says. “All these types of things can be done before purchasing the hardware, including the metal, the PLc , and the end effector.”
The Ur simulations are also concerned with safety, Sassetti adds. They can simulate what the cobot will do when next to a human operator and determine where in the process it’s necessary to slow down or even activate the emergency stop.
Hirata, a Japanese system manufacturer that supplies transmission and engine assembly lines and electric vehicle and other automotive production equipment to numerous manufacturers, uses Siemens’ Process Simulate as part of a broad digital transformation initiative. With it, the company has been able to shorten the time it takes to go from product design to manufacturing.
Previously, Hirata required three engineers working
3–10 days to complete equipment validation. Using Process Simulate for 3D model validation, Hirata has reduced workforce hours by 90% and human-hour requirements by 66%.
Hirata has also used digital simulation tools to teach its robots offline. “Previously, we had to turn on the power, start up the robots, and then perform the teaching work to check for interferences, cable twists, and other issues,” says Shoichiro Seki, general manager of the engineering departments at Hirata. “Now all of that can be performed offline, which is incredibly helpful for manufacturing.”
Offline robot Programming
As a subsector of simulation software, offline robot programming (OLrP) can greatly benefit how integrators and manufacturers program, deploy, and reprogram their robots by eliminating the need to interrupt productivity.
Octopuz, which focuses specifically on the OLrP sector, says the software is just finding its footing in the general manufacturing market. As opposed to factory simulation software, which simulates how parts move through production, for example, and figures out bottlenecks, OLrP takes a much more focused view by creating production code that can be used in the real world.
The top application for Octopuz’ OLrP offering is robotic welding. “rather than programming the robot by standing in front of it with a teach pendant to do all the things needed to do a weld, you’re going to use software like Octopuz to do all that programming in a virtual environment,” says James Schnarr, senior product manager at Octopuz. “[Users] can make sure that the program is free of errors — so the robot’s not going to have errors and there’s not going to be any collisions. And then we actually produce the robot code at the end of it. They bring it to
Figure 3: Moving to Octopuz offline robotic programming not only saved Jomar Machining & Fabricating considerable time in programming its robotic welders but improved the quality of the welded parts.
their robot, and it’s ready to run exactly as they expected it to based on what they designed in our software.”
A key benefit to using OLrP as opposed to a teach pendant is to eliminate robot downtime. Typically, a user programs a robot to do one task. If the job changes, the time it takes to program the robot for a new task or product is time that the robot is not working.
That’s in part why robotic welding is a particularly important OLrP application. In robotic welding, changing one part can mean reprogramming 100 different welds. “If I’m standing in front of the robot with the teach pendant, I’m doing two things: I’m taking a long time to program those 100 welds, as I manually jog the robot through each of those welds and do the programming, but I’m also taking the robot off production,” Schnarr says. “That might take a day, it might take five days, it might take three weeks, depending on the complexity of the welds and of the programming. And if my robot’s getting programmed, then it’s not running production.”
conversely, with OLrP, the robot can be performing its initial weld job while the software is running on the computer. When the manufacturer is ready for the robot to move to the next job, the code is ready as well. “I might do some touch-ups, but I’m going to be ready to go with production in a few hours, maybe a day, as opposed to multiple days or weeks,” Schnarr says.
Aside from welding, applications that benefit from simulation software are other high-mix, low-volume operations, such as a fab shop performing contract work for several different customers.
Jomar machining & Fabricating in middlebury, Indiana, manufactures tire shredding equipment used for recycling tires. The company employs robots for hardfacing — the type of welds that most humans don’t like to do, says Lyndon Schlabach, robot programmer for Jomar, who also oversees the company’s welding operations.
“We had one robot that I was programming before we bought Octopuz. We were stopping the robot for a week straight just to do programming on a part,” Schlabach says. “With Octopuz, we can program the robots while they’re in production.”
Jomar has also found that the robots programmed offline produce better-quality welds. “On a surface weld, like we’re doing, to try to manually program all these paths and make them so they line up correctly to get a good even weld, it took a lot of time,” Schlabach says, adding that parts made by the Octopuz-programmed robots last longer in the field.
Artificial Intelligence and the Industrial metaverse
Simulation continues to evolve. “Today, the kind of simulation that you can run is probably a trillion times what you could do maybe 10 or 15 or 20 years ago,” Aglave says. “There are two parallel advances that are happening. One is the computing power itself, and the other is the understanding of the behavior of objects and systems — the physics behind it.”
As with many other manufacturing technologies, artificial intelligence (AI) is likely to speed the progress of simulation capabilities. “It only makes sense that we’ll see artificial intelligence integrations of all kinds,” Sarvo says. “People are certainly using AI decision-making algorithms. There are APIs [application programming interfaces] for that sort of thing, and powerful simulation tools provide open scripting environments where users can extend the software’s functionality as they like.”
AI is also gaining momentum to create simulations that are a hybrid between physics- and data-based models. “The second thing that will be gaining momentum would essentially be how to take a large simulation and reduce it down into a simpler behavioral model for controlling the manufacturing operations,” Aglave says, referring to this as an executable digital twin. “The simulation essentially acts as a distilled, intelligent brain that can be used to ask questions and immediately get answers to make changes to the manufacturing operations.”
combining AI with digital twins creates an industrial metaverse. “The next level of the digital twin is the industrial metaverse because it’s a place where we are leveraging the real data in combination with the digital twin, as well as the AI that is running behind the scenes in order to validate what is happening in the plant,” Sassetti explains. “It’s a live environment where you are able to test new possible solution improvements.”
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Listening to Female Voices: Women at ModuleWorks
In the traditionally male-dominated fields of mechanical engineering and computer science, the voices of women are often underrepresented. At moduleWorks, however, women are being empowered to thrive, with 21% of the workforce identifying as female—closely aligning with the percentages in German university engineering (10%) and computer science (22%) programs. The company is actively working to increase this representation by fostering an inclusive workplace and supporting female employees in balancing their professional ambitions with personal responsibilities.
building a culture of Flexibility and Inclusion
A 2023 study in Germany highlighted that workplace equality measures, such as childcare support and parental leave policies, can significantly decrease gender pay gaps while improving workplace satisfaction. moduleWorks has embraced this approach by offering flexibility in working hours and locations, discouraging extra hours, and implementing sabbatical policies. For parents, the
construction of an in-office childcare room further supports a family-friendly culture. These efforts place moduleWorks among a national network of family-friendly employers and align with its commitment to diversity as a signatory of the charta of Diversity initiative.
eva, a member of the research team, emphasizes the importance of flexibility: “Having children, it’s great to have the option of working remotely and adjusting my schedule when needed.” This sentiment is echoed across the company, where employees appreciate the freedom to manage both work and life effectively.
Amplifying Women’s Voices with FemWorks
One of moduleWorks’ standout initiatives is FemWorks, an internal working group aimed at increasing female visibility and supporting women in the company. Kristin, an algorithmic developer, recalls her first day at moduleWorks: “christine, my team leader, was thrilled that we now have three women in the team and quickly added me to the FemWorks group.”
The group not only empowers current employees but also works to recruit more women. roxana, QA department head in bucharest, notes: “As a team leader, I’ve always been encouraged to bring more women into my team. currently, about 40% of my team are women.”
Personal Journeys: Women Thriving in STem
The women at moduleWorks each have unique stories that reflect the supportive environment the company has cultivated. cristina, a product manager in bucharest, shares: “I’ve been passionate about engineering since childhood. moduleWorks gave me the chance to turn that passion into a thriving career in robotics and cAm.”
Similarly, Kristin candidly shares her initial doubts about entering a technical role: “I wasn’t sure my skills were applicable to a real job, but my colleagues’ support made all the difference. From the start, I felt part of the team.” This spirit of teamwork and mutual respect is echoed by christine, senior team leader: “At moduleWorks, everyone’s voice is heard. even our ceO is open to ideas and discussions.”
Overcoming challenges in Tech
While many women at moduleWorks praise the company’s inclusive culture, challenges persist in the broader tech industry. Issues like imposter syndrome, lack of peer parity, and balancing family responsibilities often create invisible barriers for women. moduleWorks addresses these
challenges by offering management training to foster awareness and ensuring equal opportunities in pay and career advancement.
eva notes, “During my studies and career, I’ve often been the only woman in meetings, but I’ve never felt like it mattered here. my colleagues treat me with respect and as an equal.”
creating a better Future
As moduleWorks continues to evolve, its commitment to diversity and inclusion remains unwavering. by actively supporting women through initiatives like FemWorks and fostering a family-friendly culture, the company is shaping a better future—not just for its employees but for the entire industry. For moduleWorks, listening to women’s voices isn’t just a step toward equality; it’s a cornerstone of innovation and growth.
About moduleWorks
moduleWorks is a global leader in digital manufacturing software, enabling the production of complex parts with efficiency and sustainability. Partnering with leading cAD/ cAm vendors and cNc toolmakers, moduleWorks drives innovation across industries, contributing to 16% of global GDP. With over 200 employees and a diverse portfolio, the company continues to empower its partners to achieve faster, smarter manufacturing solutions.
A New Patented Approach to Diffusion Bonding Offers Speed and Improved Process Control
An innovative process is reducing diffusion bonding time of aluminum and aluminum alloys by up to 50%, energy use by 30%, and improving quality.
contract manufacturers and design engineers in the aerospace, semiconductor, high-power electronics, and energy industries have been turning to diffusion bonded metals to produce new cutting-edge innovations.
Diffusion bonding is an essential joining method used to achieve a high-purity interface when two similar or dissimilar metals require superior structural integrity, and a traditional brazing approach fails to yield quality results. The process involves applying high temperature and pressure to metals mated together in a hot press, which causes the atoms on solid metallic surfaces to intersperse and bond.
Today, much of the innovation occurring in either high-demand or high-quality industrial sectors involves aluminum as one or more of the layers of metals that are bonded. Aluminum, and its broad family of alloys, is prized as a lightweight metal with strong structural integrity, high electrical and thermal conductivity, corrosion resistance, and a malleability that makes it easy to shape.
Aluminum's unique blend of lightness, strength, and purity makes it indispensable across various industries. In aerospace, its high strength-to-weight ratio is crucial for structural components. For semiconductor equipment, aluminum enables the fabrication of intricate, contamination-free channels essential for gas and fluid flow, avoiding the impurities inherent in traditional joining methods like brazing or welding. Furthermore, aluminum's compatibility with diffusion bonding allows for the creation of complex cooling channels in high-power electronics, injection molds, and specialized heat exchangers—designs often impossible to achieve through conventional machining.
Unfortunately, the characteristics of aluminum present a challenge for the traditional diffusion bonding process, which involves the application of radiant heat into the metal layers while in a vacuum furnace. Aluminum tends to reflect radiant heat and has a relatively low melting point in relation to the temperatures that must be achieved for proper diffusion bonding.
engineers cleverly confronted the issue by developing a conductive heating method which more rapidly reaches bonding temperature. This new approach offers an alternative to traditional diffusion bonding by circumventing the slow process of radiant heating structural assemblies in a vacuum environment.
The c.bOND machine utilizes precisely controlled heat conduction, instead of radiation, to enable high speed production of aluminum-to-aluminum, or aluminumto-dissimilar material parts. After several years of developmental research, the c.bOND tool can now reduce
total diffusion bonding process time essentially in half, and thus reducing the energy required during processing by as much as 30%. This also improves the quality of the bond in certain instances.
expediting Aluminum Diffusion bonding
In the traditional diffusion bonding process, a vacuum furnace provides radiant heat to the surface of the part. Subsequently the heat is conducted through the assembly and transmitted to the faying surface where required. However, when radiation becomes the dominant form of heat transfer, particularly at relatively lower temperatures in vacuum, below 600°c , aluminum’s thermal conductivity is time consuming.
Aluminum excels at conducting heat, particularly at lower temperatures, making it ideal for applications requiring efficient heat dissipation, such as in electronics and automotive components.
“Aluminum’s high reflectivity poses a challenge in traditional diffusion bonding. It’s like trying to heat a mirror with a spotlight – the energy is reflected away instead of being absorbed into the material [using the traditional diffusion bonding process],” says Horst-Gunter Leng, Product manager, PVA TePla, a global manufacturer of industrial furnaces and PulsPlasma nitriding systems.
Horst-Gunter Leng adds that diffusion bonding
throughout the process. To prevent overheating of the load, slow heating rates traditionally are applied, leading to long process times.
In addition, aluminum alloys have a narrow processing temperature range for successful bonding. When temperatures fall outside that critical temperature band a poor bond is produced.
To overcome the existing challenges of bonding aluminum, PVA TePla and its partner initiated an extensive development program and came up with an innovative solution: integrating heating elements directly into the press platens, explains Horst-Gunter Leng. “This approach speeds up the bonding process, and significantly enhances efficiency by directly transferring heat to the aluminum components.”
The culmination of extensive research and development is the c.bOND machine, features a unique combination of direct conduction heating through the top and bottom platens which are in contact with the assembly. This innovative design ensures bi-directional homogenous heating and more precise temperature at the bonding interface where it is required.
The c.bOND machine utilizes a hot-press tool with advanced software and feedback sensors to achieve micrometer-precise pressure control across the entire component surface. This ensures uniform bonding over
heating of specific areas, preventing unnecessary heat exposure to other parts of the component.
The high-vacuum atmosphere within the chamber eliminates contamination and prevents voids in the bonded joint.
“With the [c.bOND] the time to heat the part to the ideal temperature for bonding is cut in half compared to traditional radiant heating. With less processing time required, the energy requirements are reduced by up to 30% as well,” says Horst-Gunter Leng. He notes that multilayer stacking is also possible, which can further increase productivity.
The c.bOND technology demonstrates significant quality improvement of bonded aluminum components. The technology improves temperature homogenity in the load by 70%, which enhances bonding across the the entire surface. The technology also improves the parallelism of parts by 50%, which enhances the accuracy of geometric dimensions, tolerances, and product specifications.
According to Horst-Gunter Leng, the c.bOND furnace technology by PVA TePla is commercially available today for high volume production. The innovative furnace technology incorporates another feature unique to the industry, utilizing PVA TePla’s proprietary automatic bonding software (AbP).
“With the automatic bonding software, you place your parts in the furnace, input a few parameters such as
the size of the bonding area and the software calculates automatically the optimum processing parameters. No specific diffusion bonding knowledge from the operator is required,” says Horst-Gunter Leng.
He notes that the recipes can be modified according to the type of material being bonded, the thickness of the material, its surfaces, and other factors. During the process the software continuously monitors the process in real-time and adjusts parameters accordingly.
A c.bOND unit is installed at a national research facility in Germany, The Günter Köhler Institute for Joining Technology and materials Testing (ifw Jena) an independent, non-university industrial research institution that conducts research in diffusion bonding, additive manufacturing, brazing, welding, laser processing, material science, and other forms of bonding.
The c. b OND system is compact, requires minimal maintenance, and enables high-volume production of aluminum components for diverse industries. Its benefits are being realized in aerospace, where it creates lightweight yet strong aircraft components. In the semiconductor industry, it provides a cleaner alternative to brazing, eliminating the risk of solder contamination. There is also growing demand for diffusion-bonded aluminum heat sinks, crucial for cooling high-power silicon carbide (Si c) electronics.
Diffusion bonding also has applications for conformal cooling. The concept is to bond layers of sheet metal that contain machined channel/microchannel structures. When combined, the channels provide a path for heat dissipation. current applications include power electronics for effective heat management and rapid cooling of molds utilized in injection and blow molding processes.
With the size of components continually getting smaller in sectors like semiconductors and electronics, controlling the amount of time, and by extension heat, introduced into the part becomes more critical.
“As the features [of the internal channels] become more miniaturized, it becomes even more important to control the heating during the diffusion bonding process to avoid any distortion in the part,” says Horst-Gunter Leng. “If you can shorten the cycle time, you introduce less heat into the part. This will facilitate creating parts with conformal cooling channels that have finer and finer features.”
Diffusion bonding is increasingly valuable for joining dissimilar metals, such as aluminum to steel or titanium. This allows engineers to design components and assemblies with the best properties of each metal. For example, one metal might offer superior corrosion resistance while the other provides greater strength. This 'packaging' of dissimilar metals opens up new possibilities in design, particularly for overall weight reduction of design and enhancing performance in challenging environments.
When joining dissimilar surfaces, a liquid-phase diffusion bonding process is utilized, particularly when the bonding interface extends beyond r&D sized samples. This often involves an interlayer of an alloy that typically melts at the faying surfaces. When the interlayer includes aluminum, the c.bOND can delivery controlled heat to increase the bonding speed.
Although the c.bOND technology is designed to improve the diffusion bonding of aluminum, PVA TePla can design the machine around the specific needs of the customer customized for the alloy, including copper, which has many applications in specialized heat exchanger or for products used in the microelectronics industry. The company is exploring options to modify the c.bOND to achieve even higher temperatures above the current maximum of 800°c , according to Horst-Gunter Leng.
As diffusion bonding of aluminum gains importance across industries, contract manufacturers and design engineers must embrace the latest advancements to remain competitive. by adopting fast, energy-efficient diffusion bonding technologies for aluminum and other materials, they can unlock higher production volumes, reduce costs, improve or achieve global sustainability targets, and realize increased profitability.
For more information, contact PVA TePla America at 951-371-2500 or 800-527-5667 or visit www.pvateplaamerica.com.
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modern manufacturing demands innovative solutions to optimize efficiency and maximize productivity. enter the KASTO UNITOWer cnc—a state-of-the-art tower storage system that addresses the dual challenges of space optimization and operator-free cNc machine operation. Designed to automate the feeding of cNc machining centers, the UNITOWer cnc is a game-changer for manufacturers striving for peak efficiency and precision in their operations.
revolutionizing cNc machine Feeding
Supplying cNc machining centers with workpiece carriers can be both labor-intensive and space-consuming. The UNITOWer cnc solves these issues with its fully automated feeding system. capable of continuous operation, the system supports cNc machining centers by supplying fully loaded pallets to the machines. Simultaneously, employees can prepare fixtures and workpieces at separate workstations, ensuring minimal downtime and maximum productivity.
One standout feature of the UNITOWer cnc is its ability to operate autonomously during operator-free shifts, such as at night. by continuously supplying pre-loaded pallets, the system keeps machines running efficiently, even in the absence of direct supervision. This capability not only enhances productivity but also reduces labor costs, making it an ideal solution for manufacturers seeking to streamline their operations.
compact Design with maximum Flexibility
The UNITOWer cnc is based on KASTO’s proven UNITOWer tower storage system, which has been a staple in industrial storage for years. With heights of up to 20 meters, the tower provides an impressive amount of storage space while requiring minimal floor space. The system accommodates machine pallets up to 3,000 millimeters long and 1,500 millimeters wide, with each storage compartment capable of handling loads up to five tonnes.
The UNITOWer cnc’s modular design offers unparalleled flexibility, making it suitable for a wide range of applications and industries. It can store one or two machine pallets per compartment, depending on the load size, and its zero-point clamping system maximizes available space while offering a cost-effective alternative to traditional machine tables.
Advanced Automation capabilities
One of the most impressive features of the UNITOWer cnc is its ability to integrate seamlessly with multiple cNc machines, regardless of the manufacturer. The system uses overhead gantry cranes (OGcs) and transfer trolleys to move pallets between the storage tower and the machining centers. The intelligent control system, powered by KASTOlogic software, ensures that workpieces are delivered to the appropriate machines based on specific production orders.
The KASTOlogic software goes beyond simple logistics. It checks for the availability of required Nc programs and tools, monitors production processes, calculates completion dates, and determines the optimal orderhandling sequence. These advanced capabilities make the UNITOWer cnc an indispensable tool for manufacturers looking to optimize their workflow and minimize downtime.
The buffer function allows UNITOWER cnc to link upstream setup work to the machining centre.
The workpieces can be
at
at the front of the system and fed into one of the two machining centres. In preparation for operator-free shifts, users can buffer
ergonomics and employee Well-being
The UNITOWer cnc is not just about automation—it’s also about improving workplace ergonomics and employee well-being. by minimizing the manual handling of heavy workpieces, the system reduces the risk of workplace injuries and frees up employees to focus on more valueadded tasks. This focus on ergonomics is part of KASTO’s commitment to creating a safe and efficient work environment for its customers.
Future-Proofing manufacturing Operations
With its modular design and extensive automation capabilities, the UNITOWer cnc is a forward-thinking solution for manufacturers looking to future-proof their operations. The system can be expanded as needed, making it a scalable solution for growing companies. Its ability to integrate with a wide range of cNc machines and other equipment ensures that it remains relevant as manufacturing technologies evolve.
A Proven Solution with real-World Applications
KASTO’s expertise in sawing, storage, and automation technology is evident in the design of the UNITOWer cnc. With more than 140,000 sawing machines sold worldwide and over 2,400 automated storage systems installed, KASTO has a proven track record of delivering high-quality, reliable solutions for the manufacturing industry.
The UNITOWer cnc is a prime example of this expertise. Its compact design, advanced automation features, and focus on ergonomics make it a standout solution for manufacturers looking to optimize their operations. companies interested in seeing the system in action can visit KASTO’s headquarters in Achern, Germany, where the UNITOWer cnc is showcased in a real-world production environment.
conclusion
The KASTO UNITOWer cnc is more than just a storage system—it’s a comprehensive solution for automating cN c machine feeding and improving manufacturing efficiency. b y addressing the challenges of space optimization, automation, and employee well-being, the UNITOWer cnc sets a new standard for precision machining and fabrication.
For manufacturers looking to stay ahead in an increasingly competitive market, the UNITOWer cnc offers a reliable, scalable, and future-proof solution. With its advanced features and proven performance, it’s no wonder that the UNITOWer cnc is quickly becoming a must-have tool for modern manufacturing operations.
For more information on the KASTO UNITOWer cnc, visit www.kasto.com or contact KASTO maschinenbau GmbH & co. KG directly.
clamped
workstations
workpieces in the UNITOWER cnc.
Elevating Automation Through Education: Bridging the Skills Gap with Industry and Academia
As the manufacturing landscape continues to evolve, driven by rapid advancements in automation and emerging technologies, there is a growing need to ensure the future workforce is equipped with the necessary skills to thrive in this changing environment. At the forefront of this effort are industry leaders like Ted rozier of Festo Didactic and Stephanie Kobayashi of Universal robots, who are working to bridge the gap between industry and academia.
In a recent interview on Universal robots’ "reanimated" podcast, rozier and Kobayashi shared their insights on the critical role of education in preparing the next generation of manufacturing professionals.
rozier, the Director of Digital Advanced Technology and robotics for Festo Didactic North America, has a unique perspective on this challenge, having spent 18 years as a system integrator before transitioning to the education space. "When I got the opportunity to join Festo and bring that 18 years of experience into the classroom, I realized that there was more to it than just putting the emerging technology in front of the students," he explained. "Part of that full-blown turnkey solution is the curriculum."
This sentiment is echoed by Kobayashi, who is the Global Industry Segment manager for education at Universal robots. She too recognized the importance of curriculum and content development when she first started working on education programs while at Zeiss, a leading manufacturer of optical and optoelectronic systems.
"I actually sat down and built educational curriculum and content based off of our industrial training materials that we had, that could go and be used by schools for teaching," Kobayashi said. "I could really resonate with what Ted said about content being king."
The emphasis on content and curriculum is critical, as it goes beyond simply providing the technology and equipment. It's about ensuring that students not only have hands-on experience with the latest tools and systems, but also a deep understanding of the underlying principles and concepts.
"When we speak specifically to the project that we've worked on together with the robot safety training cart, something that I love about that is that in working with different schools, when they pull the product out the box, they want to know how do I get started," rozier explained.
"They don't want to know about theory. They want, you need to be able to show what it does."
Kobayashi echoed this sentiment, highlighting the importance of creating a comprehensive learning experience that combines theory, interactive lessons, hands-on activities, and knowledge checks. "We've got an amazing e-learning platform. It's actually free on Universal robots Academy. And you can go in and you can actually start programming through an interactive e-learning interface without a robot, without anything next to you. So really just start to get a feel for how this is going to work."
but the learning journey doesn't stop there. rozier emphasized the significance of certification, noting that it serves as a critical bridge between education and industry. "When a student goes to get a job, how is he interviewed? And if you can show me a certificate that you have specific skill sets, I know how to query you to see if you know what you're talking about. Without the certificate, I have to start from scratch."
This focus on certification is not just about validating the student's knowledge, but also about ensuring that the curriculum and content are truly aligned with the needs of industry. "curriculum is the gas to certification. You can't certify unless you've done a good job on the curriculum side. If you do it the opposite, it's not going to be stackable," rozier explained.
The partnership between Festo Didactic and Universal robots is a prime example of how industry and academia can collaborate to create robust, industry-aligned educational programs. by integrating Universal robots'
collaborative technology into Festo's "manufacturing Production System" (mPS) training cart, they've developed a comprehensive learning platform that goes beyond just teaching the basics of robotics.
"That cart attaches to approximately 10 other modules. And that's why it's a great transition from the core into the systems approach, because now you're not only building a part, but it's going to be processed," rozier said. "So that student, not only do they understand or get a chance to learn about safety that's integrated into that system, but functional safety. What does it mean to the whole system?"
the workforce of the future.
Kobayashi emphasized the importance of this systemslevel approach, noting that robots rarely operate in isolation in the real world. "robots are never working alone on a production floor. Anyone who's worked with robotics knows that. And while it's really important to get a base understanding of operation with robotics, which universal robots curriculum and hardware set is a really great place to start with that. Students really need that real-world exposure to other elements, to PLc , to really understand how robots communicate and interact with other peripheral equipment."
This holistic approach to education, integrating theory, hands-on practice, and real-world systems thinking, is a testament to the collaborative efforts of Festo and Universal robots. but it's not without its challenges, as rozier pointed out.
"The hardest part, I would say, when it comes to, we'll speak to emerging technology and some of the buzz out there, Industry 4.0. Okay. When you talk about our communication architecture, sometimes you want to walk in the classroom and you want to hit the easy go button. Okay. A tightly integrated system, when everything is aligned and it's put together, it runs like a champ. but there are issues come up within our cyber physical platform and manufacturer production system."
To address these challenges, Festo has incorporated an "Overall equipment effectiveness" (Oee) platform, which adds an additional layer of complexity to the learning experience. "It takes the student and makes it where they're not just working on or troubleshooting electrical, mechanical, IeLTS software. but big picture, what does the ceO care about in a manufacturing plant? Throughput. So, when you start to integrate all of that technology, try and slow everyone down and get them to understand each layer. It does take a little more time."
but the payoff is worth it, as rozier and Kobayashi both believe that this holistic, industry-aligned approach to education is crucial in bridging the skills gap and preparing
"employability. We've seen students go through and they're able to walk into a manufacturing plant and they're able to read the program," rozier said. "They should be able to read that story, just like they went to their new employer. They walk in that manufacturing plant up to the line, whatever it is, they're going to grab the program and they should be able to read it."
Kobayashi echoed this sentiment, emphasizing the value that these educational programs bring to both students and employers. "That tells future employers that this student understands these skills and these competencies and has this level of understanding on a specific topic, whether that be mechatronics, industry 4.0, robotics. So really brings a lot of value, I would say, both to students, but then also to those future employers that they can understand where students are understanding is and what their specializations are."
As the manufacturing landscape continues to evolve, the importance of bridging the skills gap through innovative and industry-aligned educational programs cannot be overstated. rozier and Kobayashi's work at Festo Didactic and Universal robots, respectively, serves as a shining example of how industry and academia can collaborate to elevate the future of automation and manufacturing.
"It's one of the things that really excites me. How can you demystify emerging technology methods in the classroom?" rozier said. "being able to bring smart manufacturing into the education space is extremely exciting. It's what gets me up every morning."
by prioritizing content, curriculum, and industryrelevant certification, while also embracing a systemslevel approach to learning, Festo and Universal robots are paving the way for a new generation of manufacturing professionals who are equipped to thrive in the ever-changing landscape of automation and Industry 4.0. This collaborative effort serves as a model for how industry and academia can work together to address the skills gap and ensure the long-term success of the manufacturing sector.
PRODUCT SHOWCASE
Industrial machinery Digest's monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.
ANc A’s Peel Grinding Solution: Seamless Tool Production on the mX7 Platform
ANc A introduces an innovative peel grinding solution on its m X7 platform, allowing blank preparation and tool grinding in a single setup. equipped with the P-axis Arobotech for enhanced blank support and precision, this system delivers exceptional surface finishes below 0.2 ra and reduces cycle times. The m X7 features six wheel packs, eliminating wheel changes while supporting a wide range of tool shapes and geometries. With a 3000 rPm headstock and tailored hydraulic pump for clamping pressure control, productivity and accuracy are maximized. The solution accommodates tool diameters from 1mm to 25.4mm and supports diverse tools like taper ballnose and lollipop cutters. The "blanket grinding" capability further boosts efficiency by enabling automatic bar stock loading for batch production. ANc A’s Loadermate software complements this with detailed tracking and management of blanks. The m X7 platform ensures seamless integration for manufacturers seeking reduced setup times, precision, and increased throughput.
For more information, visit www.anca.com.
Arnon electrical Steel: Driving efficient motor and Generator Performance
Arnold magnetic Technologies introduces Arnon™ Non Grain Oriented electrical Steel (NGOeS), designed for smaller, lighter, and more efficient motors and generators. by reducing eddy currents through optimized thicknesses— ranging from 0.004" to 0.007"—Arnon NGOeS improves
ANCA’s Peel Grinding Solution: Seamless Tool Production on the MX7 Platform
energy efficiency and minimizes heat buildup. This material is ideal for high-speed, high-efficiency applications in motors, transformers, and generators operating at frequencies above 400 Hz. Its thinner laminations significantly reduce core losses, enhance design flexibility, and achieve performance levels exceeding 98% efficiency. As a standout in the NGOeS market, Arnon supports advanced applications like motors with switching frequencies above 1K Hz. Arnold’s expertise in precision thin metals positions this solution as a leader in achieving sustainable and high-performance energy solutions for demanding industrial environments.
For more information, visit www.arnoldmagnetics.com.
bradley’s Stainless Steel enclosed Safety Shower with Halo™ eye/Face Wash
bradley corporation debuts its stainless steel enclosed safety shower, equipped with advanced Halo™ eye/Face Wash technology for superior emergency drenching. crafted from durable 300-series stainless steel, the design ensures resistance to harsh chemicals and hygienic performance. The modular system features a sloped center drain and removable floor grate for easy maintenance. The Halo technology offers 20% better protection with a uniform spray pattern and a self-draining mechanism to prevent stagnant water buildup. Additional features include antimicrobial modesty curtains and a dual-entry design set for 2025. The unit complies with ANSI/ISe A Z358.1 standards and is ideal for data centers, pharmaceutical facilities, and other cleanroom environments. bradley’s enclosed shower redefines emergency safety with unmatched hygiene and durability.
For more information, visit www.bradleycorp.com.
eSAb’s OK Goldrox 7018: Premium Stick electrodes for easy Operation
eSAb introduces the OK Goldrox 7018, a low-hydrogen Stick electrode designed for smoother arc characteristics and easier restrikes. Delivering exceptional arc stability and low spatter, this electrode ensures enhanced control in out-of-position welding and easy post-weld cleaning. Available in multiple diameters and packaging options, the
OK Goldrox 7018 suits applications in power generation, structural steel, and petrochemical industries. classified as AWS e7018-1 H4r , it features excellent moisture resistance and low hydrogen diffusion, ensuring durability in harsh conditions. Welders, from professionals to occasional users, benefit from its wider operating range and ease of manipulation, offering improved productivity and welding quality.
Fixtureworks announces its line of pneumatic shaft-locking clamps, designed for quick-change and workholding applications. These clamps come in compact (PSLc-L) and heavy-duty (PSLc-m) models, supporting shaft diameters ranging from 8mm to 30mm. engineered from durable aluminum and steel, they provide secure clamping during machinery adjustments while enabling frequent disassembly and reassembly. Features include spring clamping for safety during air loss and optional sensor brackets for enhanced functionality. The clamps are ideal for industrial automation, multi-clamping cycles, and applications requiring precision and efficiency. Fixtureworks continues to lead in offering robust and versatile clamping solutions tailored to modern manufacturing needs.
For more information, visit www.fixtureworks.net.
beckhoff’s Am8300 Servomotors: High Power in compact Design
beckhoff introduces the A m8300 series, a water-cooled servomotor line delivering up to 40 kW of power in a compact form. Offering three times the standstill torque of conventional motors, this series is ideal for high-speed and dynamic applications. With IP65 protection, integrated water cooling, and modular configurations, the A m8300 excels in harsh environments and
high-temperature operations. Its seamless compatibility with AX5000 and AX8000 servo drives and optional accessories ensures flexible integration for demanding industrial setups. beckhoff sets a new standard in motor performance, prioritizing efficiency and durability.
For more information, visit www.beckhoff.com.
bruker Alicona’s FocusX enhanced with real3DUnitX for 5-Axis measurement
bruker Alicona upgrades its FocusX measuring system with the real3DUnitX, adding two axes for comprehensive 360° measurement. Designed for production environments, this system excels in inspecting complex geometries and reflective surfaces. The real3DUnitX automates measurement alignment, enhancing efficiency and accuracy in applications like cutting tools, electronics, and medical devices. Paired with metmaX software, it ensures precise and intuitive operation. bruker Alicona highlights these capabilities in an upcoming online event, demonstrating its transformative impact on quality control.
For more information, visit www.alicona.com.
Danfoss Power Solutions Launches editron em-PmI540b electric motor
coxreels® extreme Duty XTm Series with Dual Hydraulic reel coxreels introduces the Dual Hydraulic XTm-DmP-450 reel, part of its e xtreme Duty XTm Series. Designed for demanding applications, such as mining and off-road industries, the reel combines durability and innovation. Featuring a dual-bodied hydraulic swivel with single-sided inlet connections, it is ideal for remote hydraulic equipment like rescue tools and saws. With a twin-line bonded hose and a 2500 PSI rating, it ensures smooth performance and reliable hose management. built on the robust TmP T-Series platform, it incorporates stainless steel rollers, permanently lubricated bearings, and vibration-resistant components. The reel's heavy-duty spring motor and solid steel construction enhance stability and performance, even in extreme conditions. made in the USA, the XTm-DmP-450 offers unmatched durability and efficiency.
For more information, visit www.coxreels.com.
Danfoss introduces the editron em-PmI540b electric motor, offering market-leading efficiency of 96% and 24/7 continuous power. Designed for electric and hybrid machinery, it is compact and lightweight with IP67-rated housing. Improvements include a higher altitude rating of 4,000 meters and versatile mounting options. Ideal for mining, forestry, and marine applications, it supports torque ratings from 1,500 Nm to 4,000 Nm and power ranges up to 1,000 kW. The liquid-cooled motor's robust design enhances machine productivity and simplifies operations in demanding environments.
For more information, visit https://www.danfoss.com/en-us/
eSAb cutmaster® 50+ and 70+ manual Plasma cutters
eSAb launches the cutmaster ® 50+ and 70+ plasma cutters at FAbTecH, delivering cutting-edge performance for metal fabrication. The cutmaster 50+ cuts up to 5/8 inches, while the 70+ cuts up to ¾ inches, with severing capacities up to 1 ½ inches. both models feature a
Bruker Alicona’s FocusX Enhanced with Real3DUnitX for 5-Axis Measurement
4.3-inch TFT display, glove-friendly knob, and automatic voltage detection. Optional mechPak kits enhance mechanized cutting, while ergonomic designs reduce operator fatigue. With IP23S rugged housing, these machines suit diverse industries like HVAc , pipeline, and automotive.
For more information, visit www.esab.com.
e XAIr Turboblast® Safety Air Gun: Powerful and Adjustable
e XAIr introduces the Turboblast® Safety Air Gun, designed for tough industrial cleaning applications. With an adjustable gate valve, it provides variable force for removing debris, part drying, and heavy-duty cleanup. The gun features a cast aluminum handle with an ergonomic grip, a "Dead man's" safety trigger, and integrated nozzle guard. multiple flow rates and extensions up to 6 feet enhance reach and adaptability. ce-compliant and OSHA-certified, it meets rigorous safety and performance standards.
For more information, visit www.exair.co/tbvalve.
e-Z LOK Adds Insert and Torque Out Testing equipment
e-Z LOK now offers in-house pull-out and torque out testing for its threaded inserts. The equipment measures performance in metal, plastic, and wood materials, providing engineers with detailed test data for bolted joint designs. results will be available online in the " resources" section and as downloadable PDFs. This capability ensures accurate performance metrics and supports future product innovations.
For more information, visit www.ezlok.com.
Hamilton caster’s Field Installable Toe Guard enhances Safety
Hamilton c aster unveils its Field Installable Toe Guard, designed for workplace safety and operational efficiency. made from 3/16-inch steel, it features heavy-duty and ergonomic brakes, optional floor brushes, and a height-adjustable skirt. The versatile design integrates seamlessly with existing casters, offering protection and debris management. Available in eight sizes for wheels ranging from 4 to 12 inches, this robust solution meets diverse safety needs.
For more information, visit www.hamiltoncaster.com.
HemcO’s enclosures for Lab Automation and robotics
HemcO introduces enclosures tailored for lab automation and robotics, offering protection for personnel and processes. These units isolate liquid handling, HPLc , weighing, and screening tasks while providing HePA filtration or exhaust air systems. With modular designs and customizable sizes, HemcO enclosures suit various laboratory needs, ensuring safety and contamination-free operations.
For more information, visit www.hemcocorp.com/enviro.html.
KHK USA Inc.
Highlights ratchets & Pawls for motion control
KHK USA Inc., distributor of KHK® metric gears, highlights its SrT series of ratchets and pawls designed to restrict rotational motion to a single direction. made from durable 1045 carbon steel with induction-hardened teeth, these components withstand torque loads ranging from 3 Nm to 550 Nm. Ideal for applications needing reverse rotation prevention, the ratchets support customization with open bores, keyways, and set screws, requiring just three business days for production. KHK’s ratchets and pawls combine precision engineering with versatile application in motion control systems.
For more information, visit www.khkgears.us
KHK USA Launches extensive metric Worm Gears Line
KHK USA Inc. announces its extensive line of metric worm gears, offering quiet, efficient power transmission for compact, high-reduction applications. Available in diverse materials, including carbon steel, bronze, and nylon, these gears accommodate secondary operations like bore adjustments and keyway additions. Unique to KHK is the Duplex Worm Gear, featuring variable pitch to eliminate backlash for precision applications. KHK’s worm gears are suitable for various industries requiring high efficiency in constrained spaces.
housings, short switching distances, and high tolerance to misalignment. With IP67 and IP69K ratings, the series is ideal for hygienic and washdown settings. Options include various cable lengths, quick disconnects, and versions rated up to 3A for Ac/Dc voltage. High-temperature models are also available.
Norstat’s P.Tr Ace transducer offers precise pressure measurement for liquid, gaseous, and viscous fluids, with a range up to 8700 PSI. compact yet robust, the stainless steel device features a ceramic measuring element for high accuracy and fast response times.
For more information, visit www.khkgears.us/products/ worm-gear-pair/.
Norstat introduces the magnasafe series of magnetic, non-contact safety switches for machine guarding applications. Designed for harsh environments, the switches feature robust AbS or stainless steel
Designed for hydraulic circuits and industrial plants, it operates under harsh conditions with IP65, IP67, or IP68 protection. The transducer supports three seal options for diverse applications.
For more information, contact Norstat.
russelectric Offers System control Upgrades for critical Power equipment
russelectric, a Siemens business, provides system control upgrades to enhance the performance, lifespan, and capabilities of critical power equipment. Upgrades include automatic transfer switches, operator interfaces, PLc systems, and circuit breakers, addressing obsolescence concerns while improving reliability. These cost-effective solutions are implemented by russelectric
Field engineers, ensuring minimal downtime and professional service. The upgrades enhance monitoring, communications, and overcurrent protection, keeping equipment at peak efficiency.
For more information, visit Field Services & AftermarketSiemens USA.
Sandvik coromant Introduces Automatic Tool change for Turning centers
Sandvik coromant launches automatic tool change (ATc) for machine-adapted clamping units, enabling unmanned production in turning centers. This innovation eliminates manual tool changes, enhancing machine utilization
and productivity. The ATc solution ensures precise tool handling, reduces energy consumption, and streamlines complex part production, delivering a quick return on investment. Sustainability benefits include minimized waste and improved overall equipment efficiency.
For more information, visit the Sandvik coromant website.
TAb Industries has announced its patent-pending TAb ribbed Stretch Wrap has passed compatibility tests on various stretch wrapping machines, including the TAb Wrapper Tornado, horizontal turntable wrappers, and straddle wrappers. Designed for packaging and material handling professionals, the ribbed wrap features Power band technology that weaves thick plastic ribs into the film for added strength and tear resistance. This proprietary cast film ensures high compression force while maintaining smooth dispensing, even at high speeds. Suitable for heavy-duty applications, the stretch wrap comes in rolls of 20 inches wide and 4,000 feet long, stocked at TAb Industries' reading, PA headquarters.
For more information, visit www.tabwrapper.com.
Vogelsang eP Series: High-Performance rotary Lobe Pumps
Vogelsang introduces the eP series rotary lobe pumps for extreme industrial applications in oil, gas, and petrochemical industries. With uniform pressure output up to 260 psi, the
pumps handle abrasive, high-temperature, and chemically aggressive media. Features include a robust one-piece housing, pulsation-free conveying, and groundbreaking seal technology for enhanced reliability and uptime. The AirGap design separates the gearbox from the pump chamber to prevent leaks. Two seal options, coX- c artridge and API- c artridge, accommodate aggressive media and meet API 682 guidelines. The optional Automatic Supply Unit (ASU) prolongs seal life by maintaining consistent lubrication.
For more information, visit www.vogelsang.info/en-us/.
Walter m2029 Octagon Face milling cutter enhances Productivity
Walter's new m2029 octagon face milling cutter delivers low axial pressure and superior performance for finishing cast iron and steel parts. Featuring indexable inserts with 16 cutting edges powered by Tiger·tec Gold® grades WKP35G and WSm35G, the cutter offers exceptional durability and cost savings. Applications include automotive and mechanical engineering, with benefits such as time savings, reduced tool material costs, and even surface finishes. In a competitive trial, the m2029 machined 80% more parts than a comparable tool. Available in diameters ranging from 2.0 to 10.0 inches, it supports reliable operations under low-rigidity conditions.
For more information, visit Walter’s website.
Walter PcD milling cutters for Non-Ferrous metals
Walter introduces the mP060, mP160, and mP260 P cD milling cutters for machining aluminum, composites, and plastics. These cutters offer a service life 20 to 200 times longer than carbide tools, thanks to Walter’s WDN20 grade poly-crystalline diamond. The mP060 is ideal for roughing and finishing large surfaces, the mP160 for ramping and slotting, and the mP260 for small flat surfaces and full slotting. All models feature internal coolant supply and compatibility with mQL or emulsion cooling. reconditioning options extend tool life further, ensuring cost-effective and precise machining for aerospace, automotive, and general engineering applications.
For more information, visit Walter’s website.
THE LEADER IN INNOVATIVE SURFACE FINISHING SOLUTIONS
DIE GRINDERS & DISC SANDERS
+ Durable, American Made air tools are ideal for rapid material removal, deburring, finishing and polishing.
+ Straight-Line, Right Angle and 7° Offset models offered in front and rear exhaust configurations.
+ Tools available in horsepowers ranging from 0.3 hp to 3 hp, with speeds from 3,200 RPM to 100,000 RPM.
