Tessy Plastics & Mantle 3D Printing: A Game-Changer in High-Volume Molding
Evaluating 3D-Printed Inserts vs. Machined Inserts for Durability and Precision
Revolutionizing Workplace Safety and Efficiency with Sky Hook
The Future of Robotic Welding and Fume Extraction
Bowman International Enhances Quality Control with LK Metrology
Boosting Productivity and Profits with Automation: Strategic ROI Benefits
Industrial Automation Technologies Give Manufacturers a Competitive Edge Amid Labor Shortages and Rising Demands
Brake System Design for the Future: Enhancing Performance, Aesthetics, and Sustainability
Fraunhofer Report: Practical Solutions for Intelligent and Safe Production
How to Evaluate the Quality of Precision Tooling
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North America’s Manufacturing Resource for Industry Professionals Since 1986
William c. Strickland III, Publisher william.strickland@indmacdig.com 800-366-0676 ext. 103 | Fax: 866-826-5918
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
CIRCULATION & SUBSCRIPTIONS
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REPRINTS
To purchase article reprints please call 800-366-0676 ext. 103 or email wstrickland@indmacdig.com
SETTING NEW STANDARDS FOR SAFE LIFTING
• Large range of sizes, up to M1000/UNC 4 "
• Embedded RFID creates easier inspections
• Replaceable bolt extends use, saves money
• Spring mechanism prevents sagging and transverse loads
• Huge selection of sizes are IN STOCK!
THE
TURNADO
Forging the Future: Innovation, Precision, and adaptability in Manufacturing a s manufacturing evolves, innovation remains the key to staying ahead. across sectors, from fabrication to robotics, companies are redefining efficiency and precision. Tessy Plastics & Mantle 3D Printing is proving that high-volume molding can be transformed through additive manufacturing, while the ongoing comparison of 3D-printed inserts vs. machined inserts highlights the balance between modern technology and traditional precision. In material handling, advancements like Sky hook are optimizing workplace safety and efficiency, showing that smart solutions can reduce strain and enhance workflow. Meanwhile, in safety, the integration of robotic welding and fume extraction is not only improving air quality but also ensuring cleaner, safer environments for workers.
Quality control remains a top priority, with Bowman International enhancing precision through LK Metrology, demonstrating the role of advanced measurement in modern production. Even the slightest variation can have major consequences, making metrology a critical component of manufacturing success. Industrial automation is also shaping the industry, helping companies maintain productivity despite labor shortages. In metalworking, future brake system designs must merge performance, aesthetics, and sustainability—three pillars shaping the next generation of engineering. Meanwhile, software innovations, like Fraunhofer’s intelligent production solutions, highlight how aI and automation are driving efficiency while ensuring workplace safety.
Finally, tooling and workholding remain the foundation of precision manufacturing. Understanding how to evaluate the quality of precision tooling is critical in a field where accuracy and efficiency define success. a s these developments continue to shape the industry, it’s clear that the future will be defined by those who embrace change, leverage cutting-edge technologies, and uphold the craftsmanship that built this sector.
Welcome to the future of manufacturing.
Warm regards,
William Strickland, Publisher, IMD
Heavy Gauge Steel Design
Press Bed bolted on, not welded, to prevent distortion.
Large press bed to accommodate a variety of tooling other than just punching.
Pump, motor, valve and reservoir are all easily accessible for maintenance.
Large rectangular tubes used at base of machine to give safe, instant portability.
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INDUSTRY NEWS
Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industry's top companies. WANT TO BE FEATURED? Send your press releases to
announces New Leadership for the rMaG and Executive committee america Makes, the National additive Manufacturing Innovation Institute, has appointed new chairpersons for its roadmap advisory Group (rMaG) and Executive committee.
a ndrew Thompson, Deputy chief Engineer for additive Manufacturing at Northrop Grumman Space Systems, will serve as the chair of the rM aG. In this role, he will guide the group’s strategic direction, recruit members, and engage with working groups. Thompson will also oversee the strategic-level roadmap, ensuring alignment with a merica Makes' mission while advising the Executive committee on key project topics.
at Northrop Grumman, Thompson is responsible for advancing additive manufacturing ( a M) technologies, leveraging his expertise in aerospace component design and manufacturing. his leadership in assembly integration, testing, and additive processes has contributed to high-quality, cost-effective solutions that exceed industry requirements.
rick russell has been named chairperson of the Executive committee, where he will lead a team of industry experts spanning academia, government, workforce, and economic development sectors. russell, a Principal aDDvisor® with The Barnes Global advisors, specializes in Metal a M certification and qualification. his experience includes leading Na Sa’s Materials and Processes and Fracture control efforts for the commercial crew Program, as well as authoring Na Sa-STD6030, the additive Manufacturing requirements for Spaceflight Systems.
Joining him, Sandra DeVincent Wolf, Ph.D., will serve as Secretary of the Executive committee. a s the Executive
Director of c arnegie Mellon University’s Manufacturing Futures Institute, she leads manufacturing research initiatives and partnerships.
John Wilczynski, Executive Director of a merica Makes, emphasized their impact, stating, “ rick and Sandra are highly respected leaders in the additive community. Their expertise in certification, research, and collaboration will be invaluable in guiding a merica Makes forward.”
For More Information: www.americamakes.us
announces New customer Service & Support Team for North america
h SG Laser, a global leader in metal shaping equipment, has announced the launch of a dedicated customer service team for North a merica. The new team will be led by Fernando r amos as c ustomer Service Manager for the U.S., c anada, and Mexico, with r icardo h errera appointed as Spare Parts and Warehouse Manager at h SG Laser U.S.
ramos brings over 14 years of experience in the industrial sector, with prior roles at a mada and BLM Group. he is recognized for his commitment to customer service and technical expertise. In his new role, he will oversee service operations, technical support, and spare parts management to enhance customer service across North a merica.
herrera, with a background in logistics and warehouse management, will be responsible for inventory control and stock efficiency. his experience in freight coordination and operational management ensures streamlined warehouse operations to support customers more effectively.
Founded in 2006, hSG has grown into a global automation leader with over 25,000 machines installed
worldwide. This new customer service expansion reinforces the company’s commitment to providing world-class support and technical expertise to North a merican customers.
For More Information: www.hsglaser.com
Where the Supply chain Industry comes Together
ProMat 2025 is set to be the most comprehensive event for supply chain innovation, featuring over 1,200 exhibitors, 200+ educational seminars, and four keynote presentations. The event will take place from March 17-20, 2025, showcasing cutting-edge technologies that drive efficiency, transparency, and resilience in supply chain operations.
attendees will explore innovations in automation, robotics, aI, and warehouse management solutions through hands-on demonstrations and expert-led sessions. Key networking events, including the Women in Supply chain Forum and MhI Young Professionals Networking Event, will provide opportunities for industry leaders to connect and collaborate.
With 88% of attendees holding purchasing authority and 80% seeking the latest product innovations, ProMat is expected to serve as a critical hub for decisionmakers looking to optimize their supply chains. Interest in aI-driven logistics, automated storage and retrieval
systems ( a SrS), and collaborative robotics continues to rise, reflecting the industry's shift toward greater efficiency and adaptability.
For More Information: www.promatshow.com
Expands Footprint with Larger Facility in Tampa
Norwalt a utomation Group, a leading provider of custom-built automation and line integration machinery, has expanded into a new 28,000-square-foot facility in Tampa, FL. This move marks rapid growth for the company, which originally established operations in Tampa in 2023.
The expanded facility will support machine and system integration activities for various industries, including medical devices, food and beverage, personal care, and household products. Norwalt’s expertise in packaging automation, post-mold automation, and robotics continues to drive demand for its precisionengineered solutions.
“Tampa has proven to be a successful expansion for Norwalt, and this larger facility allows us to continue delivering high-quality automation systems while meeting increasing customer demand,” said Keith harman, Director of Business Development for Norwalt.
ron christaldi, chair of the Tampa Bay Economic Development council, emphasized the company’s
DIE HORMOLD ANDLING? DIE HORMOLD ANDLING?
Handling, moving and working with large dies or molds can present a ton of problems. Damage to equipment, dies or molds, as well as worker safety are just the beginning.
With EMH Overhead Cranes, count on safety, efficiency, and precision accuracy, while you dramatically reduce the chance of damage. Then, with virtually unlimited tonnage capacity and availabiltiy in varied configurations to suit almost any application need, you can count on all the lift you need. Visit us. Find out more at ProMat: Booth #S2784
impact, stating, “Norwalt’s investment in our community is a testament to the strength of Tampa’s manufacturing sector.”
With a focus on reducing downtime, maximizing efficiency, and addressing labor-intensive tasks, Norwalt’s expansion reinforces its position as a leader in automation and line integration technology.
For More Information: www.norwalt.com
Forklift Donation raises $40,000 for higher Education
Toyota Material handling MidSouth, in partnership with Toyota Material handling, has donated a 5,000-poundcapacity Toyota core Ic Pneumatic forklift to the concrete Industry Management (cIM) program’s annual charity auction.
The donation raised $40,000, contributing to a total auction proceeds of $2.15 million to support cIM’s higher education programs.
“Toyota is proud of our dealership, Toyota Material handling MidSouth, for their commitment to philanthropy and the future development of our industry and workforce,” said Bill Finerty, President and cEO of Toyota Material handling. “With Toyota’s local and national involvement, we hope to highlight the incredible impact of the concrete Industry Management’s annual charity auction.”
cIM, which operates at five universities, prepares students for careers in the concrete industry by providing technical, communication, and management expertise. The proceeds from the auction support scholarships and curriculum development for these programs.
held during the World of concrete event, the auction featured over 100 items, showcasing the industry’s commitment to philanthropy. TMh MidSouth’s forklift donation aligns with Toyota’s corporate social responsibility initiatives and mission of “helping others carry the load.”
“Toyota embodies the belief in supporting local communities and the future of others,” said Nick Edwards, TMh MidSouth Sales Manager. “TMh MidSouth is grateful for the opportunity to support a new generation that shapes the communities and industries we serve.”
This donation builds on Toyota’s legacy of giving back, with past contributions to non-profit food banks, Goodwill Industries, and flood relief efforts in East Tennessee. By supporting cIM, Toyota reaffirms its commitment to empowering future professionals and strengthening workforce education.
For More
FABRICATION
Transforming Materials Into Excellence
Discover the innovative tools and technologies shaping today’s manufacturing landscape. Highlighting processes that transform raw materials into precision-crafted products, from advanced cutting and forming systems to welding and finishing techniques, the focus remains on efficiency, accuracy, and innovation driving modern fabrication.
From advancements in automation and sustainable manufacturing practices to the latest developments in material processing, gain insights into trends and solutions that enhance productivity, improve quality, and maintain competitiveness in a rapidly evolving industry. This overview showcases the equipment and expertise behind the products powering industries worldwide.
Tessy Plastics & Mantle 3D Printing: A Game-Changer in High-Volume Molding
Evaluating 3D-Printed Inserts vs. Machined Inserts for Durability and Precision
The fabrication industry is witnessing a transformative shift as 3D printing continues to disrupt traditional manufacturing methods. Tessy Plastics, a global contract manufacturer specializing in injection molding, recently conducted a benchmarking study to evaluate the accuracy, durability, and efficiency of Mantle’s 3D-printed metal mold inserts compared to conventionally machined S7 steel inserts. The results demonstrated that additive manufacturing can deliver the same level of precision and longevity as conventional methods while significantly reducing production time.
Instead of machining away material from a solid metal block, Mantle’s TrueShape™ technology
was used to create two test inserts for a high-cavitation injection mold producing personal-care products. after 3.8 million molding cycles, the 3D-printed inserts proved just as durable and precise as their machined counterparts.
addressing the Industry’s Key challenges
Tessy’s moldmaking team had specific goals in mind:
» accuracy and Durability –Ensuring that 3D-printed inserts could match the longevity of conventional inserts.
» Faster Production Times –reducing the time required to manufacture inserts and speed up time-to-market.
» cost Efficiency – Evaluating
whether additive manufacturing could lower production costs while maintaining performance.
although 3D printing is often praised for its ability to create complex geometries and conformal cooling channels that reduce cycle times, Tessy’s primary focus was durability. “While it’s great to be able to print geometry that you can’t achieve in conventional manufacturing, our main concern was how well 3D-printed inserts would hold up over time,” said rich Smith, Engineering Manager at Tessy.
comparing additive vs. Subtractive Manufacturing
For the test, three inserts were produced for a 32-cavity mold:
» One printed using Mantle’s P2X material
» One printed using Mantle’s h13 material
» One machined from S7 steel to match the existing 29
inserts in production
» To fairly compare the two manufacturing methods, time-to-production was tracked:
» Machined Insert: 150 hours over three weeks
» Mantle 3D-Printed Insert: 54 hours plus 6 hours finishing
» 60 percent faster production time for the printed insert
Tessy’s production mold already had four million cycles before the test began, making it the perfect real-world application. Over 6.8 million parts have been produced using Mantle’s inserts, all of which have passed Tessy’s rigorous quality control standards.
The Future of Tooling with additive Manufacturing
Mantle’s TrueShape™ technology is proving to be a game-changer for mold manufacturers. By reducing lead times and maintaining exceptional durability, 3D-printed inserts are
paving the way for a new era in fabrication. With a cleaner, more efficient, and cost-effective process, manufacturers can reduce downtime, accelerate production, and improve part quality—key factors in today’s competitive market.
a s Tessy Plastics continues to innovate, this study underscores the potential of additive manufacturing in Our Genuine Metaris 4WRLE and 4WRPEH Series valves are high performance proportional directional valves that are very reliable, stable, and highly accurate. Available now with multiple options and sizes, these are excellent direct interchange options for Rexroth® 4WRLE & 4WRPEH series valves. To learn more, give us a call, email us or visit us at HYDRAULEX.COM.
high-volume production. The results speak for themselves: 3D printing is no longer just for prototyping—it is ready for full-scale manufacturing.
For more information: www.mantle3D.com
10X ENGINEERED MATERIALS
Expands Logistics Capabilities with Bulk Rail Delivery Across North America
Streamlined supply chain efficiency for industrial abrasive materials
10X Engineered Materials (10XEM.com), a leader in advanced blasting abrasives, has expanded its logistics capabilities to include bulk rail delivery across North a merica. This strategic move enhances supply chain efficiency, reduces transportation costs, and improves sustainability for industrial customers requiring high-performance abrasives in large volumes.
The company has successfully completed its first bulk rail shipments, ensuring a more reliable and environmentally responsible supply chain. By leveraging North a merica's rail network, 10X can now deliver materials with shorter lead times and reduced costs, benefiting industries such as shipbuilding, infrastructure maintenance, and heavy manufacturing.
"Expanding into bulk rail delivery aligns with our mission to empower people through sustainable engineering and innovation,” said Dr. Stephen ricci, cEO and co-founder at 10X Engineered Materials. “We are now able to provide our efficient, high-performing abrasives in high volumes to customers thousands of miles from our factory, reducing emissions while maintaining cost efficiency.”
With this development, 10X Engineered Materials reinforces its position as the most innovative and customer-centric abrasive supplier in the industry.
For more information: www.10xem.com
Showcases Innovative Solutions for Medical Device Manufacturing at MD&M West 2025
Advanced welding, laser processing, and precision solutions for medical applications
a M aDa WELD TEch , a leading manufacturer of welding, marking, cutting, sealing, and bonding systems, exhibited its latest technologies at MD&M West 2025 in a naheim, c alifornia. The company highlighted its newest innovations designed to enhance reliability, quality, and efficiency in medical device manufacturing.
a mong the showcased products was the WL-300a Galvo Laser Welding System, featuring continuous wave fiber laser integration, four-axis motion, and a high-precision laser welding process monitor.
The UB-1500a Low Power Linear Dc Micro Spot Welder and SL-321 a Light Force Motorized Electromagnetic Weld head were also demonstrated, offering robust and repeatable micro-welding capabilities.
a M aDa WELD TEch further highlighted its SIGM a® LS laser micromachining subsystem, ideal for high-precision manufacturing applications, and the SIGM a® Laser Stent and Tube cutter, optimized for stent fabrication with stateof-the-art digital controllers and high-speed linear motors.
"By combining our expertise in laser welding, micromachining, and resistance welding, we offer comprehensive solutions for medical device manufacturers," said an a M aDa WELD TEch representative.
For more information: www.amadaweldtech.com
the First Functional Large-Format 3D-Printed Monolithic Boat
A groundbreaking achievement in additive manufacturing for the nautical industry
V2 Group, a Spanish leader in large-format 3D printing, and c aracol a M, an Italian expert in additive manufacturing,
AMADA WELD TECH
V2 GROUP & CARACOL AM
have unveiled the first-ever functional 6-meter-long 3D-printed monolithic catamaran for open waters. This project represents a major leap toward sustainable, efficient, and industrialized boat production.
By leveraging robotic 3D printing, the companies have demonstrated how customized designs, material efficiency, and reduced environmental impact can be seamlessly integrated into nautical manufacturing. The boat’s development process meticulously analyzed material selection, printing optimization, and structural integrity, laying the foundation for future large-scale production of 3D-printed vessels.
This innovation sets the stage for a new era in nautical manufacturing, where sustainability, scalability, and advanced materials converge to revolutionize how boats are designed and built.
For more information: www.caracol-am.com
MACHITECH
Introduces the Fiber PRIME S Laser Cutting Machine
High-speed, high-power fiber laser cutting for heavy-duty applications
Machitech has launched the Fiber P r IME S Laser c utting Machine, a next-generation system that combines 4G acceleration with high-power capabilities ranging from 12KW to 60KW. This state-of-the-art laser can cut mild steel up to four inches thick, providing fabricators with an unmatched level of precision, speed, and efficiency.
The Fiber PrIME S includes the Precitec cutting head, which integrates gas mixing and focus compensation for optimal performance. a n optional Machitech Bevel head enables complex bevel cuts—including V, X, Y, and
K angles—in a single operation, reducing production time and improving cut quality.
With intelligent path nesting, remote monitoring, and cNc automation, the Fiber PrIME S sets a new benchmark for high-speed, high-power cutting in fabrication and manufacturing.
For more information: www.machitech.com
MACK MOLDING
Makes Largest Press Investment in Over 25 Years
Expanding capacity with advanced injection molding technology
Mack Molding, a leading custom plastics molder and contract manufacturer, has announced a $3 million investment in new injection molding presses, marking its largest equipment upgrade in more than two decades.
The company has added hybrid Milacron presses across its Vermont and North c arolina facilities, with tonnage ranging from 500 to 1500 tons. These stateof-the-art machines provide increased output, energy efficiency, and precision, reinforcing Mack’s position as a leader in large-part molding for medical, industrial, and transportation applications.
“This investment underscores our commitment to delivering high-quality, precision-molded components while increasing efficiency and productivity,” said Josh Pang, President of Mack North.
By integrating automation and hybrid molding technology, Mack Molding is enhancing its ability to support growing customer demand while ensuring sustainability in its operations.
For more information: www.mack.com
MATERIAL HANDLING
Empowering Efficiency and Precision
Material handling is at the heart of efficient industrial operations, focusing on the movement, storage, and organization of materials. This section highlights strategies and technologies that streamline these processes, from automated storage and retrieval systems to advanced conveyor solutions. Readers can explore innovations like forklifts, cranes, hoists, and magnetic lifters, which play a pivotal role in optimizing material flow across warehouses, factories, and supply chains.
In addition to hardware advancements, this area emphasizes cutting-edge solutions like warehouse management systems and parts tracking technologies, which integrate seamlessly into modern production environments to enhance operational control. Topics also cover sustainable practices, such as energy-efficient lift equipment and ergonomic tools designed to improve workplace safety while reducing strain. Whether tackling inventory management or enhancing material logistics, this section provides the insights and tools needed to excel in today’s industrial landscape.
Revolutionizing Workplace Safety and Efficiency with Sky Hook
In today’s industrial settings, safety and efficiency go hand in hand. heavy lifting operations, particularly in extreme environments, require not only strength but also precision and reliability. One company recently put the Sky hook lifting device to the test under challenging conditions, and the results were nothing short of transformational.
The challenge: a risky and Inefficient Lifting Process
When the Ben E. Keith company initially purchased the Sky hook, they hoped they would never need to use it. however, when their freezer crane drive wheel experienced a bearing failure, they found themselves facing a complex and demanding repair operation. The process required the removal and replacement of a 350-pound motor and gearbox assembly—a difficult task made even more challenging by the -10-degree Fahrenheit conditions inside the freezer.
a similar failure had occurred previously on their ambient crane. With no designated lifting device at the
time, the team had to improvise using a forklift, fork extensions, straps, and chains. This method, while ultimately successful, was extremely difficult and presented significant safety risks. The precarious setup required excessive manual handling, increasing the potential for workplace injuries and damage to critical machinery components. after completing the repair, the company’s leadership
recognized the need for a better approach and decided to invest in the Sky hook lifting system.
The Sky hook Solution: Enhancing Safety and Precision
When the freezer crane experienced the same type of failure, the Sky hook was ready for action. The difference in the lifting process was immediately apparent. By leveraging the Sky hook’s precise lifting capabilities, the team was able to execute the repair in nearly half the time it took using the old forklift method. The previously unsafe and cumbersome procedure was now streamlined and controlled, eliminating the need for risky balancing acts with heavy chains and straps.
Working in a -10-degree Fahrenheit environment is already challenging, requiring workers to operate with limited mobility due to insulated gloves and cold-weather gear. The Sky hook allowed for more controlled lifting, reducing the physical strain on workers and ensuring greater accuracy in maneuvering the heavy components.
Using the Sky hook, the team successfully removed the drive wheel assembly, swung it out of the maintenance cage, and placed it directly into the shipping crate. The new drive wheel was then lifted and positioned seamlessly into place. Unlike the previous method, which required extensive manual adjustments, the Sky hook provided precise lifting and movement control, making alignment and installation significantly easier.
Protecting critical Equipment with Precision Lifting
One of the standout benefits of the Sky hook was its ability to lift and position the heavy motor and gearbox assembly without damaging critical components. aligning the new drive wheel drive shaft with the motor and gearbox assembly required extreme precision to avoid damaging the delicate gearbox oil seals and the drive wheel shaft surface. With the forklift method, workers had to rely on manual adjustments, increasing
the risk of misalignment and accidental damage.
The Sky hook allowed for smooth, controlled movement, reducing the likelihood of costly repairs due to mishandling. By eliminating abrupt or uncontrolled movements, the team ensured that the repair was completed without compromising the integrity of the machinery.
Maximizing Productivity and reducing Downtime
Beyond safety and precision, the Sky hook also delivered significant efficiency gains. In the industrial sector, downtime due to equipment failure can have serious financial implications. The previous forklift method was not only unsafe but also time-consuming, extending repair time and keeping the crane out of operation longer than necessary. With the Sky hook, the entire process was completed in nearly half the time, allowing the crane to be returned to service much faster.
For companies that rely on overhead cranes for critical operations, reducing repair time means minimizing production disruptions and improving
overall workflow. The ability to conduct maintenance quickly and safely translates to substantial cost savings over time.
a Testament to Workplace Safety Best Practices
This company’s experience with the Sky hook highlights the importance of investing in the right tools for workplace safety and operational efficiency. Instead of relying on makeshift lifting solutions, they proactively addressed the safety risks associated with their previous method. The decision to purchase the Sky hook was driven by a commitment to safety and innovation, and the results speak for themselves.
after witnessing the dramatic improvement in their lifting process, the company now strongly recommends the Sky hook to other organizations with heavy lifting needs. Their story serves as a compelling case study for businesses looking to enhance workplace safety, reduce downtime, and improve operational efficiency.
Why Every company Should consider the Sky hook
The benefits of the Sky hook extend far beyond this single case study. companies across various industries can leverage this innovative lifting solution to:
» Enhance Worker Safety – By eliminating the need for unsafe lifting practices, businesses can reduce workplace injuries and ensure compliance with safety regulations.
» Improve Precision and control – The Sky hook’s design allows for precise lifting and positioning, reducing the risk of damage to delicate components.
» Increase Efficiency – completing tasks in less time means reduced downtime and improved productivity.
» Lower Maintenance costs – By protecting critical equipment during repairs, businesses can avoid unnecessary damage and expensive replacements.
» adapt to challenging Environments – Whether working in extreme temperatures or confined spaces, the Sky hook provides a reliable and adaptable lifting solution.
conclusion: a Smart Investment for Industrial Operations
The Sky hook has proven to be more than just a lifting tool—it is a game-changer for companies looking to optimize their maintenance operations. This company’s experience demonstrates how the right equipment can make a critical difference in both safety and efficiency. By replacing an unsafe, time-consuming process with a streamlined, controlled lifting solution, they have set a new standard for workplace safety and operational best practices.
For any organization that handles heavy lifting tasks, investing in a Sky hook is a proactive step toward a safer, more efficient work environment. Whether dealing with emergency repairs or routine maintenance, having the right tools on hand can make all the difference.
CJ LOGISTICS AMERICA
AI-Powered Warehouse Operations
Transforming Efficiency and Safety with Computer Vision Technology
c J Logistics a merica is advancing warehouse operations through its partnership with OneTrack, integrating aI-driven monitoring and analytics to improve efficiency, safety, and overall performance. With OneTrack’s Warehouse Operating System implemented across 40 North a merican locations, the company has significantly reduced safety incidents, improved productivity, and minimized product damage.
By leveraging aI-powered camera sensors and real-time analytics, cJ Logistics america provides continuous visibility into warehouse operations. automated alerts identify inefficiencies, allowing supervisors to focus on targeted coaching and process improvements. The system also tracks labor performance, pinpointing areas where additional support is needed to keep operations running smoothly.
a s the company continues expanding its aI applications, future developments will focus on predictive
analytics and quality control to drive even greater efficiency and reliability in warehouse logistics.
For more information: www.cjlogisticsamerica.com
CYNGN
DriveMod Tugger Expands into Consumer Packaged Goods
AI-Powered Automation Optimizing Distribution Centers cyngn is expanding its autonomous material handling solutions with the deployment of its DriveMod Tugger at a leading consumer Packaged Goods (cPG) distribution company. This deployment highlights the growing demand for automation in warehouse logistics, as businesses seek to optimize intra-facility material movement while reducing reliance on manual labor.
The DriveMod Tugger is equipped with advanced aI, 360° vision, and collision avoidance technology, allowing it to navigate dynamic environments safely and efficiently. Integrated with cyngn’s fleet management platform, the system enables real-time monitoring and task optimization, ensuring seamless coordination across distribution centers.
With many cPG companies still in the early stages of automation adoption, cyngn’s technology offers a scalable solution to improve logistics efficiency, lower costs, and enhance operational agility.
For more information: www.cyngn.com
Hawk Multidirectional Reach Truck Debuts at LogiMAT 2025
A Compact, High-Capacity Solution for Narrow Aisles DIMOS is introducing the hawk electric multidirectional reach truck at LogiMaT 2025, offering a highly maneuverable solution for warehouses with tight storage spaces. Designed with 360° continuous steering, the
DIMOS
hawk allows smooth direction changes without stopping, reducing handling time and improving workflow efficiency.
With a 3-ton load capacity, the hawk is built for industries managing both palletized and long goods, such as steel, wood, and building materials. Its compact, fully electric drive provides a low-maintenance, emission-free alternative to traditional warehouse equipment. Braked load wheels enhance stability, while the ergonomic crosswise seat cabin improves visibility, allowing operators to maneuver with precision in confined spaces.
The hawk will be showcased at LogiMaT 2025 in Stuttgart from March 11-13 at Stand 10a 21 in hall 10.
For more information: www.dimos-maschinenbau.de
FEHR & MATTER
Two AS/AR Leaders Unite
Strengthening Automated Storage
Solutions
Across Industries
Fehr Lagerlogistik aG has acquired Matter srl, expanding its capabilities in automated storage and retrieval (aS/ar) systems for various industries. Both companies specialize in advanced warehouse solutions, including robotic material
handling, automated picking, and vertical storage systems designed for metals, tubes, billets, and sheets.
The acquisition enhances Fehr’s ability to provide fully integrated handling solutions, offering customers a more comprehensive suite of automated systems. While both brands will continue to operate independently, their combined expertise will strengthen market reach and support customers with more advanced intralogistics solutions.
With a shared focus on automation and material optimization, Fehr and Matter are positioned to drive greater efficiency across manufacturing, metal service centers, and industrial storage operations.
High-Capacity Waste Management for Industrial Facilities
US Duct has introduced the Self-Sealing hopper, an innovative addition to its Legend Line of industrial dust collection solutions. Designed for Legend Open Baghouses (10hP & 15hP models), the new hopper streamlines waste collection, reducing the frequency of bag changes and minimizing downtime.
With a 1.02 cubic yard capacity, the Self-Sealing hopper holds the equivalent of six standard collection bags. Its modular design allows for dual-hopper rotation, enabling users to swap out hoppers in seconds to maintain continuous operation. This advancement improves workflow efficiency and helps industrial facilities manage high-volume waste more effectively.
The Self-Sealing hopper is now available for purchase.
For more information: www.us-duct.com
SAFETY & MAINTENANCE
The Cornerstones of Operational Excellence
The Safety & Maintenance section is dedicated to creating safer workplaces and ensuring equipment longevity. Covering everything from cutting-edge machine guarding systems to advanced air filtration and dust collection solutions, this section provides actionable insights into workplace protection and preventative maintenance. Whether you're exploring ergonomic tools to reduce operator strain or electrical systems that enhance reliability, this section focuses on products and practices that prioritize both people and machines.
In addition to highlighting safety innovations, this section delves into essential maintenance strategies, including retrofitting, rebuilding, and remanufacturing, ensuring that machinery operates efficiently and reliably over time. Maintenance supplies, facility equipment, and accessories are explored alongside new safety technologies designed to meet evolving compliance standards. Readers will discover how a proactive approach to safety and maintenance not only minimizes risks and downtime but also fosters a culture of care and continuous improvement within industrial settings.
The Future of Robotic Welding and Fume Extraction
The adoption of robotic welding systems in the metal fabrication industry has grown significantly over the past several decades. With market projections indicating a continued compound annual growth rate (caGr) of 7-10%, manufacturers are increasingly turning to automation to improve productivity, enhance efficiency and quality, and mitigate labor shortages. however, along with these advancements comes the challenge of weld fume management, a critical issue for worker safety and compliance.
The Need for Effective Weld Fume control
While robotic welding delivers undeniable advantages, it also generates higher volumes of weld fumes than manual welding. These fumes contain hazardous airborne particulates, including manganese and hexavalent chromium (cr(VI)), which are known to cause severe health risks such as respiratory diseases, metal fume fever, and even cancer. OSha’s stringent regulations on cr(VI) exposure further emphasize
the importance of effective fume extraction solutions.
Traditional fume extraction methods, such as overhead hoods and ducted dust collectors, have long been used to control welding emissions. however, these systems present challenges in robotic applications. Large, open weld cells make it difficult to contain fumes, while air currents and cross-drafts can significantly reduce their effectiveness. Moreover, high costs associated with large-scale
Housing assembly designed to integrate seamlessly with existing robotic welding torches. This innovative solution optimizes source-capture technology, ensuring high-efficiency fume extraction while maintaining adaptability for diverse welding applications. Capable of delivering up to 150 CFM airflow, FumeVac’s design enhances weld fume control without requiring costly modifications to welding systems.
FumeVac Robotic Weld Fume Extraction – A custom 3D Fume
air movement and filtration systems make them impractical for many manufacturers.
Source capture: The Next Evolution in Weld Fume Extraction
The most effective strategy for controlling weld fumes is capturing them at the source—directly at the point of generation—before they can disperse into the surrounding environment. Source-capture systems not only improve air quality but also reduce the need for large-scale air filtration, minimizing energy consumption and operational costs.
robotic torch-mounted extraction systems are emerging as a preferred solution for manufacturers seeking a balance between efficiency and cost-effectiveness. These systems integrate directly with robotic welding torches, extracting fumes at the arc to prevent airborne contaminants from spreading. compared to traditional overhead extraction systems, high-vacuum source capture can be up to 50% more cost-effective, making it an attractive option for fabricators aiming to enhance safety without overhauling their existing setup.
FumeVac’s custom 3D Fume housing: a Game-changer
To meet the growing demand for flexible and high-performance fume extraction solutions, FumeVac has developed custom 3D Fume housing assemblies designed to integrate seamlessly with specific robotic torch brands and models. Unlike standard solutions that require fabricators to adopt new torches or reprogram robotic systems, FumeVac’s approach allows manufacturers to retain their existing torches while achieving superior fume capture.
FumeVac’s robotic source-capture systems deliver airflow of up to 150 cFM, ensuring high-efficiency fume extraction even in heavy-duty welding applications exceeding 400a . By focusing on adaptability, these solutions eliminate the need for costly equipment modifications while providing better containment of hazardous fumes.
a key component of effective fume extraction is the vacuum source itself. The FumeVac FV-190Sc Series offers industrial-duty, high-vacuum extraction designed for continuous operation in demanding environments.
» Push-button vibratory filter cleaning for easy maintenance
» Brushless variable speed control blower (230V/1-phase or 460V/3-phase)
» Overload and over-temperature shutdown circuitry
» Noise level of 78 dB at 5 ft, ensuring a quieter operation
conclusion
For manufacturers adopting robotic welding, effective weld fume extraction is no longer an option—it’s a necessity. FumeVac’s advanced source-capture technology provides a cleaner, safer, and more efficient alternative to traditional hooded systems. By enclosing the welding torch in a custom 3D-printed fume housing, this solution enhances air quality, reduces worker exposure to hazardous contaminants, and significantly cuts down on costly ventilation infrastructure.
a s companies continue to prioritize workplace safety and regulatory compliance, robotic welding fume extraction will play an increasingly vital role in the future of automated manufacturing.
For more information, visit www.hastingsair.com.
JELMAR
Jelmar Launches New High-Performance Industrial-Strength Cleaning Solution
The New CLR PRO MAX Industrial Degreaser Saves Time, Effort on Tough Degreasing Jobs
Jelmar, a family- and women-owned manufacturer known for its industrial cleaning brands cLr®, cLr PrO®, cLr PrO Ma X®, and Tarn-X®, has expanded its industrial product offerings with the launch of cLr PrO Ma X Industrial Degreaser. This powerful cleaning solution is designed to penetrate and dissolve heavy grease, oil, and grime found on machinery, equipment, and various industrial surfaces.
“We saw a need in the industrial market for a high-performance concentrated degreaser that is both competitively priced and safer for the end-user, and we are meeting it,” said Dan Bucci, director of B2B sales at Jelmar. “customers will find they are saving time and effort on degreasing jobs with the new cLr PrO Ma X Industrial Degreaser.”
Building on the success of its cLr PrO Ma X Industrial Descaler, which effectively removes scale and rust from drains and industrial equipment, the company has introduced this new degreaser to provide an industrial-strength solution for manufacturing, automotive, utilities, and food service applications. The non-flammable, water-based formula contains no abrasives, acids, petroleum solvents, or VOcs, making it safer for both users and building occupants. It is also NSF registered and approved for use in food processing and storage facilities.
Independent laboratory testing has demonstrated that cLr PrO Ma X Industrial Degreaser outperforms existing solutions even when diluted, offering superior cleaning power at a competitive cost. It is suitable for machinery, tools, oil tanks, concrete floors, engines, transformers, trains, exhaust hoods, and more. available starting February 4, the product comes in 32 oz., 1-gallon, 5-gallon, 55-gallon, and 275-gallon sizes.
Jelmar plans to continue expanding its cLr PrO Ma X product line in 2025, introducing even more industrial-strength cleaning solutions to meet the needs of heavy-duty environments.
For more information, visit www.clrbrands.com.
EXAIR’s New Catalog 36 Now Offers BETE Products and a Comprehensive Guide to Industrial Solutions
as industries continue to evolve, ensuring efficiency and safety in industrial environments remains a top priority. To support this mission, EX aIr has launched catalog 36, a full-color, in-depth resource that provides manufacturers with solutions for conveying, cooling, cleaning, blowoff, drying, coating, and static control.
The latest edition features an expanded selection of products, technical guides, and expert insights, helping businesses optimize their operations. among the key additions, catalog 36 now includes BETE’s industry-leading precision spray solutions, a trusted name in spray technology since 1950. EX aIr.com will now offer select BETE Spray
Nozzles, available for same-day shipping if ordered by 2 PM (Eastern Time).
Beyond new product highlights, catalog 36 serves as a comprehensive reference for industry standards, safety best practices, and energy conservation techniques in compressed air systems. With detailed technical explanations, application photos, and dimensional drawings, it empowers manufacturers to make informed decisions about their industrial processes.
Manufacturers looking to enhance operational efficiency while maintaining safety can now access a free copy of catalog 36 or explore the digital version online.
For more information, visit www.exair.com.
Enhanced SAVAGE A41 Welding Helmet Offers Digital Interface, Extended Shade Range
ESaB has unveiled the enhanced SaVaGE a41 automatic welding helmet, offering superior protection and user-friendly features for both occasional and professional welders. The updated model features an internal digital user interface for fine-tuning auto-darkening filter (aDF) settings, an extended shade range of 8-13, and a streamlined Grind Mode that switches the lens to shade 4 for grinding and cutting applications.
“The new interface eliminates the external shade selection knob, ensuring shade settings won’t accidentally change,” said Kevin Beckerdite, Global Product Manager –PPE at ESaB. “additionally, the shade 8 setting is perfect for low-amperage welding applications like small-diameter MIG wires or tungsten electrodes.”
The SaVaGE a41 helmet is lightweight (17.6 oz.) and features True color lens technology, providing a high-contrast view of the weld puddle for precise bead placement. Its 3.93 x 1.96-inch (100 x 50 mm) viewing area offers a wide field of vision, while four sensors ensure quick response time, even in out-of-position welding.
additional options include an optional hardhat adapter for enhanced safety. The 1/1/1/2 optical class rating ensures a clear, consistent view, balancing performance and value.
The SaVaGE a41 welding helmet is available through welding supply distributors and online retailers.
For more information, visit www.esab.com.
ESAB
QUALITY
Ensuring Precision and Performance
Quality control and assurance are the backbone of manufacturing, ensuring every product meets rigorous standards for precision, performance, and reliability. This section delves into the tools and technologies that enable manufacturers to uphold the highest quality standards. From advanced coordinate measuring machines (CMM) to vision systems and laser inspection equipment, the spotlight is on innovations that enhance accuracy and efficiency in measurement and inspection.
Nondestructive testing (NDT) equipment and positional measuring machines are also featured, allowing manufacturers to evaluate products without damage. Tools such as form measurement gauges, cutting tool inspection systems, and tool condition monitoring devices refine production processes and reduce errors. Whether through shrink-fit technologies or video inspection systems, this section highlights the importance of advanced solutions in maintaining precision, ensuring compliance, and driving continuous improvement in industrial operations.
Bowman International Enhances Quality Control with LK Metrology
Bowman International, a UK-based leader in bearing manufacturing and precision-engineered components, has significantly upgraded its inspection processes with the purchase of an LK Metrology altera 10.7.5 coordinate measuring machine (cMM). This investment is part of Bowman’s continuous commitment to quality and technological innovation, supporting its work across the automotive, aviation, defense, marine, and rail industries.
Previously, Bowman’s existing cMM—purchased in 2016—was struggling to keep up with increasing production demands and required extensive manual data handling. after evaluating multiple cMM providers, Bowman selected LK Metrology due to its advanced scanning capabilities, accuracy, and efficient reporting functions.
Enhancing Efficiency and accuracy
The altera 10.7.5 cMM offers enhanced metrology capabilities with a SP25M scanning probe and a Ph10M Plus motorized indexing head, significantly improving measurement accuracy. The system’s caMIO 2024 r1 multisensor software provides powerful
For bearings manufactured in-house by Bowman at its factories in the Midlands, five from each batch are routinely inspected by analogue scanning to check for accuracy and repeatability.
scanning, data analysis, and reporting functions, allowing Bowman to conduct high-precision measurements faster and more efficiently.
according to Owen White, Bowman’s Quality Manager:
"On one of our 20 mm diameter bearings, we used to measure 12 points around the top and bottom of the ID. Now, we capture more than 100 points in a shorter time, giving us a much better understanding of both accuracy and overall bore form."
Quality control Optimization
With the new cMM, Bowman has streamlined its quality control process across multiple areas:
» Faster measurement cycles: cutting measuring time down to five to six minutes per cycle.
» Improved report generation: reducing report preparation time by up to 75%.
» higher accuracy in complex components: Essential for its growing 3D-printed component production.
additionally, the company refurbished its quality control room to maintain strict temperature control at 20 ± 1°c , ensuring consistent measurement accuracy.
Strategic Investment in UK Manufacturing
Bowman’s Managing Director, Paul Mitchell, emphasized the strategic benefits of partnering with a UK-based manufacturer:
"We have thousands of product lines and pride ourselves on innovation, technical superiority, and next-day delivery. The ability of the LK cMM to improve the speed and quality control of our bearings is hugely important to us. The fact that LK is a British manufacturer was a real plus, as it meant fast delivery, local expertise, and strong service backup."
With the LK altera 10.7.5 cMM, Bowman has accelerated its quality control processes, enhancing precision, reducing inspection time, and improving customer confidence in its high-performance bearings.
For More Information: www.lkmetrology.com
CINCINNATI TEST SYSTEMS
CTS Introduces the Sentinel IX5: A Re-Engineered Generation of Leak Testing Instruments
cincinnati Test Systems (c TS) has launched the Sentinel IX5, a multifunctional leak test platform designed for pressure, flow, and vacuum testing. a s the first instrument in the fifth generation of the trusted Sentinel family, the IX5 features a bold new design, an intuitive touchscreen interface, and advanced engineering enhancements to optimize leak test accuracy and efficiency.
Bowman International's quality manager Owen White operating the LK Altera 10.7.5 CMM in Abingdon.
“The Sentinel line of leak test instruments has become well-known and respected for delivering accuracy and repeatability,” said Eric Kersting, General Manager at c TS. “This new, innovative Sentinel re-design is the next step in that evolution, providing the most efficient and effective way to perform leak testing.”
Key features include:
» all-new UX/UI with simplified menus, real-time data visualization, and customizable screen options.
» Industry-first visual Test Sequence creator to preview and configure tests with ease.
» Expanded leak test capabilities with 9 different test methods on one instrument.
» Improved speed and accuracy, automatically adjusting for temperature and pressure changes.
» Enhanced I/O control, allowing the instrument to replace a PLc for test operations.
“The Sentinel IX5 was designed with manufacturers in mind, delivering a streamlined user experience with enhanced precision, performance, and flexibility,” said
Thomas Beischel, Director of Standard Product at c TS.
“With the Sentinel IX5, it’s now easier than ever to set up, operate, and improve your leak tests.”
For More Information: www.cincinnati-test.com
FARO TECHNOLOGIES
FARO Leap ST: A Versatile Handheld Scanner for Greater Insights
FarO® Technologies, Inc. has expanded its 3D metrology portfolio with the launch of FarO Leap ST®, a new handheld scanner designed for ultra-fast, high-accuracy scanning across a wide range of surfaces and parts. The Leap ST is a compact, portable solution that provides manufacturers with greater flexibility and speed in measurement and verification tasks.
“We wrapped up 2024 with exciting new product launches, and we’re kicking off 2025 with the same momentum,” said Peter J. Lau, President & cEO at FarO.
“Leap ST underscores our dedication to the manufacturing sector and 3D metrology, the backbone of FarO Technologies for over 40 years.”
Key features of the Leap ST include:
» Five scanning modes: ultra-fast, hyperfine, deep hole, large area, and photogrammetry.
» Seamless integration with the newly updated FarO ca M2® Software.
» compact, lightweight design for enhanced portability and usability.
» hybrid functionality, allowing a combination of probing and scanning for more comprehensive measurement solutions.
rFK racing, an eight-time NaScar champion and longtime FarO customer, praised the Leap ST’s integration capabilities.
“The new handheld scanner will seamlessly integrate into our processes, further boosting our manufacturing efficiency,” said Kevin Kidd, Director of Software and analytics at rFK racing.
For More Information: www.faro.com
KISTLER GROUP
Kistler Expands ISO 17025-Accredited Calibration Services for Low-Force Sensors
Kistler has expanded its traceable calibration services to include piezoelectric force sensors and measuring
chains in the low-force range of 1 to 50 N. This ISO 17025-accredited calibration service meets increasing industry demands for precision measurement in medical technology, semiconductor manufacturing, and quality assurance.
“Traceable calibration is becoming the standard in more and more industries,” said christian Streili, Field Service Development Manager at Kistler. “This service extension underlines Kistler's commitment to high-quality standards in measurement technology.”
Key benefits include:
» accredited calibrations for low-force applications from 1 to 50 N.
» achievable measurement uncertainty of up to 0.75% (±5 mN).
» compliance with global quality standards, including ISO 9001, ISO 13485, and IaTF 16949.
Industries such as automotive, aerospace, and consumer electronics now require traceable calibrations to ensure product accuracy and reliability. Kistler's latest service ensures customers meet these strict requirements while maintaining high measurement accuracy.
For More Information: www.kistler.com
ROBOTICS
Driving Automation and Innovation
Robotics and automation are transforming modern manufacturing, redefining efficiency, precision, and versatility across industrial processes. From welding robots and robotic tooling to autonomous technology and cobots (collaborative robots), innovations are seamlessly integrating robotics into diverse manufacturing workflows.
Key advancements include automated cells and press transfer robotics, enabling streamlined operations and reduced cycle times. Solutions like material handling systems and end effectors highlight the adaptability of robotics in tasks ranging from machining to assembly. With a focus on enhancing safety and productivity, the integration of RFID and enclosure systems, along with comprehensive training, empowers manufacturers to harness the full potential of robotics in an increasingly automated world.
Boosting Productivity and Profits with Automation: Strategic ROI Benefits
By Amanda Del Buono, TECH B2B, A3 Contributing Editor
Industrial Automation Technologies Give Manufacturers a Competitive Edge Amid Labor Shortages and Rising Demands
Today’s manufacturers face growing challenges in staying competitive, productive, and profitable in an increasingly fast-paced marketplace. a s baby boomers retire, younger generations show less interest in manual labor positions, forcing manufacturers to rethink their workforce strategies. how can companies continue to succeed in this environment?
automation
Proliferation Driving rOI
To meet production demands and remain competitive, many businesses are turning to automation technologies such as machine
vision, robotics, artificial intelligence, and deep learning. a s adoption grows, industry reports show promising expansion:
» The machine vision market is projected to grow at a 6.4% compound annual growth rate (caG r) through 2028 (Interact a nalysis).
» The industrial robotics market is expected to expand at 3.7% per year over the same period.
These technologies boost efficiency, enhance worker safety, improve product quality, and reduce costs—all while augmenting the human workforce. The ability to
optimize processes and collect real-time operational data for analysis is fueling rapid adoption across multiple industries.
“We have seen the growth of automation in many sectors. While some industries are behind, there is more of a push to drive automation into business to help with cost controls—inventory, quality, accuracy, and throughput—as well as the fundamentally changing workforce, which is impacting almost every industry in the United States,” explains Bryan Doherty, chief Technology Officer at adaptec Solutions, a New York-based system integrator specializing in material handling and automation.
competitive advantages of automation automation delivers many strategic advantages, including cost savings, improved worker safety, and increased product quality.
The human Factor
The shortage of skilled labor is a major driver of automation. a s manufacturers struggle to fill positions, automated solutions are stepping in to handle repetitive, laborintensive, and hazardous tasks.
“Worker safety is the number one reason our customers implement automation,” says Joey Koenig, Business Director at 7robotics, an Oregon-based integrator specializing in robotic systems for the wood
products industry.
7robotics’ robotic Pallet Building System enhances safety by eliminating manual nail gun handling and automating pallet stacking—two of the most dangerous tasks in pallet production.
By replacing repetitive and physically demanding jobs with automation, manufacturers can reduce workplace injuries, lower insurance costs, and improve employee retention. additionally, automation allows workers to focus on higher-value tasks, such as operating and maintaining robotic systems.
“automation has changed how the workforce is applied within a facility,” adds Doherty. “a s the workforce ages out, new generations are less likely to take on traditional manual labor roles. automation not only reduces labor needs but also shifts the workforce to higher-skilled positions.”
companies are now investing in training programs to create a new class of operators responsible for managing entire production lines, making runtime adjustments, and analyzing production data.
Boosting Productivity and Quality
automation increases throughput and efficiency by enabling operations to run continuously without fatigue. Unlike human workers, robots maintain precision and consistency over long production cycles, reducing defects and rework.
a utomated systems also provide real-time operational data, helping manufacturers analyze process deviations, identify bottlenecks, and optimize performance. This data enables improved traceability—critical for industries requiring detailed production histories, such as food and pharmaceuticals.
“Track-and-trace allows manufacturers to trace defects all the way back to raw material receipts, which is especially useful for recalls in industries like food production,” Doherty explains. “ real-time quality inspection helps reduce scrap rates and lost production time.”
With continued innovation, automation is expanding into new sectors, allowing businesses to integrate robotics in ways that were previously impossible.
By ensuring every unit is processed the same way, automation enhances product quality and consistency, reducing waste while improving customer satisfaction and brand reputation.
7robotics has integrated sensor technology into its robotic tooling to automate quality control, helping customers achieve greater reliability in their final products.
Flexibility Driving Profitability
Modern robotics and automation solutions are designed for greater flexibility, allowing manufacturers to switch between product lines more efficiently.
“One advantage of robotics comes through the power of flexible manufacturing,” says Koenig. “For example, 7robotics offers a robotic cell that can assemble pallets, skids, crates, and fencing by simply changing the jig.”
This level of adaptability allows manufacturers to improve profitability on small production runs and expand their product offerings.
One company that has leveraged this flexibility is c anopy Lumber Products, an Iowa-based manufacturer of customized shipping solutions. after implementing 7robotics’ robotic Pallet Building System, c anopy reported significant improvements in efficiency, worker safety, and profitability.
“We’ve seen increased profits on smaller runs because of the system’s ability to change over in as few as five minutes,” says Patrick Kooima, General Manager at c anopy Lumber Products.
Expanding a pplications
a utomation technology is advancing to accommodate previously challenging applications, such as working with inconsistent materials like veneer or rough-sawn lumber.
“Some products don’t lend themselves to robotic automation due to variations in size or texture,” explains Koenig. “ h owever, engineers are now developing solutions to overcome these obstacles, making automation feasible for more industries.”
Innovation for Long-Term Success
automation delivers quick rOI while positioning manufacturers for long-term growth in an increasingly competitive landscape. companies that invest in automation now will not only see immediate cost savings and productivity gains but will also future-proof their operations against labor shortages and rising market demands.
a s automation technologies advance, businesses that embrace these solutions will gain a significant edge in efficiency, flexibility, and overall competitiveness.
ATI MOTORS
Ati Motors to Showcase Advanced Autonomous Mobile Robots at ProMat 2025
ati Motors, a global leader in aI and autonomous robotics, will exhibit its cutting-edge autonomous mobile robots (aMrs) at ProMat 2025, the premier event for manufacturing and supply chain professionals, held March 17-20, 2025, in chicago, IL. Visitors to Booth #S3380 will experience the Sherpa Lifter and Sherpa XT Lite, two innovative solutions designed to optimize warehouse operations and enhance productivity.
The Sherpa Lifter is an advanced a Mr engineered for pallet, trolley, rack, and magazine transportation. It is the world’s first dual 3D LiDar-based lifter, enabling precise navigation and obstacle avoidance. With a 1000 kg lifting capacity, bi-directional travel, and a 9-hour run time, it ensures seamless operations in tight spaces.
The Sherpa XT Lite is an autonomous electric tug designed to transport trolley payloads up to 1400 kg. With auto un-hitch functionality, incline capability, and swappable 48V batteries, it delivers 8-hour run time, enabling extended, uninterrupted operations in warehouse and industrial settings.
Ati Motors to Showcase Advanced Autonomous Mobile Robots at ProMat 2025
Both a M r s are Industry 4.0-ready, integrating seamlessly with Factory MIS and WMS systems. Over-the-air (OTa ) updates ensure continuous software enhancements, while a ti Motors' Fleet Manager optimizes multi-robot coordination for complex environments.
Visitors to Booth #S3380 will see firsthand how these advanced a Mrs are shaping the future of warehouse automation, improving efficiency, flexibility, and cost-effectiveness in material handling.
For More Information: www.atimotors.com
POLLEN ROBOTICS
Pollen Robotics to Present Reachy 2, Its Humanoid Robot, at CES 2025
Pollen robotics, a leader in humanoid robotics, will debut reachy 2 at cES 2025 in Las Vegas, unveiling a modular, open-source platform designed to bridge academic research and real-world applications.
With over 100 robots deployed globally, reachy 2 reinforces Pollen robotics’ mission to provide scalable, a I-ready robotic solutions for research, healthcare, and
second place in the 2023 a N a avatar XPrize and joining Meta’s a I Startup Program in 2024.
Unlike proprietary robotics solutions, reachy 2 is modular and open-source, allowing customization to fit diverse applications. It has been adopted by leading institutions such as h ugging Face, a ccenture, c arnegie Mellon University, and cornell University, showcasing its versatility in a I research and industrial applications.
a ccording to cEO Matthieu Lapeyre, “We’re proud to offer the only modular, open-source humanoid robotics solution capable of meeting today’s market needs while anticipating future advancements.”
Three core Pillars of reachy 2’s Design:
» Expressive, Bio-Inspired Design – Enhances interaction while enabling precise and agile movements.
» robust, Open a rchitecture – Encourages innovation with adaptable, a I-integrated solutions.
Pollen robotics continues to lead the way in a I-driven robotics, empowering researchers and businesses to push the boundaries of humanoid automation.
METALWORKING
Precision and Craftsmanship in Manufacturing
Metalworking encompasses the tools, technologies, and processes that drive precision manufacturing. This area highlights advancements in machining, grinding, lathing, and cutting systems, along with innovations like EDM (Electronic Discharge Machining). It captures the synergy between precision equipment and skilled craftsmanship, essential for producing high-quality components across diverse industries.
Focusing on the integration of controls, machining tools, and accessories, metalworking emphasizes the efficiency and accuracy demanded by modern manufacturing. From contract manufacturing to heat treating and gear machinery, it reflects the essential techniques and equipment shaping today’s industrial landscape. Whether utilizing traditional methods or cutting-edge innovations, metalworking celebrates the pursuit of excellence in every detail.
Brake System Design for the Future: Enhancing Performance, Aesthetics, and Sustainability
By René van Schaik, Global Strategic Account Director at MacDermid Enthone Industrial Solutions
The automotive industry is undergoing a rapid transformation driven by several significant factors, including shifts in consumer preferences, advancements in technology, and the implementation of more stringent regulations. Over the past decade, the demand for luxury finishes, improved safety measures, and environmental considerations have led to substantial changes in how vehicles are designed and built. Today, electric vehicles (EVs) represent one of the most profound shifts in the automotive sector, changing how cars are powered, their environmental impact, and their
design. While internal combustion engines (I cE) continue to dominate the market, EVs are steadily gaining traction, with manufacturers working to overcome challenges related to vehicle range, charging times, and affordability.
a s the automotive industry continues to evolve, these changes influence all aspects of vehicle design, from the materials used to construct the car to the engineering of key components like braking systems. Braking systems, a safety critical component of a vehicle, have transformed over the years, delivering enhanced performance, aesthetics, and operational efficiency.
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Maxi Torque Bushing for Space-Saving, high-Efficiency Power Transmission
a s technology evolves, modern designs increasingly require greater attention to limiting factors. Efficiency and sustainability are now central to most engineering activities. In response to these demands, custom Machine & Tool co. Inc. (cMT) developed the concentric Maxi Torque bushing line— a proprietary hub-to-shaft connection system for power transmission and motion control components. Space-saving challenges can often seem insurmountable, particularly in automation and robotics. Our bushing system helps address these challenges by eliminating the need for a hub in many designs, as contact set screws are no longer required. With just a single tightening screw, a timing pulley can be assembled or removed in less than one minute. Once installed in the drive train, the system maintains both axial and rotational position without causing lasting damage to the
Braking System Design
Since the early 2000s, wet hydraulic braking systems have been the standard in the automotive industry, as they have proven reliable and effective. however, they require brake fluid and a fluid distribution system, which increases maintenance costs and contributes to a vehicle’s environmental footprint. To address these issues, manufacturers are now exploring dry electro-mechanical brake systems, which offer shorter braking distances and lower long-term maintenance costs.
shaft. This allows for easy disassembly, repositioning, or even reusing the pulley in separate applications—a major advantage for r&D projects.
If you’re looking for a high-efficiency, low-maintenance connection system, contact cMT to discover how the concentric Maxi Torque can enhance your timing components.
For More Information Visit: www.cmtco.com Or contact Us: Toll-Free: 800-355-5949 • Local: 781-924-1003
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Yet regardless of the braking system used, calipers remain a popular choice for braking system design. Disc brakes with calipers excel at dissipating heat due to their open design, making them ideal for delivering high braking power to decelerate vehicles. These brake calipers, typically made from cast iron or cast aluminum, require surface treatments to ensure both aesthetic appeal and corrosion protection, thereby ensuring optimal performance and longevity. a s warranties extend beyond the standard five-year assurance of zero corrosion, the demand for advanced corrosion-resistant finishes has grown. These high-quality surface finishes are essential to meet global automakers' increasingly strict quality standards.
Zinc-Nickel coatings: a Key Solution for cast-Iron calipers
Zinc-nickel coatings have emerged as the preferred choice for applications with ferrous materials requiring enhanced corrosion protection. This is particularly true in assemblies that include aluminum parts, where the zinc-nickel coating also prevents galvanic corrosion. Zinc-nickel coatings provide high hardness, wear resistance, and continued corrosion protection even when exposed to high temperatures—critical properties for brake components subjected to extreme conditions.
Brake calipers are typically made from gray spheroidal graphite cast-iron, which has a unique electrochemical profile that makes acidic electrolytes the ideal choice for electroplating zinc-nickel alloy finishes. The development of zinc-nickel electroplating technologies, including the ZINcrOLYTE™ processes, has revolutionized brake caliper finishing, delivering uniform coatings, exceptional corrosion protection, and improved thickness distribution. These advancements have allowed manufacturers to produce high-quality finishes that meet the rigorous demands of the modern automotive sector.
Enhancing Processing Efficiency and Uniformity
The latest developments in zinc-nickel alloy finishes not only improve the corrosion resistance of brake calipers but also offer increased processing efficiency. Modern electroplating technologies uniformly distribute alloy across the component, ensuring that every part of the brake caliper—from recessed areas to exposed edges—benefits from the protective properties of the zinc-nickel finish.
This uniformity is critical for ensuring the durability and performance of the brake system, as inconsistencies in coating thickness can lead to vulnerabilities and reduced service life. To achieve this, manufacturers have introduced new process innovations that allow for precise control over the thickness distribution of the zinc-nickel coating. Moreover, the use of low-foam plating systems has reduced maintenance and operating costs, making the process more efficient and environmentally friendly.
Brake caliper appearance and consumer Expectations
In addition to performance and durability, appearance has become an increasingly important factor in brake caliper design. Modern wheel designs, particularly those found in luxury vehicles, often feature exposed brake calipers. These open-wheel designs allow manufacturers to offer unique color options or finishes that align with consumer expectations for aesthetic customization.
Zinc-nickel electroplating solutions have evolved to meet this demand by providing a variety of finishes, including semi-bright and matte options, which not only improve the appearance of brake components but also enhance their corrosion protection. The combination of these aesthetic and functional benefits makes zinc-nickel coatings the preferred choice for high-end automotive applications where visual appeal and durability are paramount.
The role of anodes in Electroplating
The use of anodes plays a crucial role in the electroplating process. Traditionally, metallic zinc- and nickel-anodes have been used in acidic zinc-nickel electrolytes. a s the anodes dissolve during the plating process, they replenish the metals required to form the alloy deposit on the workpieces. however, the use of zinc anodes can lead to unwanted side reactions and require frequent maintenance of both the anodes and the electrolyte solution.
To address these issues, new anode systems have been developed that minimize side reactions and reduce the need for maintenance. These innovations not only lower maintenance costs but also reduce waste formation and energy consumption, making the electroplating process more environmentally sustainable.
Innovations in aluminum and anodizing Technology
While cast-iron remains a primary material for brake calipers, many automakers are transitioning to aluminum due to its lower weight and excellent material performance. aluminum is especially well-suited for applications where lightweight, complex geometries are required, such as in modern braking systems. however, applying coatings to aluminum can be more challenging due to the complexity of aluminum alloys, which can affect layer continuity, corrosion resistance, and aesthetics.
recent innovations in anodizing technology have overcome many of these challenges, allowing aluminum brake calipers to benefit from the same high-performance coatings as cast-iron components. These new anodizing processes deliver superior corrosion resistance, enhanced process efficiency, and improved visual appearance. The anodized finishes also provide better abrasion resistance and the ability to achieve deeper colors, allowing
manufacturers to create visually appealing components that are both functional and durable.
The Shift Toward aluminum and its Benefits aluminum’s inherent lightness makes it an ideal material for automotive applications where weight reduction is a priority, including today’s EVs. high-silicon cast aluminum alloys, for example, are perfect for producing lightweight, complex parts required for modern vehicles. The challenge with anodizing aluminum alloys has traditionally been the difficulty in achieving uniform coating thickness and high-quality finishes, impacting physical and chemical resistance. however, the latest anodizing technologies have eliminated many of these limitations, allowing for improved corrosion resistance and enhanced aesthetic finishes.
aluminum finishes also offer several environmental benefits, including being more sustainable and recyclable when compared to organic paints. along with this, the lower weight of aluminum parts contributes to vehicle weight reduction, leading to improvements in fuel efficiency in IcE vehicles and increased range in EVs, coupled with an overall reduction of emissions.
Looking ahead
The automotive industry is evolving rapidly, driven by changing consumer behaviors, tightening regulations, and technological innovations. These developments, particularly
in electric vehicles, autonomous driving, and lightweight materials, are reshaping how vehicles are designed and manufactured. The materials and technologies used in brake systems are undergoing significant advancements to meet the new demands of the industry.
Today, a diverse range of product offerings exists for cast-iron and aluminum brake components, with manufacturers continually innovating their processes to meet the needs of automakers. The development of advanced surface finishing technologies ensures that brake system components provide the necessary durability and appearance while enhancing environmental sustainability. a s the automotive sector continues to evolve, these innovations will play a critical role in shaping the future of vehicle design, delivering safety, performance, and compliance with increasingly stringent regulatory requirements.
T.J. DAVIES CO., INC.
TJ Davies Manufactures Custom Machine Components and Retention Knobs with Industry-Leading Lead-Times
T.J. Davies co., Inc., a leading manufacturer of retention knobs, specializes in custom machine components for
older equipment where parts are difficult to source. Their engineering team can create precision components from detailed drawings or reverse-engineer from supplied parts using a digital optical comparator for accurate measurements.
Made from high-strength, a merican-made 8620 alloy steel, their retention knobs withstand high load forces, centrifugal stress, and challenging machining conditions. all dimensions, including length, diameter, collar thickness, thread size, and coolant hole options, can be customized to meet exact specifications. customers can submit their requirements via a fill-in-the-blanks form at www.tjdavies. com/quote-request, with lead times averaging 3-4 weeks. all retention knobs undergo single-point threading to precise Imperial (class 2 a UNc) or Metric (class G6) standards before being heat-treated to 58-62 hrc and coated with military-spec hot black oxide for corrosion protection. They are rigorously tested for durability, including magnetic particle and pull-force testing, ensuring superior performance and extended tool life.
T.J. Davies also provides torque recommendations to prevent overtightening, which can cause premature failure or toolholder swelling. Properly fitted sockets for installation are available individually or in sets through distributors nationwide.
For More Information: www.tjdavies.com
through programmable m-codes for timed operations, ensuring optimal coolant drainage before chip extraction. By automating chip removal, the kit prevents buildup in filter baskets, improves coolant flow, and reduces maintenance efforts. running on standard 220V household power, it easily integrates into various workshop setups.
“The chip conveyor Kit takes the hassle out of chip removal, allowing machinists to focus on production instead of cleanup,” said Tom Zelickman, product manager at Tormach. With programmable run times, the system optimizes waste management, reducing downtime and increasing machine productivity.
The 1500MX cNc Mill, launched in april 2024, features an epoxy granite frame, a BT30 spindle, and servo motors with 23-bit encoders for professional-grade machining. The chip conveyor Kit further enhances its capabilities for both industrial and hobbyist machinists.
For More Information: www.tormach.com
TRUMPF
TRUMPF Receives Supplier Excellence Award from Applied Materials
Keep Your CNC Clean with Tormach’s New Chip Conveyor Kit for the 1500MX CNC Mill
Tormach introduces the chip conveyor Kit, an automated chip removal system designed for the 1500MX cNc Mill. This new accessory enhances machine efficiency by maintaining a clean chip pan and improving workflow.
The chip conveyor Kit integrates seamlessly with the 1500MX’s flood coolant tank, providing hands-free chip removal. controlled via Tormach’s open-source PathPilot® software, users can activate the conveyor manually or
TrUMPF’s electronics division has been honored with the Supplier Excellence award from applied Materials, Inc., a global leader in materials engineering solutions for semiconductor and display manufacturing.
a pplied Materials recognizes top-performing suppliers for excellence in quality, service, sustainability, lead time, delivery, cost, and responsiveness. TrUMPF earned the "Best in class Performance" distinction for its outstanding contributions.
“congratulations to TrUMPF for consistently exceeding our performance expectations,” said Dr. Paul chhabra, Group VP of Global Supply chain at a pplied Materials. “Strong supplier relationships drive our innovations in materials engineering.”
This marks the fourth time TrUMPF has received a Supplier Excellence award from applied Materials, reinforcing its role as a strategic partner in the semiconductor industry.
For More Information: www.trumpf.com
WAUSEON MACHINE
Wauseon
Machine’s New Electric End Former Offers
Enhanced Precision and Sustainability
Wauseon Machine introduces the Electric End Former, a next-generation machine delivering powerful, precise end-forming capabilities while improving operational efficiency, workplace noise levels, and sustainability.
Unlike hydraulic alternatives, the Electric End Former operates entirely on electric power, eliminating
hydraulic fluid leaks and reducing operating costs. By cutting reliance on hydraulic systems, manufacturers benefit from lower maintenance expenses and cleaner work environments.
Engineered for quiet operation, the machine reduces noise pollution, fostering a safer workplace. Its compact footprint allows greater flexibility in manufacturing layouts while maintaining industry-leading performance. c apable of handling tubing up to 2 inches in diameter with 15-20 tons of force, it outperforms many competitors in its class.
Designed with sustainability in mind, the Electric End Former supports manufacturers in reducing environmental impact and achieving sustainability goals. Its fully electric system streamlines operations, making it an ideal choice for general manufacturing, automotive, and industrial applications.
With a longstanding reputation for automation and assembly solutions, Wauseon Machine continues to innovate with cost-effective, high-performance equipment.
SOFTWARE
The Digital Backbone of Modern Manufacturing
In an era where innovation drives productivity, the Software section explores the cutting-edge tools empowering manufacturers to streamline operations, enhance precision, and optimize performance. From CAD/CAM/CAE design platforms to CNC simulation and process verification, this category reveals how digital solutions are revolutionizing the way products are conceptualized, created, and delivered.
Covering a broad spectrum of applications—such as ERP systems, factory floor software, and industrial IT—this section emphasizes the importance of connectivity and real-time data in achieving operational excellence. Topics like quality control, job tracking, and program optimization showcase how software bridges the gap between vision and execution, enabling manufacturers to stay competitive in a fast-evolving industry.
FRAUNHOFER REPORT: Practical Solutions for Intelligent and Safe Production
Digitalization is a decisive competitive factor for industry - artificial intelligence ( aI), digital twins and cyber security are considered the key technologies of the future. But how can manufacturing companies use these technologies specifically and effectively to make processes more efficient, sustainable and secure? The latest report from the International center for Networked, adaptive Production (IcNaP) provides practical answers: from zero-trust architectures and the integration of aI to the use of digital twins, the report offers solutions for Industry 4.0. It also presents an outlook on the future of autonomous production and highlights approaches for the so-called "dark factory" – a fully automated production facility. although digitalization offers enormous opportunities, many
companies are still hesitant to take the step towards Industry 4.0. high investment costs, a lack of expertise and uncertainties regarding implementation often stand in the way. Yet digitalization not only improves efficiency and product quality, but also makes a decisive contribution to achieving sustainable goals - for example by conserving resources and increasing energy efficiency. at the same time, it makes businesses more resilient by making processes more flexible and production systems more resilient to disruptions.
Sustainability and resilience were therefore already key topics at the "IcNaP Summer Meeting 2024", where researchers and industry partners worked together to develop practical approaches focusing on "Intelligent Sensing and communication" and "Data-Driven
Sustainability". For the first time, the results of these workshops have been directly incorporated into this report.
artificial intelligence - plug-and-produce for rapid deployment
The use of aI in manufacturing is a particular focus of the report. aI offers a wide range of opportunities for process optimization, from quality assurance to automation. The report presents a plug-and-produce approach that enables aI to be quickly and easily integrated into existing production systems. This is supported by a technical reference architecture and an organizational framework to guide companies.
a nother study is dedicated to generative aI and its potential to transform business processes and production workflows. The interactive platform "aI Everywhere", which was developed as part of the study, offers IcNaP partners a practical overview of tools, use cases and best practices in which generative aI is used. This enables companies to identify specific potential without having to conduct extensive basic research.
Trust is good, control is better - zero-trust architectures to prevent cyber attacks a s digitalization increases, so do the demands on IT security. New EU directives such as the Network and Information Security Directive (NIS2), the cyber resilience act (cra) and the EU Machinery regulation are making the protection of production systems a priority for companies. at the same time, the threat of cybercrime is growing.
For this reason, this topic was also explored in a study: the article "Zero trust architectures for networked industrial processes" shows how companies can protect their production systems from increasing cybersecurity risks by relying on the "zero trust" model. This model continuously verifies every access and thus significantly increases the level of security.
From digital twin to dark factory – the future of fully automated production
The Digital Twin Demonstrator is another result of the 2024 research presented in the report. Using battery cell modules as an example, it demonstrates how deep learning can be used to automatically control the quality of welds. This is a practical example of how companies can use connected modeling to make their production processes more efficient and error-free.
a nother study looks at the next step toward full automation of a production facility, bringing the vision of a "dark factory" - a fully autonomous, self-controlling production facility, is becoming more tangible. By using multidimensional digital twins and advanced analysis tools, companies can evaluate their production facilities and develop them further in a targeted manner. The report offers concrete tools for analyzing the status quo and identifying key technologies for the production facility of the future.
IcNaP – a networked
innovation platform for the digital industry
The International center for Networked adaptive Production (IcNaP) combines the expertise of the three aachen-based Fraunhofer Institutes for Production Technology IPT, for Laser Technology ILT and for Molecular Biology and applied Ecology IME as well as leading experts from industry and science. IcNaP was founded as an open research platform and industrial test environment to develop new approaches to the digitalization of production and test them in practice.
IcNaP places particular emphasis on knowledge transfer and exchange with partners from industry. The platform is open to new partnerships and regularly offers free events to provide direct insights into the work of the community and the research of the participating Fraunhofer Institutes.
The annual meeting in December 2024 was used by the members of the IcNaP community to vote on the five new studies for the following year. The newly selected topics for 2025 include
» Integration of Sensor Technology in Brownfield a pplications
» a pproval of aI Systems for Quality control - Fulfilling regulatory and Stakeholder requirements
» Production Optimization: concept for holistic Optimization of Production
» a Digital Process Twin for Manufacturing: Unlocking New Optimization Potentials
» Manufacturing "Secured by Design": a Zero-Trust a pproach to Industrial Product Development
The study report for the year 2025 will be presented at this year's annual meeting on December 9, 2025.
AQUANT
Aquant's 2025 Field Service Benchmark Report Reveals AI Enabling 39% Faster Machinery Repairs and More
aquant, an aI platform built for servicing complex machinery, has released its highly anticipated 2025 Field Service Benchmark report, offering an in-depth analysis of trends, challenges, and opportunities shaping the future of the service industries. The report highlights the widening Service Expertise Gap™—the growing divide between top-performing technicians and the rest of the workforce—driven by rising customer expectations, increasingly complex machinery, and the ongoing skilled labor crisis.
Top-performing organizations leverage strategies such as the Shift Left Method, which emphasizes remote and self-service options, and aI-driven service solutions to redefine industry standards. aquant analyzed nearly 160 service organizations, totaling over 600,000 technician service records and $9.5 billion in service costs.
“Millions in service costs are on the line for organizations failing to resolve issues quickly and live up to rising customer expectations,” said assaf Melochna, cEO and co-founder of aquant. “While challenges like the skilled labor shortage threaten operational efficiency, forwardthinking companies are setting new standards. Our latest benchmark report provides practical strategies, inspired by examples from leading companies, to close the expertise gap, enhance performance, and meet the rapidly evolving demands of today’s service industry.”
Key Findings from the 2025 Field Service Benchmark report
» Service Experience Gap™
» 14% of truck rolls—one in seven onsite service visits— are unnecessary, leading to inflated costs and technician burnout.
» One-third of service queries are solvable without a professional’s help and can be resolved through self-service.
» a I-powered solutions enable top-performing organizations to achieve a 39% faster resolution time and a 21% increase in accuracy.
» a failed first visit adds two additional visits on average, extending resolution timelines by 14 days.
» Performance Metrics
» Top companies boast a First Time Fix rate (FTFr ) of 86%, compared to just 53% for bottom performers.
» resolution time for top organizations averages three days—eight days faster than their lowerperforming peers.
» Time between service visits for leaders is 131 days, nearly triple the 50 days achieved by laggards.
» cost Disparities
» avoidable Dispatch rates are just 3% for top performers versus 24% for the bottom 20%.
» The annual cost gap between high and low performers can reach $1.8 million.
» a 1% improvement in remote resolutions can save organizations $1.1 million annually.
Blueprint for Becoming Best-in- class
The report outlines strategies top-performing organizations are adopting to stay ahead:
» Benchmarking critical KPIs such as avoidable Dispatch rates and First Time Fix rates to identify and address performance gaps.
» Proactively closing knowledge gaps and upskilling technicians by leveraging a I to democratize expertise across the workforce.
» a dopting the Shift Left Method to resolve issues earlier, reducing the need for on-site visits.
To access the full 2025 Field Service Benchmark report, visit www.aquant.ai.
BECKHOFF
TwinCAT Core Boost Accelerates IPC Performance for Next-Level Automation
Beckhoff has introduced TwincaT core Boost, a new "turbo mode" that increases computing performance by up to 50%, enabling greater flexibility and reducing controller costs in certain applications. This enhancement elevates TwincaT 3 runtime and maximizes the power of multicore processing.
With Twin caT core Boost, systems can achieve higher efficiency, adapt to unique application requirements, and possibly use lower-cost cPUs while still accessing additional processing power for specific tasks.
TwincaT’s multi-thread capabilities have long enabled applications to be distributed across multiple cores. Now, TwincaT core Boost takes this a step further by allowing users to configure the clock frequency of individual processor cores. These cores can be permanently assigned in real-time operation, ensuring higher clock rates where needed.
To maintain reliable system performance, Twin caT core Boost actively monitors:
» Power consumption
» Processor core temperature
» Overall system stability
TwinCAT Core Boost Accelerates IPC Performance for Next-Level Automation
For More Information: www.beckhoff.com
LANTEK & EUROMAC
Lantek and Euromac Deliver High Precision and Productivity in Combined Punching and Shearing Systems
Lantek, a global leader in software solutions for the sheet metal industry, has partnered with Euromac, a leader in punching and shearing innovation, to develop a fully integrated solution that redefines metal sheet processing.
This collaboration combines Euromac’s advanced punching and shearing machines with Lantek’s automation and synchronization software, delivering:
» Optimized material utilization with up to 20% reduction in waste
» continuous, autonomous production with fully automated part stacking
» Uninterrupted machine operation, even during unattended shifts
Lantek’s software integration ensures seamless sorting, palletization, and classification of cut parts, eliminating manual handling. The solution has already been successfully implemented in factories across Italy, Germany, and Spain, setting a new standard for autonomous sheet metal processing.
“With this collaboration, we are offering a
For More Information: www.lantek.com
TwincaT core Boost is available for all Beckhoff Industrial P cs with Intel® core™ I processors from the 11th generation onward.
groundbreaking solution that merges Euromac’s precision and speed with Lantek’s automation capabilities,” stated Francisco Pérez, OEM channel Director at Lantek.
TOOLING AND WORKHOLDING
Precision in Action
Tooling and Workholding is the cornerstone of precision manufacturing, ensuring that materials are securely held and processes are executed with unparalleled accuracy. This section highlights the latest innovations in clamps, chucks, collets, and magnetic workholding, alongside advancements in rotary tables, toolholders, and modular fixturing systems. Together, these solutions enable manufacturers to achieve repeatability, reduce setup times, and enhance overall productivity.
From versatile milling and turning tools to specialized threading and gear-cutting instruments, this category delves into the diverse range of equipment designed to meet the unique demands of every operation. Whether exploring robotic end-effectors for automation or custom fixtures for intricate designs, Tooling and Workholding underscores the critical role these components play in driving efficiency and precision across the manufacturing spectrum.
How to Evaluate the Quality of Precision Tooling
Key considerations for Precision Tooling Evaluation
a ssessing tooling quality involves examining the entire assembly, including tool holders, collets, nuts, and retention knobs, alongside spindle tolerance to ensure optimal precision. Even minor improvements in runout can significantly reduce cost per hole, demonstrating the long-term value of high-quality tooling.
The Impact of Low-Quality Tooling
Poor tooling leads to inconsistent performance, increased costs, and reduced precision. It can result in oversized holes, poor cutting conditions, and increased total indicator runout (TIr). Even a reduction of runout by one-thousandth of an inch can improve cost per hole by approximately 10 percent. While low-quality tooling may seem cost-effective initially, it often results in higher operational expenses and quality issues over time.
Key Factors in assessing Precision Tooling
To accurately evaluate tooling, it is essential to understand the required
tolerances and select the appropriate tooling setup. Precision depends on multiple factors, including retention knobs, tool holder aT tolerances, and the quality of collets and nuts. comparing these components across different brands provides a clearer picture of tooling quality.
Understanding aT Tolerance in Tool holders
aT tolerance refers to the spindle tolerance set by the machine manufacturer. Most machine manufacturers grind spindles to an aT1 tolerance. at BIG DaIShOWa , tool holders are ground to an aT2 tolerance, which complements standard spindle tolerances and ensures better surface contact. competitors that use aT3 tolerances compromise precision and rigidity, reducing machining accuracy.
Meticulously grinding every diameter of the V-flange enhances rigidity and improves repeatable tool changes, making aT2 the preferred tolerance level for precision machining.
Evaluating collets, Nuts, and retention Knobs
Selecting the right components for each application is critical. For example, while a standard Er collet may work for some tasks, specialized collets like the Mega E provide superior surface contact for end milling. Similarly, choosing the appropriate nut—such as a bearing nut over a friction nut—can significantly impact performance by reducing TIr
Key quality indicators include:
» Smooth, burr-free collet slots.
» Well-ground tool holder and nut threads.
» a taper free of noticeable texture, ensuring maximum precision.
Material Selection and Its Effect on Precision
Some manufacturers invest in select tooling elements while compromising on materials for collets, nuts, and retention knobs. Subpar materials lead to premature wear and hidden costs. additionally, the heat treatment and grinding processes significantly impact final product quality. Not all tooling manufacturers maintain the same standards in these critical areas.
The role of Manufacturing and Quality control
The overall quality of precision tooling is heavily influenced by the manufacturer’s processes. Thorough inspections ensure products meet the required standards. BIG DaIShOWa implements stringent quality control, including: Precision grinding to exacting tolerances.
» hand-measuring collets twice—at the nose and at four times the diameter—to ensure accuracy.
» Use of high-quality tool steel (h13) across all components, including collets, nuts, and retention knobs.
» Serial-numbered retention knobs featuring a "born-on" date, aiding in maintenance tracking.
complete in-house control over all manufacturing processes, from heat treating to grinding, ensuring superior performance and reliability.
conclusion
Precision tooling evaluation is a multi-faceted process that involves careful analysis of tolerances, materials, and quality control. Investing in high-quality tooling minimizes operational costs, enhances accuracy, and ensures reliable performance. For more information on selecting the best precision tooling for your machining needs, consult a BIG DaIShOWa expert today.
IR TURBINE TECHNOLOGY INC.
Air Turbine Spindles® New 601 Series at 65,000/90,000 RPM
air Turbine Technology Inc., the leading manufacturer of revolutionary high-speed turbine products, highlights its new air Turbine Spindles® 601 Series Spindle. This
innovative spindle combines constant high-speed in cut, energy efficiency, and a user-friendly design. a s a result of its governed high-speed performance, the 601 Series is an invaluable addition in any cNc magazine to accelerate productivity and reduce costs in today's fast-paced industrial landscape.
The compact 601 Series Spindle incorporates a ir Turbine Technology Inc.’s patented governor technology, which increases cFM airflow on demand to maintain constant speeds of 40,000 to 90,000 rPM under cutting load on the toolpath through the program. The 601 Series Spindle provides up to 0.2 hP (0.15 kW) power, delivering ample power for micro-machining applications—although a ir Turbine Technology Inc.’s range includes spindles with power up to 1.4hP (1kW) for larger tools and hard materials.
This unique governed turbine maintains the required surface feet per minute (SFM) and chip load for micro and small tools by sustaining high rPM on the toolpath. cycle times are routinely reduced by 6 to 10 times compared to standard cNc spindles at 6,000 rPM to at most 20,000 rPM. Maintaining high speed in cut also optimizes tool performance, eliminates tool breakage, and ensures the production of standardized high-quality parts.
The 601 spindle operates with no heat, ensuring 2-micron accuracy with no thermal growth. No maintenance is required, and with only two moving parts, it remains highly reliable. a connection to 90 psi (6.2 bar) air is all that’s needed to make any cNc machine a high-speed system. automated loading is available through an air supply via the machine spindle, a collar and stop block, or a manual connection through the side air inlet.
The high-speed capabilities of the 601 a ir Turbine Spindle® streamline production by eliminating secondary
operations. additionally, the 50 mm extended barrel design allows greater maneuverability for reaching tight workpiece operations, angles, and pockets, making it particularly effective in machines with limited Z-a xis travel or in 360˚ 5-a xis programming.
For More Information: www.airturbinetools.com
CERATIZIT USA
Shannon Grismore Promoted to Sales Director, Central Zone
cEraTIZIT USa , a manufacturer of standard and custom tooling for the metalworking industry, has promoted Shannon Grismore to Sales Director, central Zone. Grismore, who brings nearly three decades of machining, sales, and application experience to the role, will oversee a seven-state territory, including Indiana, Wisconsin, Michigan, Illinois, Kentucky, Tennessee, and Ohio.
Prior to assuming his new position, Grismore supported cEraTIZIT customers as a sales engineer in Southern Indiana and Kentucky for almost three years. his extensive experience includes 13 years as a machinist with the former Delaware Machinery & Tool company, Inc., where he worked on die cast component tooling. he then transitioned into applications and sales engineering roles, gaining deep expertise in cutting tool solutions.
“Shannon’s extensive experience as a machinist allows him to understand the requirements and challenges encountered on the shop floor,” said Troy Wilt, Managing Director of cEraTIZIT USa , cutting Tools Division. “That ability, combined with his deep product knowledge, will continue to drive growth and customer satisfaction in cEraTIZIT’s central Zone.”
For More Information: www.ceratizit.com
New 500 Series Rubber/Silicone Extrusion Crosshead
Guill Tool introduces the NEW 500 Series crosshead with Mechanically a ssisted Gum Space (MaGS) adjustment. Designed specifically for the flow characteristics of elastomeric compounds, this innovative crosshead allows effortless gum space adjustments from a single point using a common socket wrench. The visual indicator on the core tube enables precise, repeatable adjustments.
The patented cam lock design eliminates the need for unbolting and re-securing fasteners, reducing downtime and making cleaning and changeovers much faster. additionally, the newly designed flow inlet channel minimizes shear and heat generation, leading to lower
head pressures and a more balanced material flow. a cast aluminum liquid-fed cooling sleeve further enhances performance by allowing quick swap-outs in case of line obstructions. The 500 Series is a drop-in replacement for most existing NrM lines but can also be adapted to fit other extruder designs.
For More Information: www.guill.com
THINBIT® – KAISER TOOL COMPANY
MINI GROOVE ‘N TURN® ACME THREADING INSERTS
ThINBIT® expands its MINI GrOOVE ‘N TUrN® line with new acME threading inserts, designed for cutting threads of 6 TPI and greater. These inserts support standard 29° acME thread profiles and allow for centralizing or stub profiles through overcutting. The inserts can be used for internal acME threads on bore diameters of .325” and larger. available in multiple carbide grades with TiN, TicN, TiaIN, or diamond film coatings, these inserts are compatible with conventional, Swiss, and cNc machines. Toolholders are offered in steel, heavy metal, and carbide for maximum application flexibility.
For More Information: www.thinbit.com
PLATINUM TOOLING
Heimatec Live Tools for Haas BMT Turret
Platinum Tooling has expanded its heimatec live tool offerings for the haas BMT turret, now including driven tools for drilling and milling, static tool holders, and specialty tools such as multi-spindle, adjustable angle, and speed multipliers. These reengineered tools are designed for higher rPM capacity and extended durability, leading to shorter production times and increased tool life. heimatec’s tooling is already widely used in the industry and offers immediate support and innovative solutions for haas users.
