INNOVATORS

IN MACHINE DESIGN
Special thanks to our sponsor
2024 INNOVATORS PROFILE
Sponsored Content

WEB | www.automationdirect.com
TEL | 800-633-0405

A LITTLE ABOUT OUR PRODUCTS

We offer tens of thousands of high-value industrial automation products, both name brand and private-labeled, that are chosen
by our product engineers for their best-in-class features, price, and quality. Our name-brand products come from companies
such as Fuji Electric, EATON, and Hubbell/Wiegmann, and we co-engineer many of our private labeled products with the
manufacturer to ensure our customers are getting the features they ask for at prices they can afford.

A LITTLE ABOUT OUR PRICES

Our prices have been typically 50% less than traditional suppliers, and this is accomplished thru aggressive pricing from our
suppliers because of our volume purchases. We can offer very attractive prices on everything from programmable controllers to
terminal blocks. With our direct business model and focus on efficiency, we have the lowest overhead in the industry.

A LITTLE ABOUT OUR SHOPPING EXPERIENCE

Our product offering includes everything from cable ties, pushbuttons, sensors, wire, and tools, to pneumatics, HMIs,
and PLCs, drives, motors and more. Our online store is available 24/7 for product research and ordering (no waiting for a
distributor to contact you back) and our award-winning service is available if you need it during normal business hours.
Our store has many conveniences built in for customer satisfaction including easy online quotes, quick ordering by uploading
CSV file, reusable BOM and favorite lists, secure checkout with convenient payment options including PayPal, upfront pricing
(you get our low price no matter if you buy one item or one hundred), and real-time stock availability listed on each product
page. We also have numerous helpful product selectors/configurator tools for PLC, servo system, motor, timing belt, and field
I/O products. We have free documentation: manuals, comprehensive help files, price list, CAD files, free product tutorial
videos, free (full package, no demo) software that you can take for a spin, and we list all customer reviews that we receive for
our products, so customers know as much about the product as possible. Once the purchase is made our automated facility
has an order accuracy of 99.98% but we do offer a 30-day money back guarantee on most products for any last-minute changes
customers may need. Also, orders over $49 ship free of charge.

MACHINE DESIGN
 ,ILW VLQ\RXUSDQHOLW VDW
$XWRPDWLRQ'LUHFWFRPIRUOHVV
Circuit protection including MCCBs, circuit breakers,
and transfer switches
(Circuit breakers starting at $15.00)

Wiring solutions including cut-to-length cable, hookup

wire, wire duct, conduit, terminal blocks, and cable
entry systems (Wire duct starting at $7.50)

Drives, soft starters, and motor control devices

(Micro AC drives starting at $119.00)

Enclosure lighting and thermal management

(Thermoelecric coolers starting at $718.00)

Industrial power supplies, transformers, and

converters (DC power supplies starting at $20.00)

PLCs, field I/O systems, motion controllers,

servo and stepper systems (PLCs starting at $85.00)

Industrial Ethernet switches, gateways, and

VPN routers (Ethernet switches starting at $83.00)

Safety products including safety controllers,

safety relay modules, intrinsically safe isolators, etc.
(Safety relays starting at $121.00)

Modular and pre-fabricated enclosures

(Modular enclosure kits starting at $875.00)

Plus motors, HMIs, pneumatics, a huge assortment

of sensors and pilot devices, and so much more.
All at great prices and with award-winning customer
service and support.

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2024 INNOVATORS PROFILE
Sponsored Content

ALTECH CORP.
WEB | www.altechcorp.com
EMAIL | info@altechcorp.com
TEL | 908-806-9400
FAX | 908-806-9490

35 Royal Rd.
ABOUT ALTECH Flemington, NJ 08822
Altech Corporation is an established United States supplier of
components and devices used in industrial control, instrumenta-
tion, medical and automation applications. Altech provides a very
broad line of products that meet UL and international standards
and are RoHS and REACH compliant. Altech's commitment to
continuous quality management has been recognized since 1999
when they were awarded ISO 9001 certification.

Altech provides a multitude of services for customers. This starts

with its employees, where product managers provide technical
support and partner with customers in design assistance, ensuring
the best solution for the application. Next, an efficient customer
service department ensures that customers are informed with
complete order information. Depending on the product, the
versatile assembly department provides manufacturing, value-add-
ed, or customization services to expedite delivery. Altech’s
marketing department has been highly recognized for its catalogs,
advertising, and website designs, while the sales department
motivates the sales organizations throughout North America, LARGEST Selection of
ensuring product information is current and complete. DIN Enclosures
SERVING AUTOMATION AND Also available are metal detection systems, ferrules, marking
CONTROL INDUSTRIES SINCE 1984 and engraving systems, fuses, power distribution blocks,
Altech’s products meet UL and international standards, and all are corrugated tubes, liquid tight strain reliefs, programmable
RoHS- and REACH-compliant. Altech’s commitment to quality and relays, digital multi-timer, test and measurement devices, LED
continuous quality management had been recognized since May panel lights, mechanical thermostats, panel filters, tower lights,
27, 1999 when it was awarded the prestigious honor of ISO 9001 and wire ducts.
certification. Since then, Altech has successfully gone through the
recertification process and complies with ISO 9001:2015. OUR POLICY
Altech Corp.’s Company Policy remains to provide adequately
WIDE VARIETY OF AUTOMATION & CONTROL SOLUTIONS stocked quality products at competitive prices. Superior
The Altech product line includes miniature circuit breakers, busbars, customer service and delivery are maintained through a quality
DC-UPS devices, digital panel meters, DIN rail terminal blocks, management system and continuous process improvement
printed circuit board terminal blocks, contactors, industrial relays, and by performing these services with honesty and integrity. All
motor disconnect switches, pin and sleeve devices, receptacles, Altech employees are regularly trained in quality management
foot switches, relay modules, safety relays, slimline relays, solid systems, and as a team are committed to achieving these
state relays, push buttons, and pilot lights. goals.

2 MACHINE DESIGN
 Wide Selection of
Terminal Blocks
Quality Components
for Automation & Control Applications
• International Approvals UL, CSA,
IEC, Lloyd, ATEX, IECEX, VDE, AEx
• Wide Range of Terminals and accessories
• 3 Series - Push-in, screw, spring technologies

PCB Terminal Blocks

• Fixed PCB Terminals and Pluggable Multi-connector
• Screw and Spring Terminal Blocks
• Types include: Wire Guard Type, Lift Type,
Push-in Type, Tension Spring Type
• Pin Strips
Circuit Breakers
• UL489 Miniature Molded Case
• UL508 Listed Manual Motor Controllers Power Supplies
Suitable as Motor Disconnect • Ultra Compact, 75, 120, 240, or 480W
• UL1077 Recognized Input: 85-264VAC 47/63Hz
Supplementary Protector Output Voltage: 12, 24 & 48 V DC
• Low Profile, 15, 30, 60, or 100W
Industrial Enclosures Input: 90-240VAC 50/60Hz
• Polycarbonate, ABS, Polystyrene, Output Voltage: 5V-48V DC
Aluminum and Polyester • Slimline, 10, 20, 48, 60, or 96W
• Broad range of sizes Input: 90-264VAC 50/60Hz
• NEMA 4X available Output Voltage: 5V-48V DC
• Functional and appealing designs
• Large selection of accessories
Disconnect Switches
• AC and DC versions
• Customization and imprinting
• UL98 and UL60947-4-1 (formerly UL508)
• Across the line, motor starting - up to 75hp/600V
Cable Glands • General Use Rating 16A to 150A/600V
• Polyamide, nickel-plated brass or stainless steel
• 10kA short circuit withstand rating
• Straight-through, strain relief, bend protection,
• Horsepower ratings • Toggle switches DUAL
pull/bend protection, flat cable, multi- RATED
• Many types of Enclosed Switches
conductor, ATEX and EMI/RFI functions
• Available in PG, Metric and NPT thread sizes DC-UPS Backup
• 4 solutions in one device
MAINS
• Power supply, battery charger, batter care module and
OR AUX
BACKUP

backup module
OUT
RY
LOW BATTE
RY MAX
OR BATTE MIN
All in one
T
REPLACEMEN BATTERY
LEVEL
CHARGING
DIAGNOSIS

• Selection of 12, 24 and 48V DC-UPS

with UL Recognition

AltechCorp.com
908.806.9400
Your Source for Automation & Control Components
INSIDE INNOVATORS IN

FEATURES
PEOPLE
12 The Rise of the Sustainability Engineer
20 Nurturing Innovation Can Lead to Employee Longevity
24 Survey of Engineers: Pushing Roles to the Edge of
Possibility 12
27 Changemakers:
STEM Field
Expanding our Understanding of the

TECHNOLOGY DISRUPTORS
Big Tech & Big Ideas Permeate Industrial Thinking
38 in 2023
41 Generative AI’s Transformative Impact on Manufacturing:
Unleashing the Power of Industrial Data
38
42 Deliver Robust Automated Systems Through Servo
Maintenance

44 Pushing the Limits of Drone Capabilities

45 How to Build a Better Rat Trap—with 70 Synchronized
Servo Axes

INDUSTRY TRENDS
Additive Manufacturing Innovations Drive Industry
45
56 Forward

59 Custom Machine Builder Develops Automation Solution

That Increases Production Capacity Four-Fold

62 The Future of Connected Worker Technology and Its

Impact on Industrial Training

65 5 Common Machining Mistakes to Avoid 56

66 Master Embedded Systems Security: A Step-by-Step
Guide to Protect Critical Components

EXTRAS
5 From the Editor Cover photo credits:
6 Machine Design Online SophonK_ 1305005071 | Getty Images Plus
80 Ad Index 6245922 © Selestron76 | Dreamstime.com

65
Special thanks to our sponsor
LOOK FOR ADS ON PAGES IFC, 1, 9-11

4 MACHINE DESIGN
From the Editor
By Bob Vavra, Senior Content Director

Innovation is in the
Small Details
THERE ARE A LOT of big ideas in retention. And as we look to the future specific needs of individual manufactur-
manufacturing today. From artificial intel- worker, we discuss new ways to interpret ers. Innovation is a beacon to the future,
ligence to robotic systems to new ways to the STEM movement; in doing so, we but the way that innovation ultimately has
collect, interpret and act on data, we are increase the definition of STEM, and in an impact is more like a flashlight that
at the vanguard of seismic change in how the kind of workers we need to attract to illuminates a specific area and brings that
we design, operate, maintain and optimize manufacturing. area into greater focus.
manufacturing plants. These all are macro-level ideas, but we We don’t innovate all at once. Innova-
As we stand on this precipice and gaze look at them from an on-the-ground per- tion takes time. Above all, it takes atten-
at the future, we see the vast possibilities. spective. It is not, as we have discovered, tion to the small details. Get the small
That’s both necessary and appropriate. how the big ideas drive manufacturing things right and the innovations will yield
What gets missed as we look at the big innovation. It is how those ideas are adapt- big benefits—particularly in this age of
future are the ways to apply all of these ed, synthesized and reborn to meet the big ideas. „
big ideas in smaller, measured ways. The
barrier to implementation of big ideas is
the notion that the execution has to be on
a grand scale. As manufacturers around
the world have shown, that’s almost never
the case.
This special Innovators issue certainly
covers all the big ideas, but the real inter-
section of style and substance we want
to discuss in these pages is the practical,
nuanced ways those big ideas have been
integrated by design and operation teams.
We have an article not just about
connected workers, but how connecting
marchmeena29_1483172285 |iStock / Getty Images Plus

workers improves training efforts. We

see AI’s influence on manufacturing
as it relates to new ways to use data to
create unseen insights—and improved
operations. We look at the larger issue
of how innovation itself can drive worker
engagement—and create a longer-term
impact of employee satisfaction and

GO TO MACHINEDESIGN.COM 5
2024 INNOVATORS PROFILE
Sponsored Content

ACE WEB |
TEL |
www.acecontrols.com
800-521-3320

CONTROLS 23435 Industrial Park Drive

Farmington Hills, MI 48335

CONTROL MOTION AND VIBRATION WITH ACE

A
CE Controls Inc., located in Farmington Hills, Michigan, is a leading innovator in deceleration, vibration and
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We are committed to delivering the highest quality and the latest technology to meet your challenges.

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ACE specializes in custom engineering services, including
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ENGINEERING TOOLS & RESOURCES

ACE has simple solutions to make your job easy, including
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Connect with ACE’s application engineers who will work
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needs. Or take advantage of our online tools:

• Size, Configure and Order Online

• CAD library
• YouTube
• Blog featuring case studies
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6 MACHINE DESIGN
WHEN
PERFORMANCE
MATTERS
trust ACE Controls with your motion
& vibration control challenges

Standard products
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ƒ Industrial shock absorbers
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Resources
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ƒ Technical blog & case studies

800-521-3320 · www.acecontrols.com · Farmington Hills, Michigan

EDITORIAL
MachineDesign.com
m
Senior Content Director: Bob Vavra
bvavra@endeavorb2b.com
Editor-in-Chief: Rehana Begg
rbegg@endeavorb2b.com Machine Design Tips the
Managing Editor: Jeremy Cohen
jcohen@endeavorb2b.com
Hat to Contributors of
Technical Editor: Sharon Spielman Note in 2023
sspielman@endeavorb2b.com
Catch up on technology updates you’ve
Technical Editor: Sara Jensen
sjensen@endeavorb2b.com been meaning to read about all year.
ART DEPARTMENT Links are provided at your fingertips.
Group Design Director: Anthony Vitolo
tvitolo@endeavorb2b.com
https://machinedesign.com/21279688
Art Director: Jocelyn Hartzog
jhartzog@endeavorb2b.com
PRODUCTION
Production Manager: Sam Schulenberg
sschulenberg@endeavorb2b.com Year in Review:
Ad Services Manager: Deanna O’Byrne Machine Design’s 2023
dobyrne@endeavorb2b.com
AUDIENCE MARKETING
Cover Story Series
User Marketing Manager: Debbie Brady Flip through this year’s print issues
dmbrady@endeavorb2b.com
to uncover significant technology
Article Reprints: reprints@endeavorb2b.com
LIST RENTAL
milestones of 2023.
Smartreach Client Services Manager: Kelli Berry https://machinedesign.com/21279770
kberry@endeavorb2b.com
SUBSCRIPTION SERVICES
OMEDA: machinedesign@omeda.com
847-559-7598 or 877-382-9187
DIGITAL
VP of Digital & Data Innovation:
Annual Salary Survey
Ryan Malec rmalec@endeavorb2b.com eBook from Machine
SALES & MARKETING
Patrick Carmody
Design
pcarmody@endeavorb2b.com The latest salary and career insights
AK, AR, AZ, CA, CO, HI, IA, ID, IL, IN, KS, KY, LA, MI, MN,
MS, MO, MT, ND, NE, NM, NV, Western OH, OK, OR, SD, from mechanical engineers and
TN, TX, UT, WA, WI, WY, Western Canada other industry professionals from the
Brandy Bissell
bbissell@endeavorb2b.com
engineering community.
DE, MD, NC, NJ, NY, Eastern OH, PA, SC, VA, WV https://machinedesign.com/21278947
Liz Stott
lstott@endeavorb2b.com
AL, CT, FL, GA, MA, ME, NH, RI, VT, Eastern Canada
Stuart Bowen Featured Video
sbowen@endeavorb2b.com
Belgium, France, Luxemburg, Netherlands, Portugal,
Scandinavia, Spain, United Kingdom
Diego Casiraghi Natural Language
diego@casiraghi-adv.com
Italy Conversation Assistants
Helen Lai or Charles Liu
helen@twoway-com.com or liu@twoway-com.com
Cross Over from Vehicles
Pan-Asia to Industrial Machinery
DESIGN & ENGINEERING GROUP
iNAGO founder Ron Di Carlantonio is a
Electronic Design, Machine Design, Microwaves & RF,
Power & Motion, SourceESB, Source Today, 3DX Tokyo/Toronto-based computer scientist
EVP, Design & Engineering Group: Tracy Smith who is pitching intelligent assistant
tsmith@endeavorb2b.com https://machinedesign.com/________
platforms for industrial environments.
Group Content Director: Michelle Kopier
mkopier@endeavorb2b.com https://machinedesign.com/21278595

@MachineDesign Read Anytime,

Anywhere!
Endeavor Business Media, LLC MachineDesignMagazine View the digital edition
30 Burton Hills Blvd, Ste. 185, Nashville, TN 37215 of Machine Design at:
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CRO: Reggie Lawrence
Chief Digital Officer: Jacquie Niemiec CSIA Exchange
Chief Administrative and Legal Officer: Tracy Kane Find a system integrator here: https://www.csiaexchange.com

8 MACHINE DESIGN
FAQ
Why Should You Incorporate
Push-In Terminals in Your Next
DIN Rail Application?
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conditions, and a high-density, compact design. prevent screw loosening.

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What are the basic types of DIN-Rail
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terminal blocks used today?
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Sponsored by and machine tools.
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required to secure a wire into a push-in terminal Not at all. In fact, switching to push-in technology
block. This aspect alone saves time on installation also provides safety and reliability due to the
and maintenance endeavors. Due to advancements terminal blocks’ large pull-out force that is required
in materials and the changes in users’ needs, push-in to remove a wire once it’s in place (see Figure 2).
WHUPLQDOVFDQR΍HUDGGLWLRQDOEHQHȴWVDVZHOO

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greater than that of screw or spring type terminal blocks,
making them highly reliable for low maintenance and
long-life applications.

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with ferrules directly into the terminal block for the 7KHNH\EHQHȴWJDLQHGZKLOHXVLQJSXVKLQWHUPLQDO
fastest and most reliable connectivity on the market block technology for end users is how well it
today (see Figure 1). With minimal human interaction, streamlines the installation process for
these terminal blocks are ideal for use with interconnecting all types of devices, including
automated and robotic wiring operations. This VHQVRUVΖ2DQG'&6V\VWHPVIRUSURFHVVDQG
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technologies to push-in technology. minimum insertion force requirements — even to
connect small wire sizes. The terminal blocks are
designed to withstand harsh environmental
conditions as those found in marine applications as
well as chemical plants due to the use of non-
ferrous metals in the connection components.

Are push-in DIN-Rail terminal blocks

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allowed for 33% more wire density without
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using push-in terminals compared with other types. terminal block thickness allows a 14AWG (1.5 sq
mm) wire to be connected. In addition, specially
Sponsored by
GHVLJQHGWHUPLQDOEORFNVDUHDYDLODEOHIRUVSHFLȴF
applications such as those on the following page.
This photo shows specially designed terminal
blocks, such as the sensor and actuator terminal
block and the marshalling terminal block.

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through Altech are available in single-
level, double-level, and multi-level
versions, all of which have grounding
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Also, special sensor and actuator, knife
disconnect, and marshalling terminal
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accessories are available.

Sponsored by
People

The Rise of the

Sustainability Engineer
As a sustainability
engineer, Iana Aranda
is tasked with bolstering
sustainability efforts by
preparing the engineering
workforce for social
entrepreneurship and
cross-sector partnerships.
by Rehana Begg, Editor-in-Chief

WITH DEMAND FOR sustainability and

engineering executives on the rise, Iana
Aranda fits the profile of a woman forg-
ing change. E4C Fellow Benson Maina leads user research with farmers in Kenya, 2019. Images courtesy E4C
The senior director of Engineering for
Sustainable Development at the American what the association is doing to advance or ESG—factors that investors are con-
Society of Mechanical Engineers (ASME), solutions to the climate crisis. sidering,” Aranda said. These factors are
Aranda harnesses her mechanical engi- “I manage a portfolio of programs and creating a shift in culture, as well as “a pull
neering background to support global sus- platforms that advance the Sustainable for reporting, for understanding activi-
tainable development by leading a team Development Goals as envisaged by the ties, particularly of corporations related
that operates at the intersection of engi- United Nations,” Aranda said. “In terms to sustainability, which ultimately trickles
neering and sustainable development. She of practical application, we specifically down to the entire workforce and engi-
leans in to ASME’s climate strategy and [leverage] the engineering skill set and neers,” she said.
expertise to direct a diverse global work- The demand for sustainability in engi-
force towards how they can participate, neering solutions, Aranda pointed out,
how they can contribute. We are really is further related to President Biden’s
architecting new initiatives, new pro- Bipartisan Infrastructure Deal and the
grams, developing the opportunities for measure of investment being made in
these engineers to participate and get climate action and technology associat-
skilled in and how to contribute.” ed with advancing climate action. Given
the engineers’ critical role in developing
Sustainability Engineers solutions, products and services associ-
are Up and Coming ated with technological advancement and
The market pull for sustainable engi- the bottom line for many of these corpo-
neering roles is on the rise, confirmed rations, a move in this direction requires
Aranda. ASME hosted a stakeholder sum- attention.
mit early in 2022 to probe this demand The shift has also been observed in
and to consider the intersections of sus- academia, where students—the incom-
tainability in engineering. ing engineering workforce—are interested
“There are market forces that are in having meaningful and purpose-driven
Iana Aranda, senior director, Engineering
Global Development, ASME (The American already pushing this forward—namely work. “They want to do this as their paid
Society of Mechanical Engineers) ASME environmental, social and governance, job, which is entirely sensible,” Aranda

12 MACHINE DESIGN
said. “They want to be rewarded for their where taking work away from the econ-
time and talent and then, of course, we’re omy will likely have negative implications.
also seeing this from the perspective of For those who must know, her refined
regulatory agencies.” methodology when working with ven-
tures in low-resource settings with lim-
The Design Engineer ited access to advanced manufactur-
Aranda has come a long way from her ing and limited engineering resources
days as junior design engineer role in includes location-specific questions,
2001, when she designed hardware and such as: How do you ensure that you
manufacturing specifications for electron- design for manufacturability? How do
ic and optical systems using Solid Edge you identify the right manufacturer in
(Siemens) solid modeling software, or the sub-Saharan Africa?
time she was hands-on with SolidWorks “To ensure that you are manufactur-
(Dassault Systèmes) modeling software to ing products cost-effectively, you are
provide engineering design and develop- likely going outside of the continent,”
ment of optomechanical, electromechani- Aranda said.
cal and in-vivo imaging hardware for At stake are the short- and long-term
biomedical research facilities. implications for local communities.
These days her daily routine is as likely Aranda outlines the thought process:
to revolve around budgeting as it is to “Building out a [manufacturing] meth-
meeting with global collaborators to dis- odology that allows us to ask the right
sect the relevance of design for manufac- questions, to really pinpoint those issues,
turability methodologies in low-resource those hurdles, and then start to consider
settings, such as sub-Saharan Africa, where might there be workarounds, or Artisal gold mining in the Amazon.

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Sustainability Engineer

processes, or ways for them to partner, or

even approaches that may be transferred
from elsewhere that they can leverage for
the benefit of their venture.”

Building on Success
The success Aranda brings to her cur-
rent role is palpable, but represents a mere
sliver of her career accomplishments and
victories along the way. She led the devel-
opment of Engineering for Change (E4C)
on behalf of its co-founders ASME and
other leading engineering societies. The
digital platform educates and activates the
international technical workforce by pro-
viding resources and access to expertise
to accelerate the development of solutions
and infuse engineering into sustainable
development. E4C today services more
than 1 million engineers, scientists and
technologists around the globe.
Aranda is also the mastermind behind a E4C Impact Project, Sanergy 2022.
highly competitive E4C fellowship of 200
fellows per year. The program enabled bind gold flecks, for example. This has ferently. “It started with my first boss, who
her to promote diversity and empower demonstrated to be absolutely devastating took a bet on me and allowed me a lot of
engineers early in their careers, as well to that region.” responsibility; she allowed me to work
as to establish an operational model and CXL was tasked with sourcing techno- with her and believed in me,” she said.
programs. logical innovators to deliver solutions that Being at the grassroots level of an ini-
The E4C platform works by exposing address the crisis. The team developed an tiative that has grown to be massive and
engineers to critical issues across sectors accelerator, the Amazon CoLab, as part to rise to the forefront of the field has
(including water, sanitation, energy and of their advancement model, which pro- its rewards. “It’s been truly incredible to
health), offering training through online vides technical guidance and mentoring see how E4C, for example, has grown
programs and by supporting organiza- to business leaders, as well as guidance from an idea in 2009 to a platform that
tions with their sustainability goals. “For on how to scale innovations further and encompasses more than a million people
instance, we augment their workforce with enter the market. around the world,” Aranda said. “I’ve had
our subject matter experts, our fellows, E4C’s experience with social entre- more than 200 fellows and worked with
staff and partners,” Aranda explained. preneurship and supporting innovators an incredible array of partners. We’ve had
In one impact services project, Con- around the globe was instrumental in true opportunity to effect change.”
servation X Labs, the work focuses on helping support Amazon CoLab by con- Most recently, she helped to assemble
preventing the sixth mass extinction. necting their cohorts to “the right people, a strategic advisory group, ASME’s Com-
Working with USAID, the program aims right networks,” and by helping them mittee on Sustainability, which she now
to address negative social and environ- think through their scaling strategies in facilitates. Aranda will also attend COP28
mental impacts in artisanal small-scale order to get them on the track to succeed. on behalf of ASME.
mining in the Amazon region. Still, the path to success is not always
“Artisanal miners are flying under the Grassroots to Greatness smooth. “When you are in uncharted ter-
radar of regulatory agencies, often try- Aranda credits her success only partly ritory, you have to make your own plan,”
ing to extract gold throughout the Ama- to being prepared to put out ideas and said Aranda. “Some things work and some
zon region,” Aranda said. “This requires watch them grow. She said none of the things don’t. In the unknown, you have to
using methods to extract gold that [are] milestones in her career could have been be comfortable in discomfort.” „
incredibly detrimental to the environ- achieved without her mentors and the staff
ment, local and indigenous communi- she worked with and who mirrored the
ties. And that includes using mercury to desire she had to practice engineering dif-

14 MACHINE DESIGN
2024 INNOVATORS PROFILE

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2024 INNOVATORS PROFILE
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16 MACHINE DESIGN
2024 INNOVATORS PROFILE
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18 MACHINE DESIGN
People

Nurturing Innovation
Can Lead to Employee
Longevity by Sharon Spielman, Technical Editor

According to Machine Design’s

2023 Salary Survey, only 14%
of companies have managed
to retain their workforce for at
least 25 years. Fabco-Air Inc.,
a member of Festo Group in
Gainesville, Fla., is one of them.
Sharon Spielman

20 MACHINE DESIGN
In an ever-changing ACCORDING TO U.S. BUREAU OF according to Kevin Cradduck, director of
business landscape, Labor Statistics, more than 50 million operations at Fabco-Air.
people quit their jobs in 2022, and the A visit to the facility revealed that
where employee turnover rate in the manufacturing sector employee longevity can be found across
turnover rates are high, is roughly 39%. all departments. Cradduck says the
how can manufacturers Machine Design’s 2023 Salary Survey average tenure is 25 years and succession
reveals that 41.7% of companies plan is balanced with experienced and
retain their workforces to increase the number of engineering entry-level employees. Manufacturing
and fuel innovation? jobs; 14% of respondents this year have Technical Specialist Chris Kazimier is
worked at their company for at least 25 just one of the long-time employees
years, and 36% have worked at their cur- (34 years), and he offered insight into
rent company for less than four years; the factors that contribute to at least
but 46% of respondents have worked in one company’s sustained success and
engineering for at least 25 years, and 16% employee longevity.
have worked in engineering for less than
four years. Culture of Innovation,
There are struggles to fill and retain Experimentation
manufacturing positions today, and the According to Kazimier, at Fabco-Air,
longevity of most people in engineering innovation is not confined to the board-
needs to improve. According to the Soci- room but rather permeates every level of
ety for Human Resource Management, the organization. Employees are motivat-
the cost to replace an employee can range ed and empowered to share their ideas for
from 50% to 400% of their annual salary, process improvement.
depending on the position. And because
manufacturing facilities usually require
specialized skills and knowledge, training
costs can be significant.
Whatever the reason—from the skills
gap to the changing perception of manu-
facturing to an aging workforce to global
competition and outsourcing—the manu-
facturing sector will require effort from
its stakeholders to address the challenges
associated with employee longevity.
On the heels of a post-pandemic Great
Resignation, however, certain companies
have managed to cultivate a culture that
not only retains their workforce but fuels
continuous innovation. Among the 14%
of companies that have managed to retain
their workforce for at least 25 years is
Fabco-Air Inc., a member of Festo Group
based in Gainesville, Fla.
The pneumatic components maker has
helped its customers build machines for
more than 60 years thanks to its commit-
ment to foster employee creativity, lever-
age new technologies and embrace cal-
culated risks. The company was acquired Chris Kazimier, a 34-year Fabco-Air
employee, let Machine Design in on the
by the German family-owned Festo in
factors that he said contribute to at least one
2018 to supplement its metric product company’s sustained success and employee
line with Imperial English inch products, longevity. Courtesy Fabco-Air Inc.

GO TO MACHINEDESIGN.COM 21
Nurturing Innovation

How a Fabco-Air Technician Helped His Daughter Become a Doctor

MAHDI KARIM (pictured below) is a secondary operations technician at Fabco-Air. He has been working there
for 38 years, and he used his income to support his daughter’s education. “She wanted to be a registered nurse,
and I never wanted to go to college,” Karim told Machine Design. “I also didn’t want her to have a mountain of debt
when she finished school, so I was able to use the money [I earned at Fabco] to finance [my daughter] up through
school,” he said.

His daughter, Bridget, wanted to be a registered nurse (RN),

and Karim paid for her nursing college. He also encouraged
her to pursue higher degrees and become a nurse
practitioner (NP) and then a medical doctor (MD). He shared
a story of how a note from an NP inspired Bridget to continue
her studies.

“I kept nudging at her to go higher…as dads do,” Karim said.

After a jaunt in the hospital led him to ask a nurse practitioner
what it was like to be a nurse practitioner versus a registered
nurse, Karim said, “She said, ‘The view is so much better up at
the top. You stay in the nice hotels in the big suites.’”

Karim wanted this for his daughter, so he asked that NP to

help him plant a seed by writing a note to her. She obliged:
“‘Dear Bridget, the view is so much better from up here as
a nurse practitioner. I look forward to having lunch with you
one day,’ she wrote. And that did it. The seed was planted,”
Karim said.

Bridget went on to become an NP, and Karim kept working

at Fabco-Air to pay the tuition. He saw the potential in his
daughter and encouraged her to keep going to become a
doctor. He kept working and his daughter kept learning, and
today she is an MD.

Karim is proud of his daughter’s achievements and his role in

helping her reach her goals.

“From the onset of my employment at When asked for an example of how this to find tooling that would last through
Fabco-Air, everyone from the floor-level company encourages employees to experi- an unattended shift of operations. This
management to the president of the com- ment with new ideas and take calculated was all done with the teamwork from top
pany has always encouraged the people risks to drive innovation, Kazimier talked management to shop floor foremen and
operating the equipment to put forward about the purchase of its first multi-axis machine operators.”
new ideas to improve the way a job/task is CNC machine in 2007.
processed,” Kazimier said. There is encour- “This machine took a process that Keys to Establishing Employee
agement for employees’ perspectives, and required five steps and five different Longevity
this allows them to think outside the box. people down to two,” he said. “It was Company longevity and employee
“Upper management has always had through the collaboration of multiple longevity can be correlated. One factor
an open door policy and pools the ideas shop floor employees to work together that has contributed to this company’s
of many employees before making criti- and develop the strategy for this machine’s longevity, according to Kazimier, is the
cal decisions regarding new technology success—everything from the placement commitment to customer support. A
to the production schedules we keep,” of the tools and why, to the types of tool- company’s approach to staying ahead
Kazimier added. ing used, trials of many different vendors in the market starts by listening to its

22 MACHINE DESIGN
Russel Ramkumar has been a machinist for Dan Peck joined Fabco-Air in 1993 as a As a newer employee, Wendy Audas, senior
29 years, nearly the last decade of which tool and die maker. Today, he is one of the CNC setup/programmer/operator, came on
he has spent as a master CNC machinist at company’s custom tool makers and trainers board in 2021 and is a beneficiary of long-
Fabco-Air. Sharon Spielman as well as a senior CNC setup/programmer/ term Fabco employees’ experience. Sharon
operator. Sharon Spielman Spielman

customers, he said. “The Fabco sales year with multiple new hires at the con- “I have been offered many opportunities
team has always paid strict attention to trols of the equipment, teaching the use during my tenure here, and I feel it’s been
the customer’s needs and challenged our of G-code and how to set up machines a good decision. It has provided me with
engineering team to make it happen.” from beginning to final product.” a stable home life and relationships that
He adds that “the support we provide During his tenure, Kazimier has seen I hold dear.”
our customers and always being willing a transition and transformation from
to go above and beyond” has contributed manual machines to being able to run For more than three decades,
to sustained success and reputation in lights out. “When I started working at Kazimier, along with dozens
the industry. Fabco in 1990, the whole shop was filled
of his colleagues, have
With 46% of respondents to Machine with manual machinery that required a
Design’s Salary Survey having worked in person or more to process any job. I’ve chosen to stay with Fabco-
engineering for at least 25 years, there is watched Fabco embrace the CNC technol- Air. This loyalty appears to
much knowledge to be passed along. To ogy and continually drive out waste from stem from the company’s
drive innovation further and preserve the company, making Fabco a world-class people and culture.
institutional knowledge, Fabco-Air has company,” he said.
found success with leveraging the expertise For more than three decades, Kazimier, Motivated and empowered employees
of its long-term employees. By developing along with dozens of his colleagues, have can lead to continuity and stability, reduc-
standard operating procedures and digi- chosen to stay with Fabco-Air. This loyalty ing high turnover that disrupts work-
talizing various processes, the company appears to stem from the company’s peo- flow, increases training costs and creates
ensures that valuable knowledge is shared. ple and culture. The stability and strong an overall negative work environment.
Seasoned employees, like Kazimier, play relationships formed at Fabco-Air have Long-term experienced employees, on
an instrumental role in mentoring new enriched Kazimier’s personal and profes- the other hand, can provide mentorship
hires and transferring critical skills. “For sional life. and guidance, contributing to overall team
the past five years, Fabco has been using “Fabco has been my workplace for all cohesion, performance and higher reten-
the development of S.O.P. to digitalize these years because of the great group tion stats. „
specific processes and tasks,” he said. “I of people and knowing the grass isn’t
have personally been working this past always greener on the other side,” he said.

GO TO MACHINEDESIGN.COM 23
People
p

Courtesy Stephanie Holko

Survey of Engineers:
Pushing Roles to the Edge
of Possibility
A thought leader on advanced manufacturing and professional engineers analyzes
research on what drives attrition in engineering and answers the question of
applicable skills.

by Rehana Begg, Editor-in-Chief

WHEN MACHINE DESIGN INVITED from the field to seek out adjacent lines Holko’s twin roles—at OSPE and NGEN
Stephanie Holko, director of project of work. Canada—uniquely positions her to tackle
development at NGen Canada, a non- Holko, a licensed professional engi- an analysis of current trends in the engi-
profit innovation cluster focused on neer based in Ontario, is also the presi- neering profession. “NGEN Canada, or
advanced manufacturing, to discuss a dent and chair of the Board at OSPE. next generation Canada, was founded on
recent survey of engineers conducted Holko brought 17 years of experience the principle that digital transformation
by the Ontario Society of Professional to these roles, having worked as a pro- and advanced manufacturing will enrich
Engineers (OSPE), we learned that the cess engineer and engineering man- the lives of Canadians delivering better
findings suggest a profession that is mov- ager, leading teams and projects in the products and good jobs while generating
ing toward more equality and equal repre- steel industry. She holds a Bachelor of economic growth, which is essential to
sentation for women and men. However, Applied Science in chemical engineering our better future,” Holko said. “It aligns
an analysis further revealed that systemic from the University of Waterloo and an very well with my own beliefs in my role
barriers limit women’s participation and MBA specializing in the management of as director of project development. We
slow the transition. In fact, some talented innovation and new technology from currently have an open call for projects
engineering professionals are driven away McMaster University. in the zero-emission vehicle supply chain

24 MACHINE DESIGN
Stephanie Holko on Protecting Psychological Safety in the Workplace
“I look at this from two lenses. If you’re management or a senior leader, there are certain things that need to
be in place. And then, as an individual, how do you protect yourself? One is for management and leadership
to foster a culture of psychological safety; encourage collaboration and support, establish clear and realistic
deadlines and workload expectations, and allow people to make mistakes…Psychological well-being is just a
no-brainer, but very difficult to do by accident. Be intentional.

And for the individual, cut yourself some slack. If there’s a day where you only have 60% to give, don’t beat
yourself up for giving that 60%. That’s everything you had to give. And, you’re not alone. So, find your people.
If they’re not at your work, then they’re going to be elsewhere in your network. Find your mentor if you don’t
know how to approach a particular situation. I have used Google from time to time. See how to manage
something or how to approach a tricky email or tricky conversation. You’re not alone...reach out.”

and upcoming funding in quantum tech- The survey results indicated that 29% of ing up and OSPE is looking to address
nologies and industrial decarbonization. employed engineers and engineering these gaps.
So very topical, very exciting work that I graduates were between 50 and 64. So EDIA is one of OSPE’s core pillars and
get to do at NGen.” not too far from retirement. Established advocacy is one way of interfacing with
In the abridged Q&A that follows engineers and engineering graduates, typi- government bodies, regulators and other
below, Holko discusses how the bench- cally older and more often male, expressed stakeholders to advocate for good prac-
marking report, Ontario’s Engineering greater positivity towards the profession. tices and to promote EDIA in engineering.
Community and Transition, is used to The report also looked at the opinions When OSPE conducts research, they’re
define the shape and scale of change of and perspective of the different groups looking to conduct research with that lens

“
the engineering pipeline. that were interviewed. Gender-diverse, so that they have more to offer.
younger and internationally trained
Machine Design: Can you give us a engineering graduates were positive, but Fewer than half
snapshot of human resources in the expressed noticeably more hesitation and of engineers and
engineering landscape? Who is com- uncertainty on key questions about engi- engineering graduates
ing, who is leaving? What is happening neering reputation in society and their
around you? own career opportunities.
believed that the schooling
Stephanie Holko: With OSPE, one One-third of all engineers and engi- was affordable, that gender
of their primary pillars of advocacy is neering graduates, predominantly from representation and other
equity, diversity, inclusion and acces- those latter groups, reported that the metrics of EDIA in the
sibility (EDIA). OSPE believes—and I profession might be falling out of step
as well—that EDIA, and the lack of, is a with modern society. And certainly,
profession are sufficient and
major contributor to the success of indi- that’s a concern. And there was a reduced that wage standards are
viduals in STEM. So, I want to preface the emphasis on core engineering disciplines, equitably applied.
comments about who is in the profession which makes sense because we’ve seen a
and what’s happening there with that lens. lot of change in society over the last three MD: You’ve alluded to the idea that
OSPE’s report was published in late years, but also over the last few decades. core disciplines are shifting. These find-
2022. Of the 821 engineers and engineer- Certainly, since I graduated. ings, with respect to an interdisciplinary
ing graduates surveyed for the research, Fewer than half of engineers and shift, resonate across North America.
roughly half were over the age of 50 and engineering graduates believed that the We’ve seen it in other research as well,
only a quarter under the age of 35. You schooling was affordable, that gender rep- where there is greater demand for soft
can see that there’s a demographic shift in resentation and other metrics of EDIA in skills—for example, communication
industry, and it’s happening in the engi- the profession are sufficient and that wage skills—certifications, use of emerging
neering community as well. standards are equitably applied. There’s technology and emphasis on applied
Of those respondents, 78% were men definitely some work to do there about knowledge. Can you weigh in on what
and they were mostly educated in Canada. how folks are seeing the profession show- the in-demand skills are as you see it?

GO TO MACHINEDESIGN.COM 25
Survey of Engineers

What, in your estimation, does the trating to me, because these folks had Mentorship programs are not new and,
industry get wrong? self-selected into technical fields and certainly, I don’t think difficult to imple-
SH: Classical engineering is always then they leave due to a variety of fac- ment. You just have to do it with intention.
going to be required; it’s always impor- tors—not because the work is difficult Two-thirds of the respondents agree
tant to a functioning society. We always or they’re not capable, but they could that mentoring improves women’s career
need bridges and roads and water treat- feel unwelcome. The attrition that we’re prospects and retention in the engineer-
ment and buildings and those types of looking at in STEM roles and engineer- ing profession. So that’s very important.
things. And from a technical perspec- ing roles could occur due to job dissat- Lack of confidence is common in the
tive, those things don’t shift. When you isfaction, inadequate support or a lack workplace—particularly among wom-

“
look at can we recycle, can we renew, of belonging. en—leading to dissatisfaction, often
are there heritage buildings that we can mental health issues due to work. So,
reuse...those types of trends shift the The top challenges OSPE found that women in engineering
field of practice to align with societal survey respondents struggled to foster the credibility that is
trends. But the fundamental principles, afforded to their male colleagues.
I would say, don’t particularly change.
face as women engineers And, I will say that there have been
They may upgrade. include fewer opportunities times where I’ve maintained my profes-
What’s emerging as a cross-disciplin- for field work than sional licensure because it gives me that
ary focus that I see across the board, colleagues (23%). And then credibility when I walk into a room. That’s
including skilled trades, and not just a personal anecdote, but you can see that
within technical disciplines, is being able
feeling disrespected and it translates in the research as well.
to translate ideas into a business con- undervalued by managers The top challenges survey respondents
text, or even sales, when you’re trying or coworkers (>20%). That’s face as women engineers include fewer
to express your ideas or move a project definitely something to dig opportunities for field work than col-
forward. By-and-large, the essential skills leagues (23%). And then feeling disre-
that are coming out are being able to find
deep. spected and undervalued by managers
the right and correct information. It’s no or coworkers (>20%). That’s definitely
longer about going to an encyclopedia. There’s a lot of implications that come something to dig deep.
There’s so much information, and it is on from that. So now you’re not only losing If you’re leading a team or you’re run-
the engineer to find the right informa- that talent and knowledge, but also a dif- ning a business, you need to dig deep and
tion and then test it to make sure that ferent perspective. A lot of the world is maybe consider some of the other factors
it’s correct. We need to understand new designed for a very typical male. Whether that are affecting your workforce. And
technologies and how those technologies you look at car safety or truck settings or I want to say it’s not just women. There
impact society. the way that building systems are created, are people of all genders that would feel
And then, regardless, essential lead- they were created based on the 1950s those things as well. „
ership skills of empathy, collaboration, model of a particular type of individual,
influence and communication will never and then everything else was deemed
go out of style and will become more separate from that standard.
and more important as we rely more on And that’s not going to serve the peo-
technology. It’s an increasingly noisy and ple you need to serve if that continues to
complex world, and someone who has a be your benchmark. So, understanding
very strong technical background but can the causes of attrition means that you
also communicate in a business context can get those diverse voices back at the
is going to do really well going forward. table because you can launch those initia-
tives to address those issues. It benefits
MD: Let’s pick on women and under- individuals, it benefits companies and
represented groups within the study. it’s going to benefit society as a whole.
The research in that study shows that A little bit older research: In February
women feel less welcome in the profes- 2015, OSPE conducted a needs assessment
sion. What did they cite as the barriers survey of over 1,500 respondents. In that
and what are the biggest challenges? study, 97% of female respondents thought
SH: This is a tough question; it speaks mentorship was important when starting
to a leaky pipeline. And…was so frus- an engineering career after graduation.

26 MACHINE DESIGN
People

186662507 © SimplyAdrienne | Dreamstime.com

Changemakers:
Expanding our Understanding
of the STEM Field
Lifting up some of the amazing women who shared their expertise in Machine
Design’s WISE (Workers in Science & Engineering) series in 2023.

by Rehana Begg, Editor-in-Chief

NOTHING MAKES A GOAL seem Another study investigated the impor- Greater scrutiny of the data will show
more achievable than seeing others have tance of exposure to innovation and esti- why representation and intersectionality
done it—and that they want to help you to mated that if girls had the same number matters, pointed out the Society of Wom-
succeed as well. Yet, women continue to be of women inventor role models as boys en Engineers’ (SWE) associate director
underrepresented in science, technology, have of male inventors, the gender gap of research, Roberta Rincon. “We are a
engineering and math (STEM). in innovation could be cut in half. Might gender equity organization, but there are
Over time, the gender imbalance has that suggest that without intervention and other identities that we want to acknowl-
been shown to be a reflection of under- active discussion, the industry will con- edge, and part of that acknowledgment is
lying issues rooted in bias and discrimi- tinue to perpetuate the same biases that looking at the data,” she said.
nation that have resulted in far-reaching reinforce stereotypes? Rincon highlighted during a virtual
consequences on the personal, economic An important aspect of drawing roundtable that organizations that are
and future well-being of communities and more women to STEM roles is letting serious about their DEI efforts and about
the industries they serve. them know that they belong. Machine diversifying engineering and technology
Women remain underrepresented Design’s Workers in Science & Engineer- would benefit from disaggregating data
in engineering (15%), computer (25%) ing (WISE) hub is grounded in covering from their research and across the general
and physical science (40%) occupations, workplace issues affecting equity-seeking population, as it exposes prevailing gaps
according to Pew Research Center. In cut- groups. The coverage reinforces a com- in the education system and across the
ting edge fields such as artificial intelli- mitment to help the industry create a workforce.
gence, only one in five professionals (22%) more equitable landscape for current and “Black women are earning only about
is a woman. future generations. 1% of all engineering degrees right now,

GO TO MACHINEDESIGN.COM 27
Changemakers

“
We are a gender equity organization, but there are
other identities that we want to acknowledge, and
part of that acknowledgment is looking at the data.”
— Roberta Rincon, Society of Women Engineers
but they represent 6% or 7% of the U.S. Moman-Saunders, professional engineer
population,” she said. A cluster of data that and fellow at ASME. “We know that we
shows only 14% of working engineers are must be diligent. This change is not going
women, or that 22% of bachelor’s degrees to happen overnight, so we must be…fast
earned in engineering are women, elicits and consistent.”
a different understanding of where the By way of thanks, Machine Design is
needs lie than when the data is broken showcasing a sampling of the 2023 WISE
down, because the majority of those series virtual participants who volun-
degrees are being earned by certain teered their time and shared expertise
subpopulations. on developing a robust channel of skills
“That prompts us to look at the educa- from all walks of life. Not only do the
tional pathways that we have been ignor- women featured below represent a diverse
ing, whether that is the minority-serving range of talent, creativity and possibil-
institutions or the community colleges ity in STEM careers but, moreover, they Roberta Rincon
and the technical colleges looking at—not are also committed to doing the work of
just bachelor’s degrees in engineering and building a sustainable future so no-one contributions of those who have been
computer science—but also engineering is left behind. overlooked historically.
technology,” Rincon explained. We are all better for their efforts. We’ve got to take advantage of this time
If we’re going to make systemic change, and push these initiatives that we believe
she added, it is necessary to create inclu- 1. Roberta Rincon, Associate are going to create the systemic change
sive cultures and environments that are Director of Research, Society of needed to create the inclusive climate and
welcoming to all in engineering, manu- Women Engineers culture within these STEM spaces that are
facturing and technology. Dr. Roberta Rincon is the associate just missing, and causing a lot of individu-
“Data is critical, I am convinced,” director of research for SWE, where she als to choose either not to enter or to leave
reflected Jackie Mattox, founder, presi- oversees the organization’s research activi- before they reach those executive levels,
dent and CEO, Women in Electronics. ties on gender equity issues affecting girls where they can really make the change
“But if the heart isn’t in check, if there’s not and women in engineering, in education that’s needed.
actual authentic intent, that means noth- and career. She received her B.S. in civil
ing. I believe that when we can educate engineering from The University of Texas 2. Jackie Mattox, Founder,
on the heart of the matter, we will open at Austin, an MBA and an M.S. in infor- President and CEO, Women in
up opportunities to collect all the data. mation management from Arizona State Electronics
So, educate as much as possible, and have University, and a Ph.D. in Educational Jackie Mattox is the founder, president
patience and grace. Policy and Planning from UT Austin. and chief executive officer of Women in
Many organizations Machine Design Machine Design: What keeps you Electronics, headquartered in Southern
interviewed this year, including SWE, motivated to continue the work that California. Mattox started her career in
Women in Electronics and ASME (Amer- you do? the electronics industry during college at
ican Society of Mechanical Engineers), Roberta Rincon: I’ve been with SWE a small rep firm in the area, where she
reported how DEI is showing up in their for seven years, and I’ve got to say that worked her way into the roles of sales
organization’s strategic plans. “We are I just feel that this is this is such an and distribution manager and took a pas-
advancing DEI internally through vol- important time. We have organizations sionate interest in strategic key account
unteer engagement and by providing at the national level—not just here in management. Mattox graduated from
accommodations for people with dis- the United States, but in other parts of California State University, Northridge
abilities, by fostering inclusivity in event the world—that are paying attention to with a Bachelor of Arts degree in com-
participation, enhancing inclusivity for diversity, equity and inclusion. They munication/journalism.
working parents and supporting women are tying funding to some of this work MD: What keeps you motivated to
and career empowerment,” said Monica and bringing greater recognition to the continue the work that you do?

28 MACHINE DESIGN
 “
We are advancing DEI
internally through
volunteer engagement and by
providing accommodations
for people with disabilities,
by fostering inclusivity
in event participation,
enhancing inclusivity
for working parents and
supporting women and career
empowerment.”
— Monica Moman-Saunders,
Engineer & Fellow, ASME

Jackie Mattox Monica Moman-Saunders

Jackie Mattox: I would just have to more equitable our world is. I wish more management program at IMD Business
say, women like the ones on this panel, people would pay attention, but it’s very School in Lausanne, Switzerland.
are so inspiring…and, being a part of the encouraging that there are sponsor com- MD: What keeps you motivated to
change. We’re in a pivotal time. To have panies and all kinds of people investing in continue the work that you do?
the opportunity to be a part of systemic this. So that encourages me a lot. Monica Moman-Saunders: I’m a little
change is really valuable to me. This is engine that can. But as an African-Amer-
what I do with women in electronics. It 3. Monica Moman-Saunders, ican female mechanical engineer, I have
is just who I am. It’s a calling—you can’t Professional Engineer and Fellow, spent my entire professional career work-
not do it. I’m so passionate about it…I American Society of Mechanical ing in a male-dominated field—I worked
don’t want to just go around talking about Engineers in the utility industry. I’ve always worked
things or making all kinds of money. I Monica Moman-Saunders, P.E., has more to improve diversity in this field, promot-
want to make an impact, and I want this than 20 years of experience in engineer- ing STEM education. But progress is, and
world to be better than where I left it. ing management and contract negotiations has been, slow. But now that the world has
For my little part, it’s really a call- and management. Moman-Saunders joined become more diverse, and it continues to
ing. And I just love that there are other ASME in 1985, where she is now a Fellow change every day at a very fast pace, com-
people doing the same thing, dedicated and Governor-Nominee. She earned a panies have come to realize that they will
and focused. The importance of diversity Bachelor of Science degree in mechanical benefit from diversity and DEI initiatives.
in our world right now, and especially at engineering from University of Alabama, They have also begun to change their
that engineering table, with all the new a Master of Science degree in business and culture. So, I am more energized than
innovations and technology. The more management from Webster University of St. ever at the opportunity to help bring

“
diversity we can bring to the table, the Louis, Miss. and completed the executive about this meaningful societal, cultural
and systematic change. I’m actually very
Data is critical, I am convinced. But if the heart isn’t excited to work on this effort and do my
part to foster change. That’s one of the
in check, if there’s not actual authentic intent, that reasons I’m on the board of governors
means nothing. I believe that when we can educate on the within ASME. My actions are intentional
heart of the matter, we will open up opportunities to collect and my personal mission and goal in life
all the data. So, educate as much as possible, and have is very clear at this point. I want to bring
about the change that will make our world
patience and grace.” a better place for all. And so that’s what
— Jackie Mattox, Women in Electronics keeps me excited about it for sure. „

GO TO MACHINEDESIGN.COM 29
2024 INNOVATORS PROFILE
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32 MACHINE DESIGN
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34 MACHINE DESIGN
2024 INNOVATORS PROFILE
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Technology Disruptors

Big Tech & Big Ideas

Permeate Industrial Thinking in 2023
Behind industry
buzzwords are some
remarkable applications
that are changing the way
we manufacture and the
way we foster the next
workforce.
by Rehana Begg, Editor-in-Chief

THROUGHOUT THE YEAR, Machine

Design invites subject matter experts
to share insights about up-an-coming
technologies and market trends. Head-
line topics this year included sustainable
practices, energy efficiency, advances in
industrial automation technology and AI-based solutions provide the agility to respond to changing conditions in real-time. Images
courtesy Machine Design
design for high-tech manufacturing.
A philosophical thread tying these top-
ics together has been the need to “optimize rises as a key imperative. “Think about reinforcing the need to not be overly reli-
for change” through the introduction of what we’ve experienced in just the last ant on one region for sourcing critical
technologies. This theme was specifically few years,” Humpton said during a press items. Supply chain challenges have been a
laid out by Barbara Humpton, president announcement on Nov. 3, 2023. “We’ve major factor in evolving globalization into
and CEO of Siemens Corporation. seen disruption and global supply chains glocalization. It’s a world that’s bigger than
“If you listen closely, what we’re really ever. More global, evermore connected,
talking about is who we are as people, and but we’re capable of manufacturing things
how we operate in this world of incred- closer to the point of demand.”
ible opportunity,” Humpton said during
her keynote at Automate 2023. “And the Building Local Infrastructure
question I’ve been asking myself, and I Supply chain vulnerabilities, as laid
hope you’ll join me in this quest, is to out in a White House report, can be
answer this question: Instead of trying traced to insufficient U.S. manufactur-
to find an optimal state of being, what ing capacity; misalignment in incentives
would it look like if we got our teams to that fail to reward firms for investing in
focus on optimizing for being in a state long-term, sustainable productivity; and
of constant change?” industrial policies and partnerships that
In one fell swoop Humpton’s query lure away trade.
would not only express a strategic pur- The report, Building Resilient Supply
pose for her company, but also spotlight Chains, Revitalizing American Manufac-
a trajectory overriding the industry. turing, and Fostering Broad-Based Growth,
It goes without saying that a range of is replete with examples highlighting
Barbara Humpton, president and CEO,
global market forces underpin Siemens’ fragility and disruption. Consider, for
Siemens Corporation.
vision for the future, but “glocalization” example, how the semiconductor shortage

38 MACHINE DESIGN
demonstrates the need to bring manufac-
turing back on course. A new car, stated
the report, “may require more than 100
semiconductors for touch screens, engine
controls, driver assistance cameras and
other systems. The U.S. share of global
semiconductor production has dropped
from 37% in 1990 to 12% today, and is
projected to decline further without a
comprehensive U.S. strategy to support
the industry.”
For Humpton, this historical depen-
dence on globalization for finding the
next incremental savings such as labor
and materials on the supply side should
be a thing of the past. Global supply
chains must be supported by strong local
manufacturing networks that will help the Ron Di Carlantonio, is founder of iNAGO, Caspar Herzberg, CEO of AVEVA, said AVEVA
industry prosper, she argued. and an AI-driven advanced intuitive Connect is a digital experience and provides
To this end, Siemens announced in conversational assistant for automotive, the tools needed to design, build, operate and
consumer electronics and AI-driven optimize better with industrial intelligence-
November that the company would be manufacturing solutions. as-a-service.
investing $150 million into a new high-
tech manufacturing plant in Dallas-Fort
Worth. Included in these plans will be the copilot extracts automation and process The capabilities of these technologies
use of Siemens advanced manufacturing simulation information from Siemens’ hold significant potential for transforming
tools, including digital twin technology open digital business platform, Siemens industries. The general use of AI-based
and the Siemens Xcelerator portfolio for Xcelerator, and enhances it with Micro- solutions in the automotive industry, for
capturing and analyzing data in real time soft’s Azure OpenAI Service. Custom- instance, stretches across the lifecycle of
from the shopfloor on production and ers maintain full control over their data, a vehicle, from design and manufacturing
product performance. and it is not used to train underlying to sales and aftermarket care. AI-powered
“This is just the latest example of AI models. chatbots, in particular, can deliver instant,
how Siemens is expanding our Ameri- personalized virtual driver assistance, are
can manufacturing presence to meet Generative AI is the Headline on call 27/7 and can evolve with the pref-
demand,” Humpton said. “In the past No conversation this year has been erences of tech-savvy drivers.
year, you’ve heard that we’ve already seen complete without a reference to artificial AI-driven intelligent assistant platforms
Siemens invest $220 million into a new intelligence tools such as OpenAI’s Chat- are similarly working their way into the
rail manufacturing facility in Lexington, GPT, Google’s Bard or Anthropic’s Claude. smart factory, said Ron Di Carlantonio, a
N.C. And construction there is already Mainstream curiosity with artificial Tokyo/Toronto-based computer scientist
underway. It’s in addition to some pre- intelligence and generative AI have been whose company, netpeople, developed a
viously announced investments in two unyielding since the launch of ChatGPT platform that allows companies to create
electrical products manufacturing plants, on Nov. 30, 2022. ChatGPT has reportedly intelligent, conversational assistants for
one in Grand Prairie and the other in garnered more than 100 million weekly their products.
Pomona, Calif.” active users. More than 92% of Fortune
Among this year’s (October) rollouts, 500 companies are using ChatGPT and Software-Defined
Microsoft and Siemens unveiled Siemens more than 2 million developers use it. Manufacturing Paradigm
Industrial Copilot, an AI-powered jointly Simply defined, generative AI refers The case for AI in industrial AI-based
developed assistant aimed at improving to a broad field of AI that has to do with solutions was made clear at AVEVA’s flag-
human-machine collaboration in manu- developing techniques and models that ship annual conference in San Francisco,
facturing. The tool allows users to rapidly are capable of generating new content. where Caspar Herzberg, CEO of AVEVA,
generate, optimize and debug complex ChatGPT is a generative AI implementa- discussed how the company was building
automation code, and shorten simulation tion trained on large language models and a new data infrastructure based on one
times, noted a Siemens press release. The is designed for conversational purposes. industrial intelligence platform.

GO TO MACHINEDESIGN.COM 39
Big Tech & Big Ideas

“This platform that we call Connect is

designed to empower you at every step
of the design, build, operate, optimize
cycle, Herzberg said. “And what we are
doing with our R&D is to bring disparate
software together, so that users can easily
exchange data, and so they operate seam-
lessly with each other.”
Whether data is accessed via the cloud,
on premises or is hybrid, the goal is to
enable the easy flow of “trusted data”
between AVEVA’s solutions and its users,
Herzberg said. “Trusted data in context
is the foundation of the future; it is the
foundation of industrial AI,” he said.
Building on a long-standing strate-
gic partnership, AVEVA and Microsoft
announced their relationship will be
further cemented, as Connect and the
Microsoft Fabric data analytics solution
will now be interoperable to streamline Chief Product Officer Rob McGreevy discussed how AVEVA has by combined predictive and
prescriptive analytics capabilities with large language models (LLMs) to develop industry
the process of collecting, transform-
specific use cases.

“
ing and organizing data from various
sources. Their combined offerings will
leverage AI and machine learning (ML) Our view of the world over the next five to 10 to
and allow users to make better, faster 15 years is as follows: We believe that industrial
data-driven decisions.
manufacturing and critical infrastructure is going to continue
“Our view of the world over the next
five to 10 to 15 years is as follows: We to grow through fairly dramatic transformation, ushered in
believe that industrial manufacturing and by huge market forces and market dynamics, geopolitical
critical infrastructure is going to continue uncertainties, supply chains, energy transition, sustainability,
to grow through fairly dramatic trans-
formation, ushered in by huge market
as well as the vortex of interesting new technologies such as
forces and market dynamics, geopolitical cloud computing, edge, AI (generative AI for example).”
uncertainties, supply chains, energy tran-
sition, sustainability, as well as the vortex expected the last few hours. Are there any prompted for and infuses the response
of interesting new technologies such as issues I should be aware of?” with real time min/max values.
cloud computing, edge, AI (generative AI The system was able to parse what “We’ve actually taken this and made it
for example),” said Rob McGreevy, chief the prompt meant and responded by dynamic, whereas a lot of large language
product officer, AVEVA. indicating what the issues related to the models are static,” McGreevy pointed out.
turbine were and with a notification that In the context of industrial manufactur-
AI Makes Machines Talk it stopped functioning. An engineer or ing critical infrastructure, he said, genera-
During the keynote McGreevy dem- technician could then ask for a utiliza- tive AI is a toolset and a means by which
onstrated how AVEVA has created tion dashboard, said McGreevy, and the companies like AVEVA can change the
industry specific use cases by tying system would produce data showing, for way users and community interact with
predictive and prescriptive analytics example, that the turbine was producing, the systems they design and build.
capabilities together with large language but then flipped to a non-producing state “Together, these things command a new
models (LLMs). because of high temperature problems. way of doing things that demand a hyper,
A chat-based UI (user interface) was Further interrogation allows the user to interconnected digital backbone upon
set up in McGreevy’s windfarm reference pinpoint all of the bearings and their tem- which we can erect the building blocks
case. He prompted the program as fol- perature readings over the last 12 hours. for the next generation of our solutions,”
lows: “The output we saw was lower than The system lists all of the variables it is said McGreevy. „

40 MACHINE DESIGN
Technology Disruptors

Generative AI’s Transformative

Impact on Manufacturing:
Unleashing the Power of Industrial Data
An insider’s view on why industrial generative AI capabilities hold promise for asset-
heavy industries, this article highlights three common obstacles: hallucinations,
data leakage, and access control to maintain privacy and security.

by Moe Tanabian, Chief Product field engineers, data must be contextual- industries. From field productivity to
Officer, Cognite ized and easily accessible. This involves maintenance planning and robotic auto-
liberating data from siloed source sys- mation, generative AI can make a signifi-
SOME WOULD SAY that ChatGPT tems and creating a strong contextual- cant impact by making operations more
unleashed the iPhone moment for digital ization engine. productive, safe and sustainable. However,
transformation. Arguably, it is generative The goal is to enable SMEs to extract the for it to thrive, a platform must provide
AI that will unleash the transformation of full value of industrial data. Operational- essential AI features that grant easy access
industry. But to harness it properly, it must izing data and establishing a robust data to complex industrial data for engineers,
be safe, secure and hallucination-free. foundation are key steps toward achieving data scientists and subject matter experts.
The business value of generative AI is this. It not only enhances work efficiency A promising example of an interactive
only in its application to the real-world but also lays the groundwork for generative user experience is an Industrial Canvas.
needs of field engineers and others operat- AI to accelerate various workflows. Delivering simple access to all industrial
ing in asset-heavy industries. When used data in a single workspace requires a
correctly, generative AI can enable bet- LLMs + Knowledge Graph = unique way to leverage contextualized
ter collaboration, task automation, field Data You Can Trust data. Field workers deserve a way to
productivity, maintenance planning and The key to making AI work for indus- work with live sensor data, interactive
robotic automation, but the technology try lies in the magic formula of Large engineering diagrams, images, 3D mod-
is only as strong as its data foundation. Language Models (LLMs) + Knowledge els and more within a visual workspace
Graph. An industrial knowledge graph where they can explore data in context,
Drowning in Data, provides an additional metadata layer to perform root cause analysis and collabo-
Starving for Context navigate relationships for both humans rate by tagging other users in an open,
Generative AI can generate new data, and generative AI to make sense of indus- free-form environment.
content or solutions based on existing data trial data.
patterns. Unlike traditional AI models, An industrial knowledge graph is the From Digital Maturity to
generative AI can learn from context- output of data contextualization and rep- Industrial Transformation
enriched data without explicit guidance, resents the connections between the many Digital transformation might be seen
making it a powerful tool for industries data types. This graph ensures that LLMs as a priority in the industry, but achieving
where data is abundant but complex. can understand and provide reliable and real ROI still remains a challenge. Many
Generative AI can ingest diverse data- deterministic responses to even the most organizations invest in cloud data ware-
sets, including historical maintenance complex queries within your field. And, houses and data lakes, but data often ends
records, sensor data, work orders and by applying this formula, you are able to up unused. The true value of data lies in
even unstructured data such as main- have a complete and trustworthy digital trust and usability.
tenance reports. However, for it to be representation of your industrial reality, To master the industrial data problem,
effective, context is vital. Industrial facili- free from AI hallucinations. we need a shift towards industrial AI at
ties generate an overwhelming amount of scale. This approach focuses on delivering
data, and they are often siloed. Without Industrial Canvas = business-ready, trusted, actionable data to
context, it becomes an obstacle rather Data You Can Use all users. It promises to improve time to
than an asset. To power generative AI, Generative AI’s transformative poten- value, quality, predictability and scalability
and empower subject matter experts and tial extends across all areas in asset-heavy in data analytics. „

GO TO MACHINEDESIGN.COM 41
Technology Disruptors

Deliver Robust Automated Systems

Through Servo Maintenance
Servo motors are critical millions of dollars in repair expenses and Creating Optimal Maintenance
lost productivity. Strategies
to the function of many Servo motor maintenance certainly isn’t These foundational steps apply to all
automated systems, so the only factor at play here, but it’s an servos, but manufacturers must get more
they require optimal important one. Most industrial robots rely granular in their repair strategies. Optimal
on servos to some extent, often to control servo motor maintenance steps and time-
maintenance. Discover their movement. As a result, issues with lines depend on the specific equipment
how to refine servo motor these components will likely impact the in question.
maintenance strategies. robot more heavily. Delayed maintenance results in higher
Servo motors are also more prone repair costs and shortened equipment
to failure than other components. As a lifespans, but what defines “delayed” var-
by Emily Newton, Technology and
critical moving part, these technologies ies between motors. Manufacturers must
Industrial Journalist
encounter high movement speeds, heavy refer to their OEM’s guidelines to learn
physical loads and long operation times, how frequently they should consider each
MOST MANUFACTURERS TODAY leading to more wear-and-tear. maintenance step. Remember that these
understand the need to automate. Fewer recommendations are typically general
realize that to make the most of their auto- Foundations of Servo baselines, so take them as a foundation,
mated systems, they must keep their com- Motor Maintenance not a strict timeline.
ponents in top condition. Servo motor Servo motors’ criticality and higher Similarly, manufacturers must deliver
maintenance, in particular, is an essential workloads make them ideal candidates for the right kind of repairs according to
process to address. maintenance optimization. That begins OEM recommendations. Some servo
Robotic systems vary widely between with understanding which care practices motors may require a specific lubricant.
facilities and workflows, but many rely on are most crucial for keeping these com- Some may have higher temperature toler-
servo motors. Despite that criticality, it’s ponents in top condition. ances than others. Understanding these
easy to overlook the importance of main- Temperature management is one of the unique factors is key to developing an
taining these small components. That most important considerations. Manufac- optimal maintenance strategy.
presents an opportunity. Manufacturers turers must routinely clean servo motors
that optimize their servo maintenance can and their cooling equipment and monitor Choosing the Right
achieve higher automation performance temperatures to keep them cool. In addi- Maintenance Method
than their peers. tion to preventing performance issues, Once manufacturers understand
lower temperatures improve energy effi- their specific servo motors’ needs, they
The Importance of Servo Motor ciency in electrical equipment, lowering can move on to selecting a maintenance
Maintenance for Automation servo operating costs. method. While it’s always best to use a
Manufacturing uses automation more As with other moving parts, lubri- preventive rather than reactive repair phi-
extensively than any other industry, and cation is another leading maintenance losophy, the best non-reactive approach
that adoption will only grow as robotics concern for servo motors. Regularly depends on the situation.
become more accessible. Given that reli- lubricating bearings and other servo There are three main methods to
ance, keeping these systems working as components will prevent excess tem- choose from—schedule-based preven-
efficiently as possible is crucial. peratures and friction. tive care, condition-based and predictive
Unfortunately, many manufacturers Electrical maintenance is another core maintenance. Predictive approaches offer
overlook the importance of equipment concern. Technicians should inspect for the most uptime and long-term savings
maintenance. Factories suffer 20 down- frayed wires, loose connections and simi- but are also the most difficult to imple-
time incidents a month on average, each lar issues to ensure all the motor’s electri- ment. This method relies on Internet of
lasting over an hour, according to a Sie- cal systems work well. Similarly, regular Things (IoT) sensors and artificial intel-
mens report. These disruptions—which calibration is key to maintaining precision ligence (AI), raising upfront costs and
better care could have prevented—cost and repeatability. requiring more IT experience.

42 MACHINE DESIGN
 255149436 © Sorapol Ujjin | Dreamstime.com
Facilities with less tech talent or small- ful. To prevent this, manufacturers must ments. If manufacturers analyze these
er budgets may prefer condition-based involve repair technicians throughout trends with AI, they can discover their
repairs. The resulting savings may be the transition, informing them of the underlying causes. They can then adjust
less impressive, but it’s easier to get right change early and allowing plenty of time their maintenance approach to reduce
and costs less upfront. In some cases, it’s and resources to re-train and adjust to servo motor failures further.
best to apply predictive maintenance to the new system.
some servo motors and condition-based Optimize Servo Motor
approaches to others. Accounting for Maintenance to Improve
Unforeseen Failures Automation
Minimizing Maintenance Errors Even if manufacturers follow these Reaching industrial automation’s full
Optimizing servo motor maintenance other servo motor maintenance best potential encompasses more than main-
is also a matter of error reduction. Auto- practices, unplanned downtime is still tenance. Similarly, maintenance optimi-
mating condition monitoring through possible. Predictive maintenance—the zation should cover more than just servo
the IoT will prevent human inspection- most effective method at decreasing motors. However, manufacturers must
related mistakes, but manufacturers can downtime—improves uptime by up to mind these smaller details to get all they
go further. 20%, but that’s not a complete elimina- can from their machines.
Manufacturers using IoT sensors to tion of failure. Consequently, manufac- As automation becomes increasingly
monitor servo conditions must careful- turers must have a plan to respond to common, robots alone won’t suffice to
ly calibrate these tools. Use the servo’s unplanned downtime. keep manufacturers ahead of the compe-
OEM’s recommendations to establish Documentation is one of the most tition. They mustn’t only automate, but
a baseline for acceptable parameters. If important steps. If a servo motor fails automate better than other businesses.
these benchmarks aren’t accurate, sen- unexpectedly, be sure to record the inci- Optimized repair strategies are a crucial
sors may fail to determine the motor’s dent. Keep track of what went wrong, how part of that endeavor, and servo motor
condition accurately. long the issue took to resolve and what maintenance is essential to those repairs.
Employee training is another criti- damage it caused. These records will help By following these guidelines and apply-
cal area to address. Switching to a new address similar issues in the future. ing the same care to all factors, manufac-
maintenance strategy will make errors Over time, data from these incidents turers can take their automation to the
more likely if manufacturers aren’t care- can inform more effective strategy adjust- next level. „

GO TO MACHINEDESIGN.COM 43
Technology Disruptors

Pushing the Limits of

Drone Capabilities
by Victorio Pellicano, Founder/CEO, Avianna

With the promise of operational efficiency and cost

savings, the latest autonomous drone functionality Avianna has developed a suite of AI-driven
and capabilities are prepping industries for greater software products—Fleet AI, Vision AI
and Mission AI—for use in robotic vehicle
integration. applications. Avianna

THE COMMERCIAL DRONE market The Monumental become more prevalent as autonomous
is experiencing rapid growth as new tech- Impact of AI Integration drone capabilities increase. Without AI
nologies and artificial intelligence break At its core, AI is machine learning with integration, drones are programmed to
into the space. natural language processing capable of deliver a package to a fixed pin location,
In 2022, the commercial drone market performing faster and oftentimes higher and they are unable to differentiate the
size was estimated at $19.8 billion and is quality output than humans. It increases front door from the back door or adapt
projected to grow at a compound annual the speed and accuracy of code writing, to any obstacles in their way.
growth rate of 13.9% between now and productivity and accuracy beyond human The only way to know where the door
2030. This growth creates space for inno- capabilities. is, what obstacles are in its way, and how
vation and integration like never before. Yet, many have hesitated to adopt such to adapt and still complete the delivery
As the industry begins to scratch the smart technology in fear that it will replace is through AI. But if there is an obstacle
surface for the integration of AI in autono- humans. In reality, it has the potential to to mission completion, the drone will
mous drones, it is proving to bring forth become a worthy co-worker. A robot with- return without delivering the package.
numerous benefits, including increased out smart AI integration capabilities is Autonomous AI integration allows drones
operational efficiency and cost savings. merely a hammer—a tool with limited to adapt and adjust to dynamic environ-
By automating tasks that were previously capabilities. Once fused with the ability ments to complete the mission.
performed manually, drones are able to to think and react to situations, that tool
perform them faster, more accurately and becomes a partner or an assistant. Overcoming Industry Challenges
at a fraction of the cost. In the drone industry specifically, AI In the face of innovation, the drone
integration allows drones to become industry is limited by regulatory control.
Current State of Drone Technology autonomous agents. One example of Government agencies including the Fed-
Drone technology is still in its infancy, this is specifically with search and rescue. eral Aviation Administration (FAA) play
which leaves room for rapid and needed Consider the scenario where a person is a major role in regulating the use of drone
innovation and improvement. Many early reported missing and is lost in a forest. technology. While these regulations are a
drones were developed for hobby and Typically, it takes cars, helicopters and crucial part of public safety, they often-
sport. Once the usefulness and potential oftentimes people by foot to search the times can suppress innovation. Finding
of what drones can accomplish was under- area. They may utilize cameras with no a middle ground is crucial to the drone
stood, industries began to see the value automated technology and will need to industry’s success.
they could bring and began to explore the take the time to analyze and process the Another hurdle to drone advancement
capabilities of commercial drone usage. footage. is battery power. Current drone battery
Then AI entered the picture. The Now consider an AI-empowered drone technology allows for a maximum flight
unique value that AI has offered to many charged with the mission to find a miss- time of 30-40 min. Once battery life is
everyday business practices makes its ing person in the forest. With extended able to evolve and be utilized for longer
potential capabilities attractive to the capabilities, this drone can hear things periods of time, drones will be able to
drone industry. ChatGPT is a formidable beyond human hearing and see beyond deliver a variety of products and fulfil
example: ChatGPT has had over 10 mil- human capabilities. With real-time adapt- services more effectively. Both the bat-
lion all-time page visits with an average of ability, a drone will be able to locate the tery and navigation technology will need
1 billion page visits monthly. This curios- missing person in a fraction of the time. to become stronger in order to achieve
ity has already inspired innovation within Also highlighting the impact of this efficient autonomy and serve a variety of
the industry. integration is package delivery, which will purposes. „

44 MACHINE DESIGN
Technology Disruptors

How to Build a
Better Rat Trap—
with 70 Synchronized Servo Axes
A case study in using PEOPLE OFTEN FIXATE on how final product—a rat trap—in just 1.5 sec.
to build a better mousetrap. An equally In addition to the servo drive technol-
PC-based control and
important pursuit, according to systems ogy, Beckhoff also supplies the required
EtherCAT tech to deliver integrator Mitec Enginy, is figuring out control performance with PC-based con-
a sophisticated, highly how to build a mousetrap better. And trol, EtherCAT networking and TwinCAT
combining both goals, the northern automation software solutions.
efficient production line
Spain-based automation experts have Mitec Enginy has been developing and
to enhance production developed a sophisticated manufactur- integrating application-specific automa-
for a major pest control ing system to produce traps for house- tion systems for customers around the
hold pests. world since 2006. According to Managing
brand.
The machine’s core element is a revo- Director Albert Gratacos, the engineering
lutionary motion control system with a company focuses on innovation in the
by Matt Prellwitz, total of 67 servo axes synchronized by automation of industrial processes, the
Drive Technology Product Manager, camming function. The result is a produc- modernization of a variety of machines
Beckhoff Automation LLC tion line that feeds, cuts and bends wire; and the implementation of comprehen-
produces springs; and mass-produces the sive solutions.

© Mitec Enginy

Despite the rather small end product, the rat trap production line is quite impressive in size. Images courtesy Mitec Enginy

GO TO MACHINEDESIGN.COM 45
Build a Better Rat Trap

The many dynamic motion sequences are provided by 67 AM8000 series servomotors from Beckhoff.

Servo Drive Technology appropriate way to do that,” said Gratacos. The system relies on 61 AX51xx and
Replaces Mechanics “At first, the idea of precisely synchroniz- AX52xx servo drives paired with 67
“Looking back at the history of automa- ing around 70 servo axes sounded almost AM80xx servomotors to power the various
tion, it is essential to appreciate the foun- crazy, but it ultimately proved to be the process steps. In terms of software, Twin-
dations that are simply taken for granted right solution for the complex process CAT 3 with the camming function (TF5050
today,” Gratacos explained. “Eighty years sequences, and we were able to implement TwinCAT 3 NC Camming) ensures pre-
ago, mechanically driven machines were it using PC-based control from Beckhoff.” cisely synchronized motion sequences.

“
quite common, often powered by a motor The EtherCAT industrial Ethernet
and connected by gears, crankshafts and system delivers optimal communication
At first, the idea
cams. These inventions still drive our for motion control as a high-speed, high-
innovations today, yet these machines of precisely bandwidth and extremely deterministic
predate 3D CAD, CNC machining synchronizing around 70 fieldbus. Ideal for all things motor- and
and software. With today’s technology, servo axes sounded almost drive-related, EtherCAT can handle the
mechanical machine components are most basic PTP systems to advanced
crazy, but it ultimately
replaced by multi-axis servo movements applications, such as the Mitec Enginy
and controlled more reliably and flexibly proved to be the right machine. In addition, EtherCAT supports
by software.” solution for the complex safe motion functionality.
For a prime example, consider the latest process sequences, and we The rat-trap machine implements all
application from Mitec Enginy—the rat necessary safety functions (STO, SOS,
were able to implement it
trap machine. “The customer needed to SS1 and SS2) directly in the automation
modernize their product manufacturing using PC-based control from system with TwinSAFE and Safety over
to remain competitive, so we devised an Beckhoff.” EtherCAT communication. A Beckhoff

46 MACHINE DESIGN
A total of 61 Beckhoff AX5000 series servo drives are housed in the control cabinets placed at the head of the production line.

CX2062 Embedded PC serves as the central automation system, which is why we have
controller, offering core processing power specialists in mechanics, electrics and pro-
using advanced Intel Xeon processors. gramming working closely together to
These features delivered serious com- develop innovative automation solutions,”
petitive advantages, according to Lluis said Gratacos, who also credited custom-
Moreno, sales engineer at Beckhoff ers and suppliers as project partners.
Spain. “[The solution] is fully equipped Among the many projects Beckhoff
with powerful servo drive technology net- has partnered on with Mitec Enginy,
worked via EtherCAT and can be reliably none have captured Morena’s interest
coordinated with the CX2062 from just more than the rat trap machine: “I have
one computer,” Moreno said. to admit that the current production line
is the most efficient and, dare I say, ‘beau-
Complex Solutions tiful’ machine in terms of design so far;
Require a Strong Team each of the many movements is just so fast,
Mitec Enginy’s success can also be attrib- precise and smooth that no unnecessary
uted to the team that has been created to stresses are transferred to the mechanics
develop complex automation solutions. of the machine.” „
“We handle all of the mechanical and
electrical design, programming and
assembly of the automation in-house. At
the same time, we recognize that no one
person can be the expert for the entire

GO TO MACHINEDESIGN.COM 47
2024 INNOVATORS PROFILE
Sponsored Content
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48 MACHINE DESIGN
2024 INNOVATORS PROFILE
Sponsored Content

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DRIVE
TEL | 978-532-1800

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Mission Statement: Harmonic Drive’s mission is Global Manufacturing and Engineering: The Harmonic
to provide motion control solutions that give our Drive Group Companies are comprised of Harmonic Drive,
customers a competitive advantage. To accomplish this, LLC (United States), Harmonic Drive Systems, Inc. (Japan)
we continually invest in the growth of our employees and Harmonic Drive SE (Germany). We have shared core
and in our company’s capabilities. values, product designs and quality standards. State of the art
manufacturing facilities in the US, Japan and Germany enable us
What we do: Harmonic Drive, LLC engineers and to locally serve the needs of our customers providing high quality,
manufactures precision servo actuators, gearheads and precision, and reliability around the globe.
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motion control.

50 MACHINE DESIGN
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2024 INNOVATORS PROFILE
Sponsored Content
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At igus®, we have been developing and manufacturing At igus, nothing is more important to us than our customers.
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and climate-neutral gas, and plan to reach CO2 neutrality
by 2025. Finally, we’ve partnered with the National Forest
Foundation to plant 10,000 trees in 2024, the same goal we
also met for 2023.

52 MACHINE DESIGN
v
2024 INNOVATORS PROFILE
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54 MACHINE DESIGN
Industry Trends

Markforged

Additive Manufacturing
Innovations Drive Industry Forward
Machine Design covered several additive manufacturing innovations during the past
year—each with the potential to reshape the future of manufacturing.
by Sharon Spielman, Technical Editor

IN THE EVOLVING field of additive manufacturing, several Take multi-material 3D printing, for example. As nano3D-
innovations have emerged that have helped to drive the industry print CEO Ramsey Stephens noted in a Q&A, “No longer is
forward. From the development of advanced and multi-materials multi-material 3D printing just about using different colored
for 3D printing, to the advent of sophisticated software and filaments; instead, it introduces material diversity by embed-
engineering platforms for enhancing the 3D printing process, ding into the design functional inks and pastes, which possess
to the increasing investment in and use of 3D printing by uni- dynamic qualities, including conductivity, magnetism, sensing
versities, Machine Design keeps its finger on the pulse of the capabilities and responsiveness to external stimuli.”
additive manufacturing industry. Manufacturers can incorporate functional materials into
Let’s explore a few of these innovations and their capacity to everyday devices, leading to the creation of custom devices like
transform the next phase of manufacturing. wearables, sensors, batteries and solar cells. “This customiza-
tion can conform to space limitations and design constraints,
Advanced Multi-materials for 3D Printing accelerating innovation and research and development while
A significant innovation in additive manufacturing lies in the reducing costs,” Stephens said.
expansion and diversification of the materials used in the 3D Another advancement in 3D printing materials can be found
printing process. Beyond traditional plastics and metals, recent in dental prosthetics and other medical solutions where high-
advancements have allowed manufacturers to create products accuracy printer platforms and biocompatible materials are used.
with improved properties and functionalities. Desktop Health (a brand of Desktop Metal) and Carbon—both

56 MACHINE DESIGN
leaders in the oral health additive manufacturing space—joined are traditional CAD tools. They don’t offer what we need.” Meta-
forces this past summer to bring the Flexcera family of resins fold’s technology addresses that, she said.
to the Carbon Digital Manufacturing Platform. At the center of the platform is its geometry computation
The collaboration opened access to the nanoceramic resin engine, which Ross said enables the design and optimization of
for use in 3D printing permanent dental restorations, as well as complex geometries for 3D printing. The web application offers
advancements in digital dentistry, providing exceptional strength, capabilities for creating lattice geometries, lightweight parts and
life-like aesthetics and long-term performance. high-surface area structures, which opens possibilities for a range
of industries where optimized structures are highly valuable.
Software, Engineering Platforms for 3D Printing One of the key strengths, she noted, is the material and process
To complement the advancements in materials, software and agnosticism. Users can access the software via the cloud and API,
engineering platforms streamline the 3D printing workflow and regardless of the hardware used for 3D printing. This flexibility
allow for design flexibility. allows manufacturers to optimize their additive manufacturing
The integration of platforms dedicated to 3D printing has processes, whether designing lightweight aerospace parts or
changed the way products are designed, tested and manufactured. creating efficient heat exchangers.
Cutting-edge software solutions allow users to create complex There are platforms to access and print parts as they are
designs, optimize support structure generation and simulate the needed, too. Markforged, for example, offers Digital Source,
printing process to identify potential issues before they arise. an on-demand parts platform that allows for licensing and 3D
These platforms facilitate communication between design- printing of manufacturer-certified parts at the point of need. The
ers and machines and have resulted in customization, quicker platform enables vendors to upload digital part designs, which
prototyping and cost-effective manufacturing. can then be licensed to customers, distributors and contract
Dr. Elissa Ross, co-founder and CEO of Metafold—the manufacturers. Once uploaded, end-users of the platform gain
developer of a Design for Additive Manufacturing (DfAM) the flexibility to license the right to print parts either onsite or
cloud-based software—told Machine Design about the tech- through a network of approved print service providers.
nology behind its computation engine. She said the company According to Jeremy Haight, principal engineer at Vestas
recognized the need for new digital tools to support 3D print- Wind Systems A/S, Digital Source allows spare parts to be
ing manufacturing technology and address the limitations of printed where needed, so the company got its machinery up
traditional CAD systems. and running faster. “Time equals a very high dollar value for
“[CAD systems] were developed for conventional manufac- us,” he said. “A line down in one of our factories is a big deal
turing, and they are excellent in those capacities,” she said. “But but a turbine that has gone down can cost even more.” He said
when it comes to supporting high complexity, geometry—that if they can access and print the part needed, the turbine can be
is…what 3D printing is really great at—those same digital tools up and operational much quicker.

Multi-material 3D printing in practice. Courtesy nano3Dprint Lattice geometries created by Metafold’s web application. Metafold

GO TO MACHINEDESIGN.COM 57
Additive Manufacturing

Learning Institutions Invest in 3D Printing

In addition to materials and software advancements, invest-
ment in 3D printing by universities is driving growth in the
additive manufacturing sector.
Universities and other higher-learning institutions have begun
to recognize the potential of additive manufacturing and are
investing in the technology. By establishing dedicated research
centers, labs and courses in additive manufacturing, these insti-
tutions are fueling innovation and preparing a new generation
of experts in this emerging field.
The collaboration between academia and industry has resulted
in cutting-edge research, advancements in materials and the
development of novel manufacturing techniques. Those that
invest in 3D printing contribute to a knowledge-sharing ecosys-
tem, helping to accelerate the adoption and development of addi-
tive manufacturing technologies and concepts. This progressive The WarpSPEE3D printer. Courtesy Bradley Deuser, Missouri S&T
approach can foster the growth of 3D printing across a range of
industries, stimulating innovation and economic development. their goal of throttling and launching the first ever bi-propellant
To support Missouri manufacturers and enhance their com- liquid-fueled rocket powered by a collegiate rocketry team.
petitive edge, for example, the Kummer Institute Center for The E-1 was three years in the making for the SEB team as
Advanced Manufacturing at Missouri University of Science and part of their goal to become the first collegiate rocketry team
Technology (S&T) made a significant investment in technology. to pass the Karman line, which divides Earth’s atmosphere and
The purchase of a large-format metal 3D printer from SPEE3D outer space. The December 2022 launch of the rocket put the
is a crucial step toward incorporating additive manufacturing team well on its way when it reached more than 11,000 feet
into the state’s industrial sector. in altitude.
Dr. Richard Billo, director of the Center for Advanced Manu- The rocket’s plenum and parachute system were printed
facturing, emphasizes the importance of additive manufacturing via selective laser sintering (SLS) with PA12 40% glass-filled
becoming the new norm for Missouri manufacturers to thrive nylon. According to Asa Garner, structures lead, the team
globally. “For Missouri manufacturers to succeed on the global researched the options and ultimately chose this material due to
stage, additive manufacturing must become the new normal,” he its strength, temperature resistance, long-term wear resistance
says, noting that the upcoming Missouri Protoplex, an advanced and cost-effectiveness.
manufacturing research and development facility set to open Garner explained that without 3D printing the team couldn’t
in fall 2025, is where the new printer and other equipment will iterate on the component designs as quickly as they did for this
be housed. project. “Both of the critical main parachute bulkheads were
Apart from supporting manufacturers’ projects, working with entirely 3D-printed and we’re using thermoplastic heat set inserts
the WarpSPEE3D printer provides undergraduate and graduate to fasten them to our primarily fiberglass airframe,” he said.
students at S&T with valuable experience and understanding of Garner and his team plan to use 3D printing and machining
challenges faced by manufacturers. Students can program the for various components in their latest project, the Eureka-2
printer, document operating procedures, design CAD models, rocket, which they plan to reach an altitude of 20,000 feet. The
perform testing and develop maintenance plans. This holistic key learnings from that launch will pave the way for what the
approach to workforce development aims to equip students team hopes is a Karman-line surpassing Eureka-3.
with hands-on experience in product development and manu- Driven by innovations such as advancements in materials
facturing methods. and software, as well as universities investing in the technology,
As additive manufacturing continues to advance, the univer- additive manufacturing continues to make progress as Machine
sity’s investment in equipment and research will play a pivotal Design continues to report on its potential. „
role in supporting Missouri manufacturers, enabling them to
embrace innovative technologies and maintain a competitive
edge in the global marketplace.
Across the country at the University of California, Berkeley,
students who are part of Space Enterprise Berkeley worked
with Protolabs to manufacture 3D-printed components for
the Eureka-1’s (E-1) plenum and parachute system, achieving

58 MACHINE DESIGN
Industry Trends

Custom Machine Builder

Develops Automation Solution That
Increases Production Capacity Four-Fold
Kamp Automation developed a mechatronic solution to meet a customer’s
requirements. By automating a labor-intensive process, production capacity for an
industrial electronic component was increased four-fold from a single machine.

by Derek Limesand, Sales Engineer, Mechatronic Solutions

AT A GLANCE: Ben Toskey, Vice President Sales, KAMP Automation

• Custom machine builder

KAMP Automation automated CUSTOM AUTOMATION suppliers ating condition of the component. The
a labor-intensive process for fill the gaps between original equipment LEDs and LCD display are protected by
a customer that increased manufacturers that supply modifiable plastic covers adhered to the metal body.
production capacity for an
industrial electronic component platform machines and end-use manufac- While the metal housing and circuit
four-fold from a single machine. turers, which may also require something boards were made efficiently and cost-
special for their operation. Automation effectively in high numbers, adhering
• The authors maintain that
solutions of all types are especially impor- three plastic covers to each housing with a
the project stickhandled by
KAMP Automation reveals the tant today as reshoring becomes a fact of quality seal was slow and labor-intensive.
importance of custom solutions life and the lack of public interest in 21st When this electronic component was first
to the health of the U.S. Century manufacturing jobs shrinks the introduced, low output was not a problem.
manufacturing sector. talent pool. As demand for the component increased,
At one time, most manufacturing however, the bottleneck of plastic cover
operations had internal talent to design application became a concern. The manu-
and build custom machines and provide facturer asked KAMP Automation to
for the organization’s unique manufactur- design an automated machine that would
ing requirements. As internal costs rose, significantly expand capacity and ensure
these teams shrank and many were elimi- quality seals for the adhered plastic covers.
nated. Now custom machine builders fill
those roles. They rely on close working The Manual Process
relationships with suppliers and distribu- In the manual process, an employee
tors to gain the latest technology. Cus- placed two metal die-cast housings on a
tom machine builders employ talented fixture and placed the fixture on a tabletop
mechanical and electrical engineers who gantry system, with one cover opening
creatively develop mechatronic solutions facing up on each housing. On the fixture,
to meet customer requirements. the employee also placed plastic covers
for that opening.
A Case in Point—The Adhesive Entering a code into the HMI for that
Application Machine cover opening, the three-axis gantry
A manufacturer came to KAMP Auto- used plasma gas to prepare the metal
mation needing to expand the production and plastic surfaces for a strong bond.
This CAD image shows the three axes.
The X transverse axis is at the top with of an industrial electronic component. Following the application of plasma gas
its energy chain. The Z axis, center, holds The photoelectric sensor unit’s small (both the gas and adhesive dispensers
the various applicators and camera. The Y
housing, made of die-cast aluminum, were mounted on the Z-axis of the gan-
axis, at the bottom, is the platform for the
housing fixtures on a rotary drive. Images protects the electronics inside. LEDs and try), a Nordson dispenser placed a bead
courtesy of Festo an LCD numerical display show the oper- of adhesive around the perimeter of the

GO TO MACHINEDESIGN.COM 59
Custom Machine Builder

housing’s opening. The operator then removed the fixture and, mounted a platform onto the Y-axis EGC to hold the housings,
using a handheld light source, visually confirmed the adhe- covers and required equipment. Housing fixtures like the ones
sive bead was continuous around the mounting surface. The used in the manual process were attached on both sides of a
employee manually picked up the plastic covers and pressed Festo DRVS semi-rotary pneumatic drive with a Festo SRBS
them onto the metal housings. position sensor.
The operator replaced the housings on the fixture, this time After covers were placed to the opening facing up, the DRVS
positioning the units so that the next openings faced up. The rotated the fixtures to bring the next cover opening to the up
operator entered the recipe for that opening on the HMI and position. Rotation eliminated the first bottleneck; there was no
repeated the process. And lastly, the employee repeated the pro- need to manually remove the housings and reposition them.
cess one final time for the third cover. The covers had different The machine did the repositioning.
shapes—round, oval and rectangular— that demanded a unique A Festo EGSC ball screw mini slide was used for Z axis motion.
coordinated movement of the X-Y axis. The manual process On the Z axis, the KAMP team mounted a plasma gas applicator,
required about 12 min. to apply plastic covers to the two units. a Nordson adhesive applicator, a Banner iVu vision sensor and a
Festo DFM pneumatic guided actuator with vacuum cup gripper.
Creative Solution The DFM automated picking-and-placing covers, eliminating
KAMP Automation studied videos of the manual process. the second bottleneck. The vision system automated inspection
The design team identified three bottlenecks: and made it more accurate.
• Loading/unloading the die-cast housings onto the tabletop The X axis—also a Festo EGC ball-screw linear actuator—and
gantry for plasma and adhesive application. the Y axis were programmed to work in harmony to trace the
• Manually picking and placing the plastic covers. precise round, oval and rectangular contours of the openings and
• Manually checking the quality of the bead. to position the applicators, vision system and pick-and-place unit
precisely where they needed to be during the assembly process.
Then, the team came up with a creative mechatronic solution
that relied on three ball-screw linear actuators for X, Y and Putting it All Together
Z motion, a pneumatic rotary actuator and a reliable vision In the new automated process, the machine operator places
inspection system. two die-cast metal housings on fixtures and six plastic covers on
The engineers applied a Festo EGC ball-screw linear actua- a cover fixture (three covers for each housing). Vacuum holds
tor for Y axis motion. The EGC and the other axes met the the metal housings and plastic covers in place. Manually load-
± 0.1 mm required accuracy for this application. The team ing the machine made sense from a cost standpoint and only

The aluminum housing of the industrial electronic component Closeup of the die-cast housing mounted on the rotary drive. The
is mounted on a machine prior to assembly. A round opening is circular cover opening is pointing up, ready to receive adhesive.
pointing up ready for the insertion of a plastic cover.

60 MACHINE DESIGN
required seconds. Housings and covers in place, the operator rotated three times and six covers are applied in roughly three
starts the machine. minutes, a 75% time reduction over the manual process.
The X and Y axes position the vision sensor above the die- KAMP Automation’s distributor, Mechatronic Solutions,
cast housings and the covers to verify all parts are present and Maple Grove, Minn., worked closely with KAMP on the project,
correctly presented. The X and Y axes then trace the contours of identifying and supplying the key components. The distributor
the cover openings on the housings and over the plastic covers used the software productivity tool Festo Positioning Drives
as plasma gas is applied to prepare the surface for a strong bond. (recently revised and renamed Electric Motion Sizing) to prop-
The Z axis vertical motion ensures proper distance between the erly size the EGC and EGSC ball screw actuators with Yaskawa
gas applicator and the part. motors and servo drives. Using Positioning Drives simplified
and speeded up the specification process.
KAMP Automation’s distributor, Mechatronic Mechatronic Solutions entered payload, loading, center of
Solutions, Maple Grove, Minn., worked closely mass, acceleration/deceleration, cycle time and dwell data into
the software, then Positioning Drives determined the right com-
with KAMP on the project, identifying and bination of actuator, motor, drive and accessories. KAMP has
supplying the key components. The distribu- never had a Festo linear actuator fail in the field.
tor used the software productivity tool Festo Mechatronic Solutions also identified a Festo CPX-MPA-L
Positioning Drives (recently revised and valve terminal as ideal for the customer’s machine. The CPX-
MPA-L offers one point of integration for both Festo pneumatics
renamed Electric Motion Sizing) to properly and remote I/O into the PLC. This single point of integration
size the EGC and EGSC ball screw actuators simplified commissioning.
with Yaskawa motors and servo drives. As this adhesive dispensing machine example illustrates, cus-
tom automation solutions companies provide a vital service to
Following plasma application, the Nordson applicator applies the manufacturing community. „
adhesive to the perimeter of the housing’s cover opening. The
vision system confirms a continuous bead has been laid down,
and the DFM picks and places the correct plastic cover. When
both housings have covers, the DRVS rotates the housings to
the next opening and the plasma, adhesive, vision inspection
and placing of covers are repeated. In all, the two housings are

The operator’s view of the adhesive machine showing the X, Y and A closeup view of the Y axis, center, and the Z and X axes, above.
Z axes. On the Z axis from left to right are the Nordson adhesive applicator,
Banner vision system and plasma gas applicator. The pick-and-
place guided actuator is mounted behind the plasma applicator and
is not easily distinguished. A box of die-cast housings is visible on
the lower left.

GO TO MACHINEDESIGN.COM 61
Industry Trends

The Future of
Connected Worker
Technology
and Its Impact on
Industrial Training
A new paradigm of work driven by technology is reshaping industrial
skills and training efforts in profound ways.

by Eric Whitley, Director of Smart Manufacturing, L2L

THE INDUSTRIAL LANDSCAPE is undergoing a transfor- The paradigm shift towards connected worker technology
mation. Gone are the days of static assembly lines and isolated has brought a fusion of wearables, augmented reality (AR) and
tasks. Today’s factories and facilities are dynamic environments the Internet of Things (IoT) into the industrial workflow. This
where automation, data analysis and interconnected devices trio of technologies is reshaping the fabric of industrial envi-
play crucial roles. ronments, making them more responsive and interconnected.
A connected worker uses technology to enhance their
capabilities and seamlessly integrate their actions with digital Key Features of Connected Worker Technology
industrial systems. Connected worker technology is reshaping Wearables are now integral to the connected worker’s gear,
industrial training in profound ways. This new paradigm is tracking health metrics and environmental conditions. They offer
crucial in enabling workers to operate with increased efficiency a dual benefit: safeguarding the worker while also collecting valu-
and intelligence. able data to inform safety practices and operational efficiency.
AR is a transformative force providing workers with real-time
The Emergence of the Connected Worker visualizations that offer guidance and clarity on complex tasks.
Industrial working environments of the past were marked by This technology has turned complex schematics and manuals
the manual execution of tasks and the segmented operation of into interactive 3D models that can be superimposed onto the
machinery. The flow of information was linear and slow, with real work environment. As a result, workers can perform intricate
improvements and innovations being implemented at a glacial procedures with greater precision and confidence.
pace compared to today’s standards. Such settings required the IoT’s prowess in data collection and real-time communication
physical presence and undivided attention of workers, often at has turned each device into a beacon of insights, with sensors
the expense of efficiency and safety. and actuators feeding a constant stream of information into the

62 MACHINE DESIGN
 148215540 © Pop Nukoonrat | Dreamstime.com
industrial network. IoT has effectively created a digital nervous personalized and engaging. These modules, often accessible via
system that spans the entirety of industrial operations. tablets or smart glasses, allow workers to learn by doing, which
is instrumental in retaining complex procedures and protocols.
Impact on Industrial Training The interactivity also ensures a more inclusive and effective
The leap from traditional classroom training to digital meth- learning environment.
odologies is a seismic shift in industrial education. Traditional
methods often relied on theoretical knowledge and simulated Advantages of Digital Training Methods
environments, whereas digital approaches provide interactive, Digital training methods have been proven to enhance engage-
hands-on experiences that mirror actual workplace scenarios— ment and significantly boost the retention of information among
and a more effective transfer of knowledge. workers. Workers are transformed from passive recipients of
information into active participants in their learning. Such
The Role of Immersive Technologies in Training engagement is crucial for translating training into practical,
Immersive technologies such as virtual reality (VR) and AR on-the-floor skills.
have taken center stage in training, propelling workers into One of the most significant advantages of digital training is the
environments that are both controllable and experientially rich. ability to provide real-time feedback and adapt learning paths
With VR, employees can navigate through life-like simulations according to individual performance. Workers can immediately
that would be too dangerous or expensive to recreate in real life. correct their actions based on the system’s feedback, which accel-
AR overlays essential information onto the real work setting. erates the learning process and personalizes the experience to
Interactive learning modules have revolutionized on-the- meet each worker’s needs. This makes training tailored endeavor
job training, facilitating an active learning process that is both rather than a one-size-fits-all model.

GO TO MACHINEDESIGN.COM 63
Connected Worker Technology

Enhancing Safety and Efficiency Adopting new technologies invariably introduces a learning
Connected worker technology has elevated safety protocols curve. Training programs must be designed to bring workers
from being reactive to proactive, with predictive analytics antici- up to speed without overwhelming them, and support systems
pating potential hazards before they occur. Wearables alert should be in place to aid in the adoption process. Successfully
workers to safety risks, and managers can monitor environmen- managing this learning curve is crucial for harnessing the full
tal conditions in real time, enabling immediate intervention potential of these innovations.
when necessary.
Real-time data and collaboration have yielded impactful and Future Trends and Predictions
measurable efficiency gains. For instance, connected devices The integration of artificial intelligence (AI) and machine
enable the immediate adjustment of machine settings to opti- learning with connected worker technologies heralds a future
mize performance, while collaborative platforms allow teams where industrial processes become even more intelligent and
to solve problems without the delays of traditional communica- adaptive. These advanced algorithms can analyze complex data
tion methods. These gains and advancements are not limited streams to enhance decision-making and efficiency. As AI con-
to speed; they enable workers to make smarter decisions that tinues to evolve, it will undoubtedly become a key feature in a
benefit the entire production line. connected worker platform.
The horizon for AR and VR in industrial training is one
Real-Time Collaboration and Decision Making of boundless potential. As these technologies mature, we can
The capabilities of IoT and AR are the foundation of a new anticipate even more refined simulations and augmented experi-
era of teamwork. IoT allows team members to share operational ences that will further diminish the boundaries between digital
data instantly, while AR can bring a remote expert’s guidance and physical realities. The future points towards a seamless
directly into a worker’s field of vision. Together, these technolo- integration of our digital tools with the natural environment
gies facilitate a collaborative environment where knowledge and of the industrial workspace.
expertise are shared regardless of physical location. The role of humans within industrial settings is transition-
Data analytics is, to put it simply, turning vast amounts of ing towards more cognitive and analytical functions. Work-
data into actionable insights. Workers and managers alike rely ers are now the strategists and problem-solvers, with their
on analytics to understand trends, forecast outcomes and make irreplaceable human ingenuity complementing the precision
decisions that align with real-time operational intelligence. This of machines. It is an evolution that underscores the value of
data-driven approach has transformed decision-making from human insight, with technology amplifying human potential
a gut-based to an evidence-based practice. rather than replacing it.

Data analytics is, to put it simply, turning vast amounts of data into actionable insights.
Workers and managers alike rely on analytics to understand trends, forecast outcomes and
make decisions that align with real-time operational intelligence. This data-driven approach
has transformed decision-making from a gut-based to an evidence-based practice.

Technology has been instrumental in bridging the gap between Retool for Growth
field workers and management, creating a unified vision of The transformative impact of connected worker technology
operational goals and challenges. With real-time data flow and on industrial training has been revolutionary, offering a new
communication platforms, the insights of those on the produc- paradigm where efficiency, safety and knowledge-sharing are
tion floor can inform managerial decisions. This synergy ensures greatly enhanced.
that decisions are not made in silos but are the result of shared The future of work suggests a landscape of continuous learning
knowledge between all organizational levels. and adaptation, where digital tools become partners in progress
and catalysts for an ever-evolving industrial workforce. „
Challenges and Considerations
One important step towards robust and efficient infrastructure
is striking a balance between data collection for operational
efficiency and respecting the personal boundaries and data
rights of employees. Robust cybersecurity measures and clear
policies are non-negotiable to maintain trust and protect against
potential breaches.

64 MACHINE DESIGN
Industry Trends

5 Common Machining
Mistakes to Avoid
From adding thin walls to raised text to “non-threadable” holes, subtractive
manufacturing such as CNC milling is not without its mishaps. Here are ways to
avoid some of the most common DfM don’ts.
by Dan Snetselaar, CNC Product tweaks attempting to cut down on part 5. Moving from
Leader, Protolabs weight, but the small tools required to Machining to Molding
machine these features add substantial Each manufacturing process has unique
DESIGN BEST PRACTICES are overall cost. Protolabs recommends think- design requirements. Protolabs often sees
highly technology dependent and CNC ing through how critical the pockets are to molded parts uploaded to its machining
machining is no exception. As a subtrac- the part. If they’re intended only to reduce services for prototyping prior to purchas-
tive manufacturing process, machining weight, consider other ways to achieve ing a mold. For example, a molded part
comes with a specific subset of design dos that in the design. may include ribs and pockets, which
and don’ts. Here are five frequent design works well for molding; however, these
mishaps we often see at Protolabs as we 4. Incorporating features add significant run time for
work with customers to address design- “Non-Threadable” Holes machining. All in all, ensure that part
for-manufacturing of machined parts. Adding threaded holes to a part is easy design is optimized for its intended manu-
if hole diameters are confirmed within the facturing process.
1. Adding Tall, Thin Walls range for the static set of threads avail- Taking a bit of extra time in the design
Parts with walls—generally—don’t able. As a digital manufacturer, quoting phase to ensure optimal machinability can
tend to work well as they’re prone to software allows users to choose the thread save significant time and overall cost.
rippling, bending, chipping or breaking and then automatically identifies holes After uploading a 3D CAD model, work
during the cutting process. Taller walls that are in the specific diameter range for with applications engineers to ensure that
will likely require added thickness for sup- the selected thread. design is ready to run smoothly. „
port. Protolabs recommends walls with a
width-to-height ratio of 3:1. Adding draft
(a slight angled taper) to a wall is one way
to sidestep potential issues.

2. Small, Intricate or Raised Text

It’s common for parts to require a
serial or identification number of some
kind. Keep in mind that adding text to
parts means added cost. While one might
equate smaller to less expensive, it’s the
opposite in this case. Small endmills that
cut the text run at a markedly slower
speed and add more time on parts,
meaning increased cost. Larger text is
a faster process to achieve and recessed
text, versus raised, is much more cost
efficient. Protolabs works with
customers to address
design-for-manufacturing
3. Out-of-Pocket Features of machined parts.
Adding square corners or internal Courtesy Protolabs
small corner pockets are common design

GO TO MACHINEDESIGN.COM 65
Industry Trends

Master Embedded
Systems Security:
A Step-by-Step Guide to
Protect Critical Components
How can you cover all the bases for embedded systems security? This step-by-step
guide takes you through best practices.

by Emily Newton, Technology and Industrial Journalist

EMBEDDED SYSTEMS SECURITY treat cybersecurity as an afterthought. target it and which approaches they’ll
is an essential concern in the modern They frequently find problems late in take when trying to steal data. For
landscape. Products ranging from aircraft the design process and may struggle to example, an adversary that launches a
control to washing machines contain and adequately address them before products software-based hack could infect the sys-
need them to run correctly. Many embed- go on the market. tem with malware or perform a brute-
ded systems work in real time, provid- Shawn Prestridge is a U.S. field- force attack. Network-centered attacks,
ing mission-critical information…which applications engineer manager for IAR including distributed denial of service
makes the consequences especially dire if Systems, which makes security tools. (DDoS) or man-in-the-middle attempts,
they’re targeted by cybercriminals. He estimates only 20-30% of compa- are also possible.
An embedded system has the highest nies prioritize minimizing security Assess your client’s cybersecurity
likelihood of being secure when everyone vulnerabilities in embedded systems. practices and identify necessary improve-
involved in designing it takes a methodi- Even worse, Prestridge said many people ments when building an embedded sys-
cal approach to reducing vulnerabilities. put little to no thought into cybersecu- tem. Designing a secure embedded sys-
Here’s how they can do just that. rity for their embedded systems or are tem is essential, but preventing attacks
wholly unequipped to safeguard them also requires client preparedness and an
Take a Security-First Approach against threats. attitude of continuously updating prac-
Unfortunately, too many people Securing a system begins with under- tices and procedures to reflect evolving
working to create embedded systems standing how cybercriminals will likely attack methods.

66 MACHINE DESIGN
113057078 © Oleg Dudko | Dreamstime.com

Once development begins, people embedded system’s state can only progress case, the IDPS would maintain activity
should strongly consider using tools that after validation. logs but leave humans to investigate fur-
perform code audits on embedded sys- ther. However, an active response might
tems. Although these checks can happen Create Logging and block network activity to thwart or slow
manually, they require time and skill to do Monitoring Features cybercriminals’ efforts.
well. One widely used approach is to let Cyberattacks are increasingly frequent People using an IDPS to safeguard
automated tools handle the initial review and costly. Statistics from 2021 revealed a embedded systems must regularly update
and then have a development professional 17% uptick in the average cost of security it to recognize the latest threats. Other-
see what may have been missed. breaches. However, improved visibility wise, it’ll be easier for attackers to break
People may push back on efforts to can help people detect intrusion attempts through the defenses.
emphasize security if it extends the devel- earlier, potentially reducing the damage
opment timeline. However, it’s far better and associated expenses. Remain Aware of
to take cybersecurity seriously from the Building logging and monitoring capa- Industry Developments
start than to later discover severe vul- bilities into the embedded system can tell Cyberattacks are occurring so fre-
nerabilities that could take longer than users about any unusual characteristics of quently that even people outside tech
anticipated to fix. the critical components. Many designers development and related sectors know
prefer lightweight and fast loggers that they must do what’s necessary to protect
Isolate Essential let the system maintain expected perfor- against them. Many IoT products will
Parts of the System mance. Some data loggers offer real-time soon feature specific labels that show they
One best practice for embedded sys- collection, helping people know precisely meet cybersecurity standards.
tems security is to isolate the aspects a when something’s amiss. More products focused on embed-
hacker might try to exploit. Successful However, just collecting the data is ded systems security are also arriving on
infiltration of one component would not insufficient for embedded systems secu- the market as vendors see the customer
allow the cybercriminal to gain additional rity. People must also develop a process demand for them. It’s also becoming more
access elsewhere. for reviewing the information and inves- convenient to update the software used for
Relatedly, people should set dedicated tigating anomalies. Some companies have embedded systems. Many enable over-the-
access control measures for each part responsible parties receive notifications air updates so the products stay current
of an embedded system. Jean-Georges of anything unusual in the logs. Then, with limited intervention from owners.
Valle, author of a book about the impor- there’s little to no delay in them checking Consider how cybercrime advance-
tance of penetration tests for hardware, it out and potentially preventing an attack ments could make it easier for outsiders to
clarified how embedded systems never in progress. compromise embedded systems security
exist in isolation, providing cybercrimi- Designers and engineers must make and proactively reduce that risk. Main-
nals access to the rest of a company’s clients aware that the embedded systems taining appropriate safeguards requires
IT infrastructure. Valle also noted how have integrated logging capabilities and putting yourself in the position of a hacker
people often mistakenly think embedded emphasize the importance of analyzing and considering what they’ll target, then
systems are inherently secure, so they them. Picking out unusual events takes creating preventive measures. Eliminat-
forget to follow established methods of time, but it’s a practical way to increase ing all threats is impossible, but you can
keeping out hackers. awareness of cybercriminals and stop their certainly minimize them.
People might apply the principle of least attack attempts.
privilege to the system as they explore the Embedded Systems
most effective ways to keep critical com- Use an IDPS Security Starts With You
ponents safe. It means users only receive It’s always wise to use an intrusion Many of these tips are for people direct-
the minimum access privileges required detection and prevention system (IDPS) ly involved in building embedded systems.
for a desired action. in addition to any logging capabilities that However, even if you only use them, you
A secure boot feature is another widely strengthen embedded systems security. can do so more securely, maximizing the
utilized protection mechanism for the People can configure the IDPS to handle usage applications for your embedded sys-
vital components hackers may target. The multiple tasks and alert the appropriate tems so they support your business. „
secure boot uses the root of trust (RoT) parties to suspected problems.
to verify all code loaded or executed. The For example, an IDPS may monitor
RoT is a reliable source within the system network traffic according to established
and uses cryptographic principles to check parameters. Then, it could take either an
the code. It also works in stages, where an active or a passive response. In the latter

GO TO MACHINEDESIGN.COM 67
2024 INNOVATORS PROFILE
Sponsored Content
WEB | www.knf.com

KNF EMAIL |
TEL |
knfusa@knf.com
609-890-8600

NEUBERGER
FAX | 609-890-8323

2 Black Forest Road, Trenton, NJ 08691

K
NF NEUBERGER is a leader in precision liquid and gas diaphragm pumps. The company has solved thousands of
design challenges for a variety of application tasks, including: waste handling; fluid supply, washing, replenishment,
recirculation, and metering/dosing; needle washing and drying; aspiration; gas transfer; chamber evacuation; vacuum
roughing/backing; pneumatics; and degassing/debubbling.

• Right-sized projects. While other

companies turn away smaller opportunities,
KNF provides application-specific support for
large and small projects.

• Cost-effective balance. KNF assists

customers in balancing required performance,
product lifetime, and cost.

• Global support. We are where our customers

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• Long-term support. KNF has many

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serve evolving needs.

• Strong technical knowledge that goes well

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MORE THAN JUST A PUMP and systems experience across many diverse
What really sets KNF apart from other pump companies? KNF is industries, including medical device and
a technology leader with over 300 patents and a solid reputation for diagnostics, environmental monitoring/
providing innovative, high performance, reliable products. However, this industrial hygiene, laboratory equipment,
is just the beginning: printing, security and defense, semiconductor,
energy, various process industries, and more.
• Sales engineers. Many of the KNF OEM sales team are engineers,
bringing technical expertise directly to customer interactions.
Contact us today or visit
• Solutions, not just pumps. By understanding customers’
applications and specs, KNF strives to optimize not only our pump, knf.com/en/us/custom
but to also assist customers in optimizing their overall system. Our to experience why KNF is
job is to fit the pump to your application – not the application to a more than just a pump.
pump. In fact, over 90% of our business involves custom-engineered
pump solutions, numbering 3,000 custom adaptations each year.
• Significant engineering and trouble-shooting support behind
our field sales team. Customers often send in problematic systems
for testing. Whether the issue is related to the pump or another
system component, we’ll provide a full report with analysis and
recommendations.

68 MACHINE DESIGN
 HIGH
FLOW-TO-SIZE
RATIO

COMPACT, EFFICIENT
MICRO GAS PUMPS
Compact KNF micro gas diaphragm pumps offer an efficient and durable solution
for environmental and industrial hygiene monitoring, inkjet printing, medical device
and diagnostics, analytical instruments, and more. With flow rates ranging from
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flow vs. speed, these products are well-suited for portable and handheld applications.
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performance, lifetime, controllability, and cost.

Learn more at
knf.com/en/us/micro-diaphragm-pumps
2024 INNOVATORS PROFILE
Sponsored Content
WEB | www.regalrexnord.com

REGAL REXNORD
TEL | 608-364-8800

111 W Michigan St.

CORPORATION Milwaukee, WI 53203

REGAL REXNORD CORPORATION is a global In short, Regal Rexnord’s 36,000 associates around
leader in the engineering and manufacturing of the world are proud to be working each day towards
factory automation sub-systems, industrial powertrain fulfilling the Company’s purpose – helping create a
solutions, automation and mechanical power better tomorrow – for its customers and for the planet.
transmission components, electric motors and
electronic controls, air moving products, and specialty Regal Rexnord is comprised of four operating
electrical components and systems. segments: Automation & Motion Control, Industrial
Powertrain Solutions, Power Efficiency Solutions and
Through longstanding technology leadership and Industrial Systems. Regal Rexnord is headquartered in
an intentional focus on producing more socially Milwaukee, Wisconsin and has manufacturing, sales
conscious and environmentally-friendly products and and service facilities worldwide.
sub-systems, the Company is regularly addressing
increasingly relevant secular demands of customers For more information, visit RegalRexnord.com.
in the medical, alternative energy, aerospace, food
& beverage, general industrial and warehouse/
intralogistics end markets, among others.

70 MACHINE DESIGN
 FULL LINE OF
ENCLOSED
GEARING
Find your solution at Pump
regalrexnord.com/gearing Drives

Quadrive®

BG Series
SS700 Gen2

V-Class®

IRONMAN™ Planetgear™

Regal Rexnord, Bauer Gear Motor, Boston Gear, Durst, Falk, Grove Gear and Rexnord are
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2024 INNOVATORS PROFILE
Sponsored Content

SEW-
WEB | www.seweurodrive.com
TEL | 864-439-7537

EURODRIVE,
220 Finch Rd.
Wellford, SC 29385

INC.
AS A WORLD LEADER in drive technology and a pioneer in drive-based automation, SEW-EURODRIVE has established
a reputation for quickly solving the most difficult power transmission and motion control challenges. Since introducing the
combined gearmotor in 1931, we have been bringing the best in drive technology to our customers worldwide.

More than just gearmotors

SEW-EURODRIVE offers much more than just
components. We offer the expertise and expanded line of
control components and software to drive them. Our team
of automation experts understand the latest technology and
can solve even the most complex motion control challenges.

Being a single-source automation partner radically sets

us apart from others. Our team of automation engineers
provides the expertise, project planning, software,
commissioning, and worldwide support for your most
challenging motion control projects. They can serve as a
valuable extension of your engineering team, reducing the
stress and demanding workload. Our experts provide a
solution of perfectly matched SEW components that have PRODUCT INNOVATION
been designed to work together seamlessly. MOVI-C® Modular Automation Platform
In addition to engineering excellence, SEW-EURODRIVE
is also known for innovative new products. Our MOVI-C
modular automation system is a flexible one-software, one-
hardware automation platform that combines fully integrated
drive components, control electronics and automation
software – all from a single source. The key to the MOVI-C
platform is that each of those components is designed to work
together perfectly, taking the hassle out of machine design.

The MOVI-C platform utilizes the latest automation

technologies – from AC motors and gear units to ultra-
efficient permanent magnet servomotors, control electronics,
and software. Machine builders will appreciate the seamless
integration and prebuilt software modules tailored to the
customer’s application.

72 MACHINE DESIGN
Driving the world

No coating.
Brilliant for the environment.
Coating-free aluminum gearmotors in the ECO2 design –
ECOlogical, ECOnomical, and uncompromisingly sustainable.

Drives in the ECO2 design: Efficient and reliable

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$OXPLQXPUHDFWVZLWKR[\JHQWR  $WWHPSHUDWXUHVRIʈˑ&XSWRDPD[LPXPRIʈˑ&
form a thin protective layer.
 7KH(&2GHVLJQPHHWVWKHUHTXLUHPHQWVRI,62ʈ
FRUURVLYLW\FDWHJRU\&

ECO2
In a dry, neutral environment,
aluminum and plastic are well
protected from corrosion.

10 0-% free
ating
co s urface
s
outer

ECO2: economical and ecological Get more

technical info
and configure
The demand for eco-friendly products is growing. We have responded to yours here
this with our sustainable, coating-free drives and our responsible use of raw
materials. ECO2 describes our high performance gearmotors made from
XQFRDWHGDOXPLQXP7KH\ɑUHERWKHFRORJLFDOʝWKDQNVWRWKHLUHQYLURQPHQWDOO\
IULHQGO\FRDWLQJIUHHGHVLJQʝDQGHFRQRPLFDODVDUHVXOWRIWKHLUFRVWHIƟFLHQW
manufacturing and assembly process. What’s more, components can be recycled
PRUHHIƟFLHQWO\DQGVXVWDLQDEO\DWWKHHQGRIWKHLUOLIHF\FOH$OOWKLVLVJRRGIRU
the environment and for your wallet.

$YDLODEOHLQVHOHFWVL]HVDQGFRQƟJXUDWLRQV

www.seweurodrive.com
2024 INNOVATORS PROFILE
Sponsored Content
WEB | www.smalley.com
EMAIL | info@smalley.com
TEL | 847-719-5900

555 Oakwood Road

Lake Zurich, IL 60047

RING AND SPRING ENGINEERING EXPERTS

As the inventor of the edgewound wave spring and with over 100 years of manufacturing excellence, Smalley is the Engineer’s
Choice® in providing wave springs, retaining rings, and constant section rings for all of your application needs.
Smalley stocks over 10,000 standard parts across 30 configurations
and 400 sizes, ready for delivery. If a standard part doesn’t meet your
requirements, you’ll work with our team of over 30 industry-specialized
engineers to quickly create an economical custom part in the material of
your choice, all without new tooling. Prototype or production volume, our
No-Tooling-Charges™ manufacturing process meets the design flexibility
your application, budget, and timeline requires.
While all of our manufacturing is produced in our U.S. based 300,000 ft2
facility, our global network of offices, engineers, and distribution partners
allows you to quickly receive parts and support from anywhere in the
world. Smalley’s dedication to quality and manufacturing excellence has
earned us multiple service and quality awards as well as the trust of OEMs
worldwide.

CREATING APPLICATION-SPECIFIC SOLUTIONS

From everyday consumer products such as the smartwatch on your
wrist to life-saving medical devices such as robotic surgical instruments,
Smalley has helped tens of thousands of engineers and professionals create
application-specific solutions across every industry.
Smalley has paved the way to become the world leader in rings and springs because of our personalized application-support,
industry expertise, and customer-driven commitment.

FOR ALL OF YOUR DESIGN CHALLENGES

Retaining Rings Wave Springs
Unique configuration providing a low radial profile, reliability, Optimize space by providing the same spring force as an
and convenience. ordinary compression spring at a reduced operating height.

• No Ears to Interfere® with undesired components • Reduce spring height by up to 50% when used to
• No lugs, ideal for tight radial applications replace an ordinary compression spring
• No gap, providing 360° retaining surface for even load • Compact design fits tight radial and axial spaces,
distribution reducing spring cavity size
• Coiled, not stamped, economical material options due • Light-weight assembly that saves production time and
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• Easy customization, design around your application • Accurate and predictable load(s) toleranced at specific
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• Safe and easy installation requiring no special tools Standard or custom, we are dedicated to delivering the right
• Groove interchangeable with stamped rings part in the right material for all of your applications.

74 MACHINE DESIGN
2024 INNOVATORS PROFILE
Sponsored Content

WEB | www.spirol.com
EMAIL | info@spirol.com
TEL | 860-774-8571

30 Rock Avenue
Danielson, CT 06239-1434

ABOUT US:
When you engage SPIROL as a design partner, you
Since the invention of the Coiled Spring Pin in 1948,
will shorten the design cycle time and get to market as
SPIROL has been a global leader and manufacturer of
quickly with a high quality, profitable product.
engineered fasteners and installation equipment. Our
core purpose is to help customers improve the quality
of their product, simplify the assembly process and WHERE TO FIND US:
reduce the overall cost of assembly.
SPIROL’s products can be found in alternative energy
/ green technology applications, gas-powered auto-
WHAT WE OFFER: mobiles, electric vehicles, airplanes & helicopters,
agriculture / heavy equipment, tractor trailers, office
SPIROL continues to introduce new products and
furniture, consumer appliances, hand & power tools,
improve existing ones. Our diverse product line
lawn & garden equipment, medical devices / medical
includes Coiled Spring Pins, Slotted Spring Pins, Solid
equipment - literally any assembly that can be mechan-
Pins, Disc Springs, Alignment Dowels and Bushings,
ically fastened together! There are no engineering fees
Spacers, Compression Limiters, Inserts for Plastics,
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SPIROL can be found on 4 continents within 12 coun-
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tries: Brazil, Canada, China, Czech Republic, England,
fastener and a standard line of Fastener Installation
France, Germany, Korea, Mexico, Poland, Spain, United
Equipment and high-performance Vibratory Parts
States.
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vide the total assembly solution!
Involve SPIROL early in the design stage
In addition to high quality products, SPIROL has of your next project!
Application Engineers throughout the world to assist
you in your designs, supported by state-of-the-art
manufacturing centers and worldwide stocking facilities Learn more at SPIROL.com
to simplify the logistics of delivering your product.
Through partnering with companies early in the design
stage, we not only help design the engineered fastener,
but we also make the critical recommendations for the
interface between our product and your assembly.

76 MACHINE DESIGN
 Since 1948!

Looking For a High Quality,

Fastening Solution?

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IDVWHQLQJMRLQLQJDQGDVVHPEO\
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• Complimentary Application Engineering Support
• Responsive, World-Class Customer Service
• In-House Manufacturing / High Quality Products
• ([SDQVLYH3URGXFW2䈱HULQJ6WDQGDUG,WHPV
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- We Are Where You Are!

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IATF 16949 • ISO 9001 • AS9100 Visit SPIROL.com!
')$56&RPSOLDQW,7$55HJLVWHUHG
2024 INNOVATORS PROFILE
Sponsored Content

WEB | www.theleeco.com

THE LEE
EMAIL | inquiry@theleeco.com
TEL | 860-399-6281

COMPANY
2 Pettipaug Rd., PO Box 424
Westbrook, CT 06498-0424

THE LEADERS IN MINIATURE FLUIDICS

T
he Lee Company is a world leader in miniature
precision fluid control technology for industries
including aerospace, automotive, diagnostics, industrial,
medical equipment, scientific instruments, motorsports, and
many others. Founded in 1948, we provide engineered solutions
for some of the world’s largest and most innovative companies.
Our product offering includes check valves, pressure relief
valves, shuttle valves, flow restrictors, flow metering valves,
solenoid valves, safety screen filters, pumps, plugs, and more.
Lee products are recognized worldwide for their outstanding
quality, unmatched reliability, and superior performance.

We specialize in transforming complex problems into

deliverable solutions. Our commitment to quality is
strengthened through research, development, and continuous
innovation. As the original inventors of all Lee products, we are
able to ensure reliable performance as well as dedicated technical support. We offer an unmatched manufacturing ability to
maintain tight tolerances and produce miniature parts that save space and weight. Thousands of companies – both large and
small, established industry leader or just starting out – trust The Lee Company to deliver a best-fit solution.

With over 1,000 employees, The Lee Company occupies

over 1 million square feet of manufacturing space in
Connecticut, U.S.A., and Cambridge, U.K. Through our
five European subsidiaries and 10 distributors worldwide,
we are able to better serve our customers in multiple
industries around the globe. Thanks to our large global
network of Technical Sales Engineers, we are able to
work locally with our customers – taking the time to
understand their issues and work through them as a team.

78 MACHINE DESIGN
 LEE MINIATURE CHECK VALVES | RELIEF VALVES | SHUTTLE VALVES | FLOW CONTROLS | PRECISION ORIFICES | EXPANSION PLUGS

WE INNOVATE.

Imitation is easy.
Innovation is hard work.
Leighton Lee II was an innovator. He founded
our company on that spirit, and it’s how we
solve tough problems today. Every product
you see here—from miniature check and relief
valves to shuttle valves, flow controls, precision
orifices and plugs—was developed to solve a
customer’s fluid control challenge. Since 1948,
we’ve been delivering engineered solutions
for a wide variety of demanding applications.
We have the experience, product breadth, and
technical know-how to provide engineered
performance, with zero risk. Don’t let an imitator
ruin your day—or your design. Contact us
today to put our knowledge to work for you.

Learn more at
theleeco.com/innovate

WESTBROOK • LONDON • PARIS • FRANKFURT • MILAN • STOCKHOLM

Ad Index

ACE Controls ................................................................................................................................................................................................................................................................6-7

Advanced Micro Controls (AMCI) .......................................................................................................................................................................................................... 16-17

Altech Corporation .............................................................................................................................................................................................................................FC, 2-3, 9-11

AutomationDirect .................................................................................................................................................................................................................................................IFC-1

Baumer ........................................................................................................................................................................................................................................................................30-31

Beckhoff Automation, LLC ........................................................................................................................................................................................................................... 18-19

Contemporary Controls .............................................................................................................................................................................................................................. 32-33

Eagle Stainless Tube & Fabrication, Inc. ....................................................................................................................................................................................... 34-35

EXAIR LLC ................................................................................................................................................................................................................................................................36-37

FAULHABER Group....................................................................................................................................................................................................................................................13

Floyd Bell Inc .........................................................................................................................................................................................................................................................48-49

Harmonic Drive LLC ........................................................................................................................................................................................................................................50-51

igus Inc. ......................................................................................................................................................................................................................................................................52-53

KHK USA ...................................................................................................................................................................................................................................................................54-55

KNF Neuberger, Inc. ........................................................................................................................................................................................................................................68-69

PI Physik Instrumente L.P. ..................................................................................................................................................................................................................................15

Regal Rexnord Corporation........................................................................................................................................................................................................................70-71

SEW-Eurodrive, Inc ........................................................................................................................................................................................................................................... 72-73

Smalley Steel Ring Co. ...................................................................................................................................................................................................................................74-75

Spirol International Inc. ................................................................................................................................................................................................................................ 76-77

The Lee Company ............................................................................................................................................................................................................................................. 78-79

Yaskawa America Inc ................................................................................................................................................................................................................................ IBC, BC

80 MACHINE DESIGN
2024 INNOVATORS PROFILE
Sponsored Content
www.yaskawa.com

YASKAWA
WEB |
TEL | 1-800-YASKAWA
847-887-7000

AMERICA, INC. 2121 Norman Drive South

Waukegan, IL 60002

W
hether you are a machine builder or equipment user, you know the daily struggle with limited resources and tight
deadlines. You can’t afford to settle for less than the right products and services to solve urgent problems, delivered
with reassuring consistency and reliability you can trust.

Experience is often the difference between solving a problem the right way
and settling for “good enough.” Yaskawa’s global expertise is unmatched
and unquestioned, with 100+ Years of manufacturing excellence, 14,800+
worldwide associates, 30 countries with sales, service, and manufacturing
locations, and $4.5 billion in global sales per year. Since 1915, Yaskawa has
produced 18 million servo axes, 30 million variable frequency drives and
540,000 robots.
We provide both standard products and tailor-made solutions, all backed
by proven quality and reliability. We’re also continuously working to save
you money, time, energy and headaches, because we believe your machine
can always run faster, smoother and more productively. It’s about making
the correct diagnoses, creating the right automation machinery, and
implementing it in the best way possible.
AC Drives: Yaskawa offers a variety of low and medium
voltage AC drives that support every application in the
industrial plant, offering size and performance options
from fractional HP to 16,000 HP. Our latest variable
frequency drives provide simple motor setup with highly
flexible network communications, embedded functional
safety, no-power programming, and easy-to-use tools
featuring mobile device connectivity with our DriveWizard
mobile app.
Servos and Controllers: Yaskawa AC Servo Systems
come to a precise position with a speed and consistency
that is unmatched in the automation industry. Connect
our rotary, linear, and direct drive motors (outputs from
3W to 55kW) to an advanced Yaskawa machine controller to achieve
SINGULAR CONTROL: the ability to manage robots, servos and drives
with a single controller and familiar IEC 61131-3 programming.
Robotics: Over 540,000 Yaskawa Robots are at work worldwide, with 150+
models to choose from and the strength of decades of application expertise.
Our industrial robots increase efficiency, provide consistent quality, and
boost productivity to deliver outstanding ROI. Our robotic portfolio ranges
from 4 to 15-axis industrial robots with load capacities of 2 to 800 kg to
special machines, devices, and turnkey robotic systems.
POWERFUL, EFFICIENT
SPINDLE CONTROL
S I G M A - S D S P I N D L E D R I V E / M O T O R C O M B I N AT I O N

Sigma-SD spindle motors and drives are designed specifically

for machine tool applications to provide machine builders the
performance and productivity to standout from the crowd.

• High Speed Motor / Matching High Frequency Drive

Shortens cutting times and boosts throughput

• High Bandwidth Drive with Analog or EtherCAT Interface

Provides higher precision speed control

• Optimized Motor Winding Design and Cooling

Increases efficiency and reduces weight with 200% maximum
continuous output motor power

• Fully Regenerative Power Converter

Conserves power, cut energy bills, and reduces cabinet size

• Gain Switching: Easy Transition Between Gain Levels

Improves spindle orient function and enhances rigid tapping performance

• Low Inertia Design

Maintains precise speed control despite rapid changes in cutting torque

Want to get an edge on your competition? Contact Yaskawa today.

FOR MORE INFORMATION:

https://go.yaskawa-america.com/yai1489

Yaskawa America, Inc. 1-800-YASKAWA

Email: info@yaskawa.com | yaskawa.com