AMTIL JUN/JUL 2025

Australian Manufacturing Technology Institiute Limited

JUN/JUL 2025

A NEW FRONTIER …

MELBOURNE ON SHOW

AMW 2025 REVIEW

ADDITIVE MANUFACTURING State Spotlight: Western Australia & Northern Territory

For the first time ever, Australia’s premier manufacturing solutions event Australian Manufacturing Week will take place in Brisbane in 2026. Save the date and join us for an amazing event in the sunshine state.

MAY 12-14, 2026 BRISBANE CONVENTION & EXHIBITION CENTRE, BRISBANE

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Australian Manufacturing Technology Institiute Limited

JUN/JUL 2025

MELBOURNE ON SHOW

AMW 2025 REVIEW

ADDITIVE MANUFACTURING State Spotlight: Western Australia & Northern Territory

EOFY SALE $20K

ENDS30

JUNE

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CL-460 • Ø460 x 1500mm capacity • 2 axis digital readout system • Quick change toolpost • 80mm spindle bore • 300mm wide induction

desktop

15,125 (W08720)

$

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SAVE $660

• Auto lubrication pump for slides • One piece cast iron base • 12 speeds, 25-1860rpm • 5.5kW / 7.5hp, 415V motor

20,295 (L607D)

$

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Hydraulic NC Panbrake Ezy Touch Screen Control - PB-830T

Hydraulic Punch & Shear 60 Tonne - IW-60H

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• 5 work stations • ø28x15mm plate punch • 350x15mm plate shear • 100x100x13mm angle shear • 50.8x90x8mm notch

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20,790 (S584T)

15,345 (P173)

$

$

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ON SALE FROM MAY 14 TILL JUNE 30

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Semi - Automatic Swivel Head-Dual Mitre Metal Cutting Band Saw BMSY-320DGH

• Inverter Variable Cutting Speeds, Dual Mitre Cuts Up To 60°, Hydraulic Vice Clamping & Includes Hydro Mechanical Blade Tension • 450 x 320mm (W x H) Rectangle Cap.

$

21,659 (S754)

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Hydraulic Swing Beam Guillotine HG-2504C

Swivel Head-Dual Mitre Metal Cutting Band Saw - EB-351DSA

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10,175 (B072)

19,745 (B136)

• 2500 x 4mm capacity • 1-Axis Estun E21S control 9CRsi blades for stainless steel • Blade gap adjusting dial 65mm throat depth • 5.5kW / 7.5hp 415V motor • Mobile foot pedal for "hands free operation" • Single point rapid blade gap adjustment • High quality blades suitable for cutting stainless steel • Programmable backgauge with 800mm travel

18,645 (S9335)

• 345 x 202mm capacity • Swivel head up to 60° • Ball bearing blade guides • Auto hydraulic clamping vice • 2 x blade speeds 36 & 72m/min.

• NT40 spindle taper • 3 Axis digital readout • (X) 890mm (Y) 400mm (Z) 415mm • Variable speed, 50-3550rpm • Hardened & ground work table • Square slideways Y & Z-Axis

14,465 (M597D)

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(02) 9890 9111

(03) 9212 4422

(07) 3715 2200

(08) 9373 9999

(08) 9373 9969

AMT_020625

Specifications & prices are subject to change without notification. All prices include GST and valid until 30-06-25

AND YES… IT WAS OUR BIGGEST SHOW! THE STATS PROVE IT.

AUSTRALIANMANUFACTURINGWEEK.COM.AU

16,105 ATTENDEES

VISITORS

DAY 1: 2992 • DAY 2: 4475 DAY 3: 5473 • DAY 4: 3165

79.0% 9.4% 5.2% 2.0% 1.6% 1.0% 1.0% 0.8%

6 ZONES ALMOST 400 EXHIBITORS

38

AUSTRALIA

TOTAL 15,749 VIC NSW QLD SA WA TAS ACT NT

INTERNATIONAL

TOTAL 16,105 SPEAKERS

FUTURE SOLUTIONS SPEAKER PROGRAM 2700+ ATTENDEES

98% 2%

AUSTRALIA INTERNATIONAL

INDUSTRY

35.68% General Engineering /Manufacturing 7.68% Construction 6.36% Electronics/Electrical 5.34% Automotive/Road Transport 4.76% Education

12,531SQM

JOB TITLE

4DAYS

JOB FUNCTION

MCEC MELBOURNE

EXHIBITION SPACE

Director Engineer Sales Managing Director Owner

38.0% 8.5% 3.2% 3.2% 47.1%

Management Sales & Marketing Production Consulting Other

1963AMWMELB25AMTJUNJUL25

10.99% 4.93% 3.25% 3.24% 3.08%

006

CONTENTS

Volume 25 Number 02 June/July 2025 ISSN 1832-6080

FEATURES AUSTRALIAN MANUFACTURING WEEK 2025 REVIEW Introduction

30

30

AMW2025 Zones Review Machine Tools Zone

32

Manufacturing Solutions Zone

34

Additive Manufacturing Zone

36

Australian Manufacturers' Pavilion

38

Weld & Air Solutions Zone

40

Robotics & Automation Zone

42

AUSTRALIAN MANUFACTURING WEEK 2025 ADDITIVE MANUFACTURING StudioKite

46

3D People

48

AXT and VisiConsult partnership

50

Objective3D

52

PLASTICS, COMPOSITES & ADVANCED MATERIALS Paktec

54

Raymax HyperSpectral

55

SDI International

56

A review of the greatest and most unexpected attractions at this AMW in Melbourne.

46

INDUSTRY 4.0 Swisslog

58

AspenTech on AI

60

Swinburne Factory of the Future

61

STUDIOKITE

Hexagon Automation

62

StudioKite and CADzilla is set to produce low-cost and durable houses from recycled consumer waste.

SECO Tools

78

Sandvik Coromant

80

ISCAR aluminium

82

56

CUTTING TOOLS

STATE SPOTLIGHT: WA & NT Goldwind

84

Novarctech WPF

85

FORMING & FABRICATION Hobson Engineering

86

OKUMA Oasis Engineering

87

Rösler shot blasting system

88

DIMAC

90

Price Steel Fabrication

94

REGULARS From the Editor

8

From the CEO

10

From the Industry

12

From the Union

14

Government News

16

Industry News

18

Voicebox

22

Tech News

26

Product News

28

AMTIL Forums

96

AMTIL Inside

98

Industry Calendar

100

Manufacturing History – A look back in time

102

AMT JUN/JUL 2025

SDI INTERNATIONAL There’s more to manufacturing dental materials than meets the eye.

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008

FROM THE EDITOR PAUL HELLARD

Mind your step Now that the Federal Election and the AMW2025 trade show are behind us, there is more to plan, and the road ahead is clearer.

But some things never change.

Manufacturing anything from scratch in Australia can be challenging. Everyone knows and understands that. Ensuring those in the cogs are treated fairly and safely as they navigate the many steps to the completed product is a minefield in itself.

AMTIL is working closely alongside Machine Safety Australia (MSA) to outline a range of Safety Workshops over the next few months. Watch for emails and mentions onsite for the dates and locations. These will all be well worth the time invested.

STEM education is the key to producing a supply of young, skilled tradespeople for our country’s manufacturing sectors. Just before the AMW show began last week, I heard a story worth repeating.

Many manufacturing companies with an eye on the next 20 years have recently made connections with secondary and technical colleges and invited groups of engineering students to their facilities for a look-see. One local manufacturer recently hosted an open day for their future employees.

Engineering students from Monash University, who are part of the Monash Railway Express, are a student-led team competing in the Institute of Mechanical Engineers Railway Challenge in England. They are dedicated to designing an innovative locomotive that champions sustainability, safety, and efficiency. On a recent tour of Catten Industries and Latink, they were shown how ideas become reality in Australian manufacturing, which hopefully sparked inspiration for their future careers in engineering. With assistance from the Department of Transport here in Victoria, they are working with local manufacturers and other sponsors to establish business goals by learning what CEOs and CFOs actually do. This approach provides an open door to manufacturers as they strive to gain a deeper understanding of how the industry really works.

With a mind to future-proofing our economy, Christopher Joye’s article in the Australian Financial Review on the Monday after the ‘election we had to have’ was an interesting read. Joye writes that Australians benefit from our world-leading population growth and never-ending public spending. He even called Australia, Asia’s Greece. He said the multidecade resources boom has bolstered government coffers with massive amounts of cash, leaving the public balance sheet relatively debt-free compared with global peers.

This means that politicians are free to spend without facing any near-term consequences.

The electorate is seemingly content with this, unaware of who will bear the burden of repaying all these gifts. ‘Word to the wise: future generations,’ he adds.

We could experience some disinflationary pressure due to the trade war, as major global manufacturers send their affordable goods our way. This situation might offer the Reserve Bank of Australia additional flexibility to lower rates. Meanwhile, Chinese demand for our resources is likely to stay strong, primarily as it works to boost its struggling economy amid challenges from the West. In the immediate future, things appear bright! However, we must keep in mind that Australia’s ongoing productivity issues may worsen over time if we do not invest in skills, training, and safety, as well as provide our future generation with a solid STEM education. The story above outlines what can be done to ensure we have the know-how in twenty years to be as educated and industry-ready as possible.

Editor Paul Hellard phellard@amtil.com.au Sales Manager Pavla Thomas pthomas@amtil.com.au Publications publications@amtil.com.au Publisher AMTIL info@amtil.com.au Visual Communications Manager Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed in Australia under ISO140001 Environmental Certification using FSC® Mix certified paper sourced using sustainable tree farming practices.

Contact Details AMT Magazine AMTIL Suite 10, 5 Corporate Boulevard Bayswater VIC 3153 AUSTRALIA T 03 9800 3666 E info@amtil.com.au W amtil.com.au Copyright © Australian Manufacturing Technology (AMT).

All rights reserved. AMT Magazine may not be copied or reproduced in whole or part thereof without written permission from the publisher.

Contained specifications and claims are those supplied by the manufacturer (contributor).

Disclaimer The opinions expressed within AMT Magazine from editorial staff, contributors or advertisers are not necessarily those of AMTIL. The publisher reserves the right to amend the listed editorial features published in the AMT Magazine Media Kit for content or production purposes.

AMT Magazine is dedicated to Australia’s machining, tooling and sheet-metal working industries and is published bi-monthly.

Subscription to AMT Magazine (and other benefits) is available upon application.

Contact AMTIL on 03 9800 3666 for further information.

1958AMTJUN/JUL2025

AMT JUN/JUL 2025

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010

FROM THE CEO LORRAINE MAXWELL – Chief Executive Officer AMTIL

Value in today’s manufacturing is additive The ‘birth’ of the Additive Manufacturing (AM) CRC came late in the Federal Election campaign, with welcome news that the Commonwealth Government would back the new CRC, along with two others (SMART and Care Economy CRCs) in medical manufacturing.

The Minister’s media release confirmed “$58 million over seven years to establish a world-class additive manufacturing ecosystem spanning the entire value chain. Their sustainable manufacturing will reduce carbon footprints across our supply chains, as well as maintenance and transport costs, whilst increasing engagement and productivity.”

This is good news for Australian manufacturing and the opportunity to leverage the global rise of AM. It's been on a steady growth trajectory over a long period of time, possibly two decades, and is now acknowledged as the fastest growing sector in global manufacturing. Globally, the AM Industrial sector is growing at 14% CAGR, according to the USA’s American Manufacturing Technology (2024, Additive Database Overview).

Australia has excellent credentials and capabilities, which lend themselves to the opportunity at hand. In terms of medical devices, defence, and aerospace, AM has the potential to catalyse the growth of Australian manufacturing, drive productivity gains, and nurture innovation across diverse sectors. In addition, sustainability, productivity, and modular, mobile manufacturing will benefit from the scope of the new CRC. The AMCRC is an industry-led collaborative research initiative that brings together 101 partners from industry, research and government to revolutionise production processes, enhance productivity, and bolster Australia’s manufacturing capabilities.

According to Simon Marriott, Director and AMCRC Bid Lead, securing $58m in Commonwealth Government funding for additive manufacturing comes at a pivotal juncture for Australian manufacturing, as new opportunities emerge as Australia transitions to a net-zero economy.

“Additive manufacturing (AM), commonly known as 3D printing, is one of the most significant technological advancements in manufacturing that is reshaping industries by enabling the rapid creation of complex geometries and customised products across all sectors, including defence, aerospace, healthcare, automotive and construction,” Marriott explained.

“Over the last decade, AM has seen remarkable growth, driving advancements in 3D printing technology characterised by enhanced precision, scalability and material diversity. This evolution has shifted the AM landscape from targeted prototyping and smallscale production to full-scale commercial production. It is now

AMT JUN/JUL 2025

transforming industrial processes and supply chains, resulting in reduced lead times and material costs, ushering in a new era of efficient and sustainable manufacturing.”

AMCRC has strong backing from industry, including Boeing and 73 predominantly SME manufacturing businesses and three industry associations ready to leverage new technologies, capabilities and processes to drive sustainable business and supply chain growth for Australia.

Matthew Wall, Boeing Aerostructure Australia’s Additive Manufacturing and Innovation Lead, and Chair of the Australian Additive Manufacturing Network (AAMN), said: “Boeing is committed to advancing AM technologies, recognising its pivotal role in the future of aerospace production. AMCRC will allow for greater collaboration with Australian technology developers and researchers to strengthen Australia’s AM capabilities for emerging technologies in AM tooling and materials.”

Australia’s AM researchers rank fifth in the world, and with 13 universities and CSIRO contributing to AMCRC, there is tremendous potential for workforce development through industry-led PhD programs, increased student enrolment in undergraduate courses, and expanded access to vocational training.

AMCRC’s Chair, Susan Jeanes, said it was rewarding to see industry, research and government acknowledging the transformative potential of AM. “AMCRC has secured $271 million in funding from industry, research and government over seven years…This support positions Australia to take the lead in what is expected to be one of the most significant transformations in global manufacturing in decades,” Jeanes said.

Under the new CRC, I have been appointed a Director and Deputy Chair. AMTIL members will access over $3m in matched funding for AM research. The resulting AM ecosystem will allow SMES to explore and develop the next generation of products and services with Australia’s world-leading researchers.

This, coupled with the new Network (AAMN), launched recently by AMTIL, will support our members looking to unlock opportunities in AM and lend itself to a cohesive national strategy to support SMES in embracing AM technologies. This is a place where we can make a significant difference in manufacturing and for the Australian economy.

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012

FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

Structural reform During the recent Federal Election campaign, neither party acknowledged the need for structural reform.

We have not seen a sustained effort for fundamental changes to our economic and business framework since the early 2000s. By Innes Willox, Chief Executive, Australian Industry Group.

The Hawke and Keating microeconomic reforms, as well as the Howard and Costello taxation changes – both subjects of significant public discussion and debate before implementation – are now a generation ago.

Economic policy settings introduced 40 and 25 years ago, as tough as they were to push through, are not enough to sustain us a quarter of the way through the 21st Century. Efforts to change the game, ranging from the 2009 Henry tax reform proposals to the 2014 Abbott and Hockey budget, have largely gone unnoticed.

If our political leaders don’t emphasise the need for change to make us globally competitive, productive, and innovative and have the courage to pursue deep and meaningful reforms, our national discussion is doomed to be shaped by declining living standards and reduced business competitiveness.

Australia’s productivity performance remains as dismal as ever.

There was almost no overall productivity growth in the Australian economy in the last financial year, and GDP per hour worked languishes at the same level as 2019.

The Australian economy has weakened, with 2024 marking the longest period of low growth in Australia since the recession of the early 1990s. Profits and margins are declining across most industries, with both consumer and industrial sectors facing particular pressure, along with small businesses. Indeed, several sectors are showing recession-like conditions.

Manufacturing is of particular concern. While some sectors such as petrochemicals are resilient, in 2024 all other manufacturing subsectors contracted in the face of much tougher operating conditions.

It saddens me to say that after several years of strong growth we have fallen into a manufacturing recession. It is imperative that we turn this around.

In our latest annual Industry Outlook survey, Ai Group asked businesses what the potential constraints for the year were and uncertainty was a key concern. This has borne out faster and to a larger extent than any of us could have anticipated.

The availability and cost of labour is key to our performance. Of the 484,000 new jobs created in 2024, only 99,000 were in the private sector. Eighty per cent of job creation occurred in either the public sector or non-market sectors, both of which rely on government funding for employment generation.

This is simply not sustainable – the private sector is the engine of our economy and provides two-thirds of employment in Australia.

Taxpayer-funded job creation simply can’t be maintained at current levels.

Cost of living pressures, housing availability, as well as the lack of sufficient public transport, are also factors in getting the right labour to where it needs to be. Energy prices have also become prohibitive, with the gas prices paid by Australian manufacturers rising a staggering 52% since 2021.

We have strategic challenges to our economy spanning geopolitics, national security and technology in addition to these persistent labour and productivity obstacles. We are told we are in a decisive decade, where the decisions we make in response to these challenges will determine much about how Australia will experience the remainder of the twenty-first century. So we need to get the structural fundamentals of our economy right.

AMT JUN/JUL 2025

Among these fundamentals is tax. For two decades governments have delivered piecemeal tax changes rather than genuine reform.

Sadly, this tinkering round the edges has only added complexity and structural problems to our tax system.

Firstly, our lack of tax competitiveness makes us unattractive for global companies allocating capital for new projects. We rank second in the OECD – behind only Norway – for corporate profit taxes as a share of GDP. Our 6.6 per cent rate is double the OECD average of 3.3 per cent, and more than four times higher than the US. Second, we labour under a cumbersome two-tier corporate tax system that discourages investment and growth, with complications around dividend imputations credits, the treatment of franking credits, and differential treatment for different ownership structures.

Third, state government taxes are rapidly growing and are increasingly inefficient and hostile to investment. The state and local government tax take has surged by 31% since the pandemic and now accounts for 5.4% of GDP. Payroll taxes on employment now raise around a quarter of all subnational tax receipts.

Tax reform has the broadest and deepest reach of any economic reform available to government and should be a major public policy priority in 2025. Once again, there needs to be a greater focus on productivity in this discussion. Rarely are tax reforms debated on their merits in lifting productivity performance. But with almost no productivity improvements in the Australian economy for five years now, we need to use the tax reform lever to turn this national crisis around. aigroup.com.au

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014

FROM THE UNION STEVE MURPHY – National Secretary Australian Manufacturing Workers Union

Productivity Let’s better understand productivity and why it matters. A few words from Steve Murphy, National Secretary of the AMWU. The AMWU has been working to build broader support and greater opportunities for our domestic manufacturing industries.

We have achieved public and political support for expanding our local industrial capability as best we can, through advocating for good public policy, collaborative supply chains and the upskilling of workers.

We can say this has been successful as commitments to support local manufacturing has been a key federal election issue in 2025.

As the world transitions to decarbonise their economies and geopolitical tensions reshape trade and supply chains, simply relying on raw resource exports leaves Australia’s economy and future exposed and less competitive.

It is critical we now develop an industry plan to value-add to our natural resources through processing and manufacturing, which includes capturing our rightful place in global supply chains particularly in areas such as green metals (iron, steel and aluminium), battery manufacturing, solar panels, and wind tower manufacturing.

For Australia to be competitive in these areas, we need to ensure that we can improve the productive performance across our manufacturing industries. Otherwise, other countries will capture both new and existing industries. To succeed in an increasingly uncertain global market, we need employers to engage in an honest discussion about productivity.

So, the questions I’d like to pose are these: what is productivity, and how can we work together to improve it across manufacturing and the economy?

Productivity is simply the capacity of a worker to produce a certain amount of goods or services within a given time frame. This is largely influenced by ‘productive forces,’ which include factors like machines, technology, tools, and the organisation of labour.

Limiting or reducing wages, removing or restricting workers’ rights, or creating insecure working conditions have never improved

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productivity. Rather, productivity is improved by management’s decision to invest. The greatest impact on productivity in many workplaces is still to improve the ability for workers to develop and expand their skills.

This means that if we have a genuine desire to get productivity moving, we need to ensure that both workers and managers receive the training necessary to understand productivity. From there, working together to identify opportunities to reshape the way we do our work. Importantly we also need to recognise these additional skills through paying higher wages.

If we acknowledge that Australia cannot compete by having the lowest wages, then the conversations shifts to quality, delivery, management capability, research and development, and brand reputation.

As the global economy faces great changes, nations' capacity to innovate will become a greater determinant of their prosperity.

Unions and industry have both an opportunity and a responsibility to engage, participate, and invest our collective ideas in the productivity discussion.

Without it, Australia risks falling behind as other nations secure dominance in the industries that will define the future world economy.

Through a new industrial policy setting, unions and industry can move beyond areas of traditional conflict and start the urgent discussions required to grow workplace productivity and to ensure the benefits are shared fairly.

If anything, recent government policy decisions, such as "Future Made in Australia," should provide us all with hope. The existing challenges facing the industry are no longer falling on deaf ears, and shaping a more secure future for manufacturing is now within our grasp. amwu.org.au

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016

GOVERNMENT NEWS

ATSE looks to future build Leading technology and engineering Academy sees Albanese Government’s re-election as an opportunity to build a more innovative Australia.

The Australian Academy of Technological Sciences and Engineering (ATSE) congratulates Prime Minister Anthony Albanese and the Australian Labor Party on their historic election win over the weekend.

ATSE stands ready, with 50 years of experience providing a trusted, independent and evidence-based voice to all governments, to work with the government to shape a strong and future-ready Australia.

Australia can be a global leader in climate change technologies, renewable energy and clean fuel, critical minerals, health technology, and environmental monitoring – among others. Diversifying Australia’s R&D relationships would provide new opportunities to leverage our national strengths. There is also an opportunity to respectfully weave Traditional Knowledge more closely into research and development, and open potential new areas for innovation.

“Congratulations to the returning Albanese Government on its re-election,” ATSE CEO Kylie Walker said. “We look forward to continuing to work with government, bringing us together to drive our national research, development and innovation priorities.”

“In this time of global change and uncertainty, Australia is and will continue to be a stable partner for research and development in our region and globally. Nurturing and attracting excellent STEM talent; investing in the infrastructure and international collaborations necessary to innovate; and building our investment in STEM research and STEM-powered industry will lead to a stronger, more diversified economy.

“National productivity growth requires decisive investment in education and innovation: the people, industries and systems that make our economy tick.”

In light of global developments, Australia is in a position to deepen partnerships with the Asia-Pacific region, including through programs such as the Global Science and Technology Diplomacy Fund, for which ATSE is the lead delivery partner (with the Australian Academy of Science).

The ongoing Strategic Examination of Research and Development is a crucial opportunity for the nation to build a strong innovation foundation. ATSE will continue to engage proactively and work with the Albanese Government to reset its approach to R&D and leverage the best potential outcomes from our knowledge economy.

ATSE urges the Government to complete the implementation of the Universities Accord, and to support the continued success of the Elevate: Boosting diversity in STEM scholarship program, as outlined in the Pathways to Diversity in STEM review from 2024.

In the lead up to the election, ATSE representatives met with candidates from across the breadth of the political spectrum: we thank all parties and candidates for their interest in a STEM-driven future.

ATSE looks forward to working with the returning government and across the 48th Parliament to advance Australia’s innovation potential. atse.org.au

Productivity lift Treasurer Jim Chalmers has flagged that productivity will be a key focus in Labor’s next term of government as inflation challenges ease.

As the Labor government returns for its second term, Chalmers has pledged to address a lingering issue that has hampered the Australian economy - our stagnating productivity performance.

“The best way to think about the difference between our first term and the second term …[is] the first term was primarily inflation without forgetting productivity, the second term will be primarily productivity without forgetting inflation,” Chalmers told ABC Insiders on May 4.

The Productivity Commission flagged that Australia’s productivity levels have not significantly improved in over a decade. Without productivity growth, Australia’s living standards are set to flatline, the commission warned.

“With global policy uncertainty again on the rise, addressing productivity directly via targeted reforms will be the best way to sustainably boost Australians’ living standards,” Dr Alex Robson, deputy chair of the Productivity Commission, said.

The commission urged policymakers to focus on enhancing economic dynamism, developing a skilled and adaptable workforce, leveraging technology, boosting productivity in the care sector, and investing in the net-zero transformation to address Australia’s lagging productivity performance.

In a discussion paper, the government flagged that Australia had lower R&D intensity than other OECD countries, at 1.66% of GDP in 2021–22 compared to the OECD average of 2.9%.

The slow commercialisation of R&D has adversely affected economic complexity in Australia, which is a significant predictor of future growth.

AMT JUN/JUL 2025

Labor has also sought to boost productivity by investing in manufacturing through its $22.7bn Future Made in Australia plan, which aims to re-establish domestic manufacturing, enhance sovereign capability, and support the transition to net zero emissions.

The Committee for Economic Development of Australia (CEDA) called Australia “the least self-sufficient economy in the developed world,” partially blaming the dominance of our commodity exports within our economy, and the subsequent hollowing out of our manufacturing sector.

They praised the Future Made in Australia (FMIA) plan as a chance to revitalise Australia’s diminished manufacturing sector, which falls behind other deindustrialised countries like the UK and Canada.

“The Future Made in Australia initiative is an opportunity to diversify and transform our industrial structure in the context of the global energy transition and the desire for sovereign capability in areas of current and future competitive advantage, as well as possible geopolitical risk,” CEDA said.

The scale of the opportunity is immense, with the market for clean energy industries alone estimated to be worth $15Tn by 2050.

Speaking to ABC Insiders, Chalmers highlighted other aspects of Labour’s plan for productivity, which included changes to occupational licensing, non-compete clauses, and other incoming policies aimed at boosting competition within the economy. industry.gov.au

GOVERNMENT NEWS

Lean Manufacturing Pilot Program New pilot program being introduced to strengthen regional NSW manufacturing.

The NSW Government is continuing its commitment to rebuilding the state’s manufacturing industry with the launch of a $800,000 pilot program aimed at boosting productivity, reducing costs, and increasing competitiveness.

The audits, undertaken as part of the program, will offer tailored recommendations to help businesses identify inefficiencies, streamline operations, reduce waste and increase productivity, and highlight staff training opportunities.

The Lean Manufacturing Pilot Program will fund small-to-mediumsized manufacturers across regional NSW to undertake audits by professional consultants that will identify ways to reorganise their manufacturing operations. Lean manufacturing is an internationally recognised business management process based on the principles of continuous improvement, waste elimination, and a customercentric approach.

Several major companies have successfully implemented lean manufacturing over the past decades to improve efficiency, reduce waste, and enhance productivity, including Toyota, Ford Motor Company, Boeing, General Electric, and Nike.

“The Lean Manufacturing Pilot Program is an important part of our ongoing support for regional manufacturers across the state, helping them overcome the challenges posed by rising supply chain, energy and labour costs,” Minister for Regional NSW and Western NSW Tara Moriarty said. “This program is an important step towards ensuring the long-term success of our regional manufacturers. We know that by supporting regional businesses to improve their operations, we’re strengthening the entire economy of regional NSW, creating more local jobs and enhancing the longterm sustainability of our regions.”

It focuses on creating products more efficiently by eliminating unnecessary steps, saving time and using fewer materials in the production process. This approach helps businesses produce goods with fewer resources, without compromising on quality.

“The Lean Manufacturing Pilot Program is a prime example of how the Minns Labor Government is working to rebuild local manufacturing right across the state,” the Minister for Industry and Trade, Anoulack Chanthivong said. “Support for local manufacturing is also an integral part of the Minns Labor Government’s recently released Industry Policy. Three new local manufacturing targets are central to the Industry Policy, which demonstrates a real commitment to supporting local manufacturing to promote a dynamic, sustainable, and diversified economy.”

More efficient processes mean production lines manufacture fewer defective products, which in turn reduces operating costs related to providing returns and waste disposal. For example, a regional food manufacturer might reorganise production lines to improve efficiency, implement preventative maintenance to reduce equipment breakdowns and implement just-in-time inventory management to reduce excess stock and waste.

Many regional NSW companies, such as the Bega Group in Bega, Donaldson Australia on the Central Coast, Belmore Engineering in Tamworth, Flavourtech in Griffith, and Tyree Transformers in Braemar, have also successfully utilised lean manufacturing principles.

Manufacturing is a key driver of the NSW economy, contributing nearly 30% of Australia’s total manufacturing output.

In regional NSW, the sector generates $32bn in sales and employs 84,000 workers, reinforcing the need for continued support to strengthen and future-proof the industry.

Industry research by Binder Dijker Otte (BDO) suggests that adopting lean manufacturing can increase small-to-medium-sized businesses’ profit margins by up to three times, depending on their size and turnover.

“Lean manufacturing plays a crucial role in the future of the NSW manufacturing sector. By focusing on eliminating waste and improving efficiency, it helps manufacturers reduce costs and enhance productivity,” HunterNet CEO Ivan Waterfield said. “The Lean Manufacturing Pilot Program by the NSW Government is a significant step towards supporting regional manufacturers in becoming more competitive on a global scale and is something that HunterNet fully supports and endorses.”

The NSW Department of Primary Industries and Regional Development designed the pilot program following in-depth industry consultation, which highlighted the need for more support in adopting lean manufacturing principles to ensure regional manufacturers remain globally competitive.

The Lean Manufacturing Pilot Program is part of the NSW Government’s ongoing commitment to supporting manufacturing industries across the state as they navigate rising costs and market challenges. nsw.gov.au

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INDUSTRY NEWS

Manufacturing jobs showing future hope KPMG Australia analysis reveals the fastest-growing jobs and the ones slowly going extinct.

KPMG has released data showing that over the last 10 years, the occupational structure has significantly changed in line with an ageing population and the rapid growth of the ‘gig economy’.

Specifically, we’ve found a resurgence in manufacturing jobs as businesses look to onshore jobs after the supply shocks of COVID-19, that care economy jobs in health and childcare dominate the list of the fastest growing occupations from 2014 to 2024. Tech & IT Professionals, Marketers, HR Professionals, Chefs & Cooks and Truck & Delivery Drivers round out the list as the gig economy and prioritising wellbeing and health significantly alter Australia’s occupational structure.

Digitisation of the economy has also seen major declines in the take-up of occupations of such as Executive Assistants and Travel Agents. A decline in the number Farmers is reflecting a shift away from smaller, family-run farms to larger farming operations.

Meanwhile, Print Manufacturing Workers and Telco Repair & Installation Workers complete the list of fastest shrinking jobs between 2014 and 2024.

Manufacturing renaissance From 2014 to 2024, the overall manufacturing occupational groups grew by 9.1%, with the workforce increasing from 779,800 in 2014 to 851,000 in 2024.

“We started to see some improvements in this sector in 2018, followed by another surge in the past couple of years. The supply chain shocks of COVID-19 and broader geopolitical uncertainty have made businesses rethink the way they manufacture products, bringing some aspects of their manufacturing process back to Australian shores,” Rawnsley said.

Supply Chain Support (Supply & Distribution Managers, Purchasing & Supply Logistics Clerks, and Product Quality Controllers) roles saw the most significant growth in the manufacturing sector, with a 23.5% increase, rising from 219,700 to 271,400 workers. This reflects the more complex and integrated supply chains that many manufacturers now operate in.

Metal Manufacturing roles saw a 5.9% rise, reaching 145,600 workers by 2024. Food Manufacturing occupations also saw a 6.4% increase, indicating a stable rise in demand for processed food products. Wood Manufacturing saw substantial growth, with an increase of 17.4% which is likely related to increased wooden fittings and components for housing.

In contrast, Assembly roles only increased by 1,600 workers, likely due to increased automation. Print Manufacturing occupations declined sharply by 23.0%, aligning with the shift towards digital media. Fabric manufacturing occupations, which have been in long term decline, fell by 17.1% in the past ten years.

“These trends highlight the evolving landscape of the manufacturing sector, with areas of both growth and decline. The data underscores the importance of adapting to technological advancements and market demands to sustain and enhance the manufacturing workforce,” Rawnsley said.

Summary Methodology KPMG calculated estimates for the size of each occupation in 2024 by combining tax returns data from The Australian Tax Office, Employment data from the Census, The Australian Bureau of Statistics Labour Force Surveys and Jobs & Skills Australia NERO data sets. Occupations classification in each dataset is based on ANZSCO (Australian and New Zealand Standard Classification of Occupations) *.

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Manufacturing Occupational Groupings 2014-2024 Occuppation

Number of workers 2014

Number Additional Growth of workers workers rate 2014

Supply Chain Support

219,700

271,400

51,700

23.5%

Metal

137,500

145,600

8,100

5.9%

Assembly

90,900

92,500

1,600

1.8%

Food

76,600

81,500

4,900

6.4%

Wood

32,700

38,400

5,700

17.4%

Fabrics

25,800

21,400

-4,400

-17.1%

Print

26,900

20,700

-6,200

-23.0%

Plastics

10,500

9,400

-1,100

-10.5%

Other 159,200 Manufacturing

170,300

11,100

7.0%

Total 779,800 Manufacturing

851,000

71,200

9.1%

Source: KPMG calculated estimates for the size of each occupation by combining data from The Australian Tax Office tax returns, Employment data from the Census, The Australian Bureau of Statistics Labour Force Surveys and Jobs & Skills Australia NERO data sets.

In combining the various data sources to create robust and up-todate insights into occupation trends, KPMG adjusts the Census data to match the average level of the Labour Force Survey for each occupation between 2016 and 2021. This is then used to derive an estimate of 2014 employment using interpolation.

The estimate for 2024 is constructed by applying the implied annual growth rates from the NERO data to the Census from 2021.

Similar occupations under the standard classification were grouped together for clarity when presenting the results. For example, the KPMG Retail Shop Floor Occupation is a grouping of Sales Assistants (General), Retail Supervisors, Checkout Operators and Office Cashiers, Shelf Fillers.

This provides an estimate that is highly consistent with the various data sources available. The estimates are an annual average for each year. KPMG is a global organisation of independent professional services firms that provide audit, tax, and advisory services. KPMG is the brand under which the member firms of KPMG International Limited (“KPMG International”) operate and provide professional services. “KPMG” refers to individual member firms within the KPMG organisation or to one or more member firms collectively. © 2025 KPMG Australia, an Australian partnership and a member firm of the KPMG global organisation of independent member firms affiliated with KPMG International Limited, a private English company limited by guarantee. All rights reserved. kpmg.com/governance

INDUSTRY NEWS

The flipping challenge Teqram unveils the hydraulic EasyFlipper for fast and safe handling of heavy parts.

Teqram is introducing the EasyFlipper, a groundbreaking tool designed to simplify the flipping of large, heavy plates and parts.

With the ability to handle up to 5,000 kg, the EasyFlipper offers a faster and safer solution for rotating heavy components. The modular design is highly scalable. A combination of 20 EasyFlippers can flip parts weighing 100 tonnes!

Traditional methods of flipping heavy parts rely on forklifts, cranes, and various tools, making the process slow, labour-intensive, and risky. The EasyFlipper automates this task, cutting down safety risks. It stands out as a game-changer, simplifying and streamlining the handling of large and heavy parts.

Operating the EasyFlipper is simple: place the part on the table, press the start and safety buttons, and let the machine do the work. With dual-direction flipping, the EasyFlipper adapts to any orientation for smooth and reliable performance. The EasyFlipper Pneumatic flips up to 1,650 lbs in under 10 seconds, while the new Hydraulic model handles up to 11,000 lbs in less than 45 seconds— far surpassing traditional methods in speed and efficiency.

Flexible and durable The EasyFlipper is designed with flexibility in mind. Its modular extension arms facilitate handling larger parts, and multiple units can be connected to accommodate long pieces. Its mobility guarantees easy integration into various production processes. A robust steel frame and heavy-duty components ensure low maintenance costs and many years of reliable performance.

Safety is central to EasyFlipper’s design. Remote operation allows workers to maintain a safe distance, while optional safety sensors continuously monitor the surroundings, halting the process immediately if an operator comes too close. Accessories like rubber

mats, plastic strips, or brush tables protect against scratches and damage during flipping. The EasyFlipper’s versatility makes it perfect for a variety of tasks, such as flipping plates or stacks for cutting or quality control, handling plasma or oxyfuel cut parts for deslagging and grinding, and flipping parts during milling, deburring, or press brake operations.

By streamlining operations and minimising the risk of product damage, the EasyFlipper delivers immediate cost savings. It aids businesses in boosting productivity, safety, and product protection, making it a worthwhile investment for enhancing handling processes.

Teqram designs and delivers fully autonomous robotic systems for loading and unloading deburring, leveling, and shot blasting machines, as well as deslagging, grinding, and deburring sheet metal parts. Powered by the advanced EasyEye 3D vision system and AI, Teqram’s robots operate independently. They automatically recognise pallets, stacks, and product geometries, eliminating the need for manual programming or teaching. teqram.com

S&P sees better PMI Manufacturing conditions improve at fastest pace since late 2022.

Australia’s manufacturing sector performance improved at an accelerated pace in March. Rising new orders supported a renewal of production growth. Job creation also resumed, aiding the clearance of backlogged orders. Meanwhile, purchasing levels were increased for the first time since September 2022, contributing to a significant rise in inventory of purchases.

On the prices front, average input prices continued to rise at a steep rate in March, but output charge inflation eased despite reduced optimism regarding future output. The seasonally adjusted S&P Global Australia Manufacturing Purchasing Manager’s Index™ (PMI®) increased to 52.1 in March, up from 50.4 in February.

Remaining above the 50.0 neutral mark for the third consecutive month, the latest data indicated that conditions in the manufacturing sector continued to improve in March. Furthermore, the latest headline index was the highest recorded since October 2022.

Contributing to the increase in the headline index was manufacturing production, which expanded at its fastest pace since October 2022.

Improved domestic economic conditions, marketing promotions, and client restocking supported the growth in new work, according to panellists. However, firms noted a renewed decline in export orders, reflecting subdued external conditions.

As a result of the increase in overall new business, Australian manufacturers hired additional staff. The job creation rate was the strongest in two years, with firms also reporting the filling of roles that had been shed earlier. The larger workforce capacity enabled another round of backlog clearance in March.

“March's manufacturing PMI data brought positive news, indicating the strongest improvement in manufacturing sector conditions in nearly two and a half years,” said Jingyi Pan, Economics Associate Director at S&P Global Market Intelligence. “The latest expansions of new goods orders and output represented a nascent recovery for the sector. That said, some forward-looking indicators offered conflicting signals regarding growth in the coming months, with the level of business confidence notably easing in March.

The headline seasonally adjusted S&P Global Australia Manufacturing Purchasing Manager’s Index™ (PMI®) posted 52.1 in March, up from 50.4 in February. Posting above the 50.0 neutral mark for the third successive month, the latest data signalled that manufacturing sector conditions continued to improve in March.

Moreover, the latest headline index was the highest seen since October 2022.

Manufacturing production contributed to the increase in the headline index, which also expanded at the most pronounced pace since October 2022. The latest acceleration in output growth was driven by rising new business inflows and increased capacity.

Australian manufacturers reported receiving new orders at the fastest rate in 28 months. According to panellists, better domestic economic conditions, marketing promotions and client restocking underpinned the growth in new work. However, firms reported a renewed fall in export orders, reflective of subdued external conditions. spglobal.com

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INDUSTRY NEWS

Briscoe Group and KNAPP KNAPP streamlines Briscoe Group’s distribution system in Auckland.

The Briscoe Group’s 25,000sqm distribution centre is set to open in early 2026. Investing at least NZ$100m in the facility will significantly enhance Briscoe Group’s supply chain capabilities and efficiency.

Situated in Drury South, Auckland, this new centre will replace the current 8,000sqm facility, increasing storage capacity by more than four times and accommodating KNAPP’s state-of-the-art automated shuttle system.

The automation contract significantly advances the Briscoe Group’s supply chain evolution. KNAPP’s advanced systems, including the Automated Storage and Retrieval System (ASRS) Evo Shuttle and Pick-it-Easy Evo goods-to-person stations, will optimise storage and picking for smaller products like apparel and footwear, enhancing efficiency across the board.

“This partnership with KNAPP enables us to enhance stock accuracy and expedite fulfilment, creating an improved customer experience while optimising in-store inventory,” said Briscoe Group Supply Chain General Manager Darren Porteous. The automation will bolster the on-shelf availability of products in Briscoe Group’s stores, allowing the Group to restock high-demand items as often as daily, thereby enhancing both operational efficiency and customer satisfaction. Various online orders will also be fulfilled from the DC using automation, minimising the time from customer ordering to receiving their goods.

Despite the advanced automation, Briscoe Group’s workforce will grow. The current 45 full-time staff at the facility will more than double to about 100 employees over time, ensuring a balance between human expertise and automated efficiency. The site will

manage larger items using traditional pallet systems alongside automation for smaller products.

KNAPP’s automation will seamlessly integrate with the Briscoe Group’s Warehouse Management System. This integration, powered

by KNAPP’s robust and flexible central software suite, KiSoft, will enable optimised stock placement, quicker store replenishments, and data-driven inventory management, ensuring the system is ready for future retail growth. “Our solutions are designed to help the Briscoe Group achieve not just immediate efficiency but also long-term scalability, preparing them for the future of retail,” said KNAPP Australia Managing Director Michael Kemeny.

The KNAPP system will be installed in late November 2025 and is expected to go live in Q3 2026, roughly six months after the site opens for operation. knapp.com briscoegroup.co.nz

UniSA on CRC The University of South Australia has been recognised as a major partner in two new Cooperative Research Centres, supported by over $500 million to promote Australia’s manufacturing sector.

UniSA’s Future Industries Institute (FII) will contribute to both the Additive Manufacturing CRC (AMCRC) and the Solutions for Manufacturing Advanced Regenerative Therapies (SMART) CRC. FII Industry Professor Colin Hall will be a key researcher in the AMCRC, which includes 73 industry partners, 14 research organisations, and five government departments, receiving $57.5 million in federal funding and $213 million in partner contributions.

Professor Hall said additive manufacturing is transforming manufacturing processes across multiple industries. “Once limited to plastic prototype parts, 3D printing today includes metal, ceramic and composite materials that are on the cusp of fullscale adoption across Australia’s manufacturing sector,” Professor Hall said. “Additive manufacturing offers significant advantages, boosting productivity, reducing waste and accelerating product development.” The AMCRC will work over the next seven years to optimise processes, develop new materials, and upskill the workforce.

UniSA Business Associate Professor Shruti Sardeshmukh will lead the Sustainable Manufacturing research theme, focusing on integrating environmental, social, and governance principles into manufacturing practices. “By embedding environmental, social and governance principles, 3D printing can fuel innovation, drive business transformation and propel Australian businesses towards a more resilient future,” Associate Professor Sardeshmukh said.

UniSA’s FII researchers will also focus on the CRC’s Surface Technologies and Post-Processing theme, further strengthening collaborations with long-term industry partners, including SMR Automotive, Starke-AMG, EntX, and Laserbond.

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From a biotechnology perspective, FII Professor Allison Cowin will play a key role in the $238 million SMART CRC, which focuses on advancing regenerative therapy manufacturing in Australia.

With $65 million in government funding and $173 million in partner contributions, the SMART CRC unites 63 partners from government, industry, and academia. Professor Cowin said the initiative will drive national growth in the regenerative therapies sector.

“The SMART CRC will accelerate the Australian regenerative therapy industry,” Professor Cowin said. “It will catalyse, drive and co-ordinate a national effort, guiding industry growth in the cell and gene therapy sectors.”

Regenerative therapies aimed at curing diseases by restoring normal cell, tissue, and organ function are expected to drive significant economic and health benefits. The SMART CRC is projected to create 1,500 skilled jobs and generate $4.5 billion in business over the next decade.

UniSA Deputy Vice Chancellor for Research and Enterprise, Professor Peter Murphy, stated that the centres present significant opportunities, especially in light of the planned merger of UniSA and the University of Adelaide into Adelaide University in 2026.

“This is a fantastic outcome for the Australian manufacturing sector and will lead to exciting times ahead, not only for our researchers but for the nation as a whole,” Professor Murphy said.

The Federal Government also announced a third CRC: the Care Economy CRC, which focuses on advancing the care sector through customised technologies, data solutions, and new care models. unisa.edu.au

INDUSTRY NEWS

Rio Tinto iron ore railcar wagon Local railcar manufacturing has hit another significant milestone with the rollout of the first iron ore railcar wagon built

by Perth-based company Gemco for Rio Tinto Iron Ore (RTIO).

Local railcar manufacturing has hit another significant milestone with the rollout of the first iron ore railcar wagon built by Perthbased company Gemco for Rio Tinto Iron Ore (RTIO).

Gemco is set to deliver 100 wagons over the next six years to RTIO, with an initial release of 40 and another 10 every year for six years. This work will also include repairing and refurbishing key wagon components. The State Government has contributed $6.9m to Gemco under the Local Manufacturing Investment Fund (LMIF) to upgrade its Forrestfield facility and establish a new facility in Karratha.

"Diversifying our economy and making more things here are key to our plan to maintain Western Australia as the strongest economy in the nation,” said WA Premier Roger Cook. "Soon, we'll create jobs across WA by building even more things here, like batteries and powerlines. We want to continue diversifying our State's economy, … supporting manufacturing businesses like Gemco."

The State Government has also provided a further $340,929 in LMIF funding to Gemco so it can modernise its railcar wagon manufacturing and maintenance plant and equipment at its Forrestfield premises. This upgrade will help the company deliver 40 iron ore railcar wagons to BHP and allow Gemco to maintain its

position as a local manufacturer into the future. The LMIF - which was a commitment made by the State Government ahead of the 2021 State Election - has awarded more than $13.5 million to metropolitan and regionally based projects. It continues to secure an ongoing stream of work for local fabricators in the manufacturing and maintenance of iron ore railcar wagons.

Through its Made in WA plan, the State Government has committed to expanding local iron ore railcar manufacturing, including through collaborating with other industries like the grain sector to investigate further opportunities.

"By working with and supporting companies like Gemco, our government is realising its ambition of building more things here in Western Australia,” said WA’s Manufacturing Minister AmberJade Sanderson. "We are directly supporting jobs, particularly in Forrestfield, where we have been building our state-of-the-art METRONET C-Series trains and where Western Power will soon begin building the poles and wires needed to power our State's energy transition. It's proof businesses in our booming resources industry are already embracing our vision for a State that builds more things in our own backyard.” riotinto.com.au wa.gov.au

Titomic REPKON Titomic enters teaming agreement with REPKON USA. Titomic Limited has announced the signing of a teaming agreement with REPKON USA Holdings, Inc. (REPKON USA), a leader in advanced metal and defence manufacturing. Titomic is a global leader in cold spray additive manufacturing technology through Titomic Kinetic Fusion.

Under the agreement, Titomic and REPKON USA will engage in joint research, development, and testing of Titomic Kinetic Fusion™ applications in cannon barrels, gun barrels, and warheads. These applications will demonstrate the advantages Titomic Kinetic Fusion™ offers to the defence and aerospace markets in support of the U.S. Government, with potential for other applications.

Titomic and REPKON have a long-standing relationship. In 2021, REPKON invested AUD 2.5 million in Titomic. This teaming agreement replaces the previously agreed Turkish joint venture agreement. It establishes a United States framework to leverage Titomic Kinetic Fusion™ cold spray technology in REPKON USA’s existing and fast-growing product lines.

"Our partnership with REPKON USA represents more than collaboration - it represents a shared commitment to fundamentally transform how we advance and sustain defense manufacturing and provides a more effective combination of our respective leading technologies than the previously announced joint venture," said Jim Simpson, CEO of Titomic. "With Titomic Kinetic Fusion™, we bring a technology that restores, enhances, and builds critical assets faster, smarter, and with greater resilience."

"We are excited to work with the REPKON USA team and begin research and development activities at our facility in Huntsville, Alabama,” added Dr. Patricia Dare, President of Titomic USA. “We are focused on delivering field-ready solutions that ensure mission readiness, extend asset life, and strengthen the U.S. allied industrial base with next-generation manufacturing capabilities."

Through this partnership, Titomic will also work with REPKON USA to leverage Titomic Kinetic Fusion™ for repairing assets in

the field. This capability restores equipment to its original form, fit, and function, providing warfighters with essential capabilities significantly faster and within battlefield or training environments.

In addition to repairs, the teams will collaborate on coatings for REPKON USA barrels, enhancing performance and delivering competitive advantages moving forward.

“As we push for advanced solutions to modernise and improve defence production, Titomic Kinetic Fusion™ cold spray technology is at the top of our list,” Bryan Van Brunt, President of REPKON USA said. “Its advantages, particularly in defense and aerospace applications, are game changers.”

This partnership reinforces Titomic’s position as a leader in advanced manufacturing, coating, and repair technologies, furthering its commitment to providing timely and innovative solutions to defense and aerospace customers worldwide, while supporting REPKON USA’s continued drive to modernize manufacturing techniques in the U.S. and allied defense industrial base. titomic.com

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Kaeser sustainability in compressed air technology Sustainability has become a key priority for industrial operations, with businesses increasingly seeking to minimise their environmental impact while improving efficiency.

Compressed air technology is one area where significant improvements can be made, as air compression can account for up to 30% of a facility’s energy consumption. By optimising system design, reducing leaks, and implementing energy recovery strategies, companies can achieve both environmental and costsaving benefits. This whitepaper explores the fundamental aspects of sustainability in compressed air systems, highlighting energy efficiency, system design, heat recovery, responsible manufacturing, and supply chain practices. The adoption of sustainable practices in these areas enables businesses to lower energy consumption, reduce emissions, and enhance operational performance.

Energy efficiency in compressed air systems The efficiency of a compressed air system is largely determined by factors such as leakage control, pressure drop reduction, and proper system maintenance. Even small leaks can lead to significant energy waste, increasing costs and environmental impact. A welldesigned system, with the appropriate pipe diameter, high-quality materials, and minimal bends, helps reduce pressure drop and enhances energy efficiency. Plastic piping, although cheaper, is more prone to breakage and deterioration, making durable metal piping the better choice for long-term sustainability.

Proper system design ensures minimal turns, sufficient bracing, and flexible fittings to reduce vibration. Planning for future expansion during the initial installation phase also contributes to sustainability, as it is more resource-efficient to upgrade an existing system rather than replace it entirely when demand increases.

Maximising energy reuse Heat recovery offers one of the most effective ways to improve energy efficiency in compressed air technology. As much as 96% of the energy used for air compression is converted into heat, much of which can be captured and repurposed. Waste heat can be redirected for space heating or integrated into hot water systems using plate heat exchangers, allowing businesses to repurpose up to 76% of installed compressor power without additional energy consumption.Beyond heating office and industrial spaces, recovered heat can also be used in drying processes, hot air curtains, or for preheating burner combustion air in heating systems. These applications significantly improve overall energy efficiency, helping businesses reduce their environmental footprint and operational costs.

Smart technology and Industry 4.0 Advancements in digitalisation are transforming energy management and efficiency in compressed air technology. AI-powered remote monitoring systems enable businesses to track air consumption patterns, detect leaks, and identify inefficiencies in real time. This data-driven approach allows for proactive maintenance, minimising unscheduled downtime and optimising system performance.

Smart control systems further enhance energy efficiency by adjusting compressor operation based on demand, ensuring minimal energy waste. A properly optimised compressor system can reduce CO2 emissions by as much as 73%, resulting in substantial energy savings and a significantly lower carbon footprint.

Sustainable manufacturing and supply chain Sustainability in compressed air technology extends beyond system operation to include responsible manufacturing, packaging, and supply chain management. Sustainable manufacturing practices

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Efficient use of energy is not only crucial for the environment but is also becoming an economic necessity.

incorporate renewable energy sources, such as solar and wind power, to reduce emissions and improve efficiency. Waste reduction strategies, including resource-efficient production processes and thoughtful disposal methods, further contribute to environmental responsibility.

Traditional packaging materials, such as polystyrene foam and plastic wrap, contribute to microplastic pollution and landfill waste.

More sustainable alternatives, including biodegradable bubble wrap, honeycomb cardboard, and paper-based packing tape, provide viable solutions that reduce environmental impact. The transport sector, one of Australia’s largest sources of greenhouse gas emissions, can also play a role in sustainability through the use of electric delivery fleets powered by renewable energy or by participating in carbon offset programs.

Waste oil management and environmental compliance Managing waste effectively is essential for environmental compliance and sustainability in compressed air systems. Large volumes of oilcontaminated condensate are generated during compressed air production, requiring advanced filtration technologies to prevent contamination and extend system longevity. Intelligent monitoring systems provide real-time tracking of filter saturation levels, ensuring optimal efficiency while reducing unnecessary filter replacements.

Safe disposal and recycling are also key aspects of responsible waste management. Engaging EPA-approved oil recycling companies ensures that waste oil is processed safely, reducing overall environmental impact.

Conclusion Sustainability in compressed air technology encompasses multiple facets, including energy efficiency, system optimisation, heat recovery, responsible manufacturing, and social responsibility.

Implementing smart controls, energy recovery methods, and sustainable materials can significantly reduce a company’s carbon footprint while improving operational efficiency.

As global sustainability targets become more stringent, businesses must embrace energy-efficient solutions, eco-friendly supply chains, and responsible waste management strategies. The future of compressed air technology depends on innovation, sustainable practices, and a commitment to reducing environmental impact while maintaining cost-effectiveness and reliability. au.kaeser.com

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ECI Solutions on secure ERP Why manufacturers must embrace ERP to optimise resources and secure skilled workers.

Australian manufacturing businesses face increasing difficulty finding skilled workers. Labour shortages are a persistent challenge, with younger generations showing little interest in traditional shop floor roles, leaving businesses struggling to maintain production schedules. Gaps in the skilled workforce make it harder to meet demand as businesses risk delays, inefficiencies, and higher costs without adequate resources and human capital. This is compounded by existing talent retiring or leaving the workforce, taking valuable knowledge with them. Businesses need to adapt, using technology to bridge this gap and futureproof their operations. That’s where modern enterprise resource planning (ERP) solutions can help, according to ECI Solutions.

“Manufacturers that integrate ERP systems can mitigate the impact of labour shortages by automating processes and optimising existing resources,” said Andrew Mamonitis, APAC vice president of manufacturing at ECI Solutions. “ERP platforms provide complete visibility across production, inventory, and workforce management, letting businesses operate efficiently with fewer resources. They give teams access to real-time data for better decision-making, reduced downtime, and increased productivity without relying solely on additional staffing.”

It’s not uncommon for manufacturers to resist investing in new technology, fearing the costs, disruption of change, or even greater efficiency will lead to job losses, making staff hesitant to adopt new systems. However, an effective ERP implementation is about empowering people, not replacing them. Automation handles repetitive tasks, freeing up skilled workers to focus on higher-value activities and letting businesses upskill existing staff instead of eliminating jobs, making them more productive and engaged.

“One of the biggest challenges in manufacturing today isn’t just finding workers; it’s equipping them with the right skills,” Andrew Mamonitis said. “An ERP system makes operations more structured and accessible, reducing the need for manual workarounds and making it easier for staff to adapt. Manufacturers that invest in technology to support their teams will be the ones that remain competitive.”

A modern ERP system also plays a critical role in attracting new talent. Younger workers entering the job market expect digital tools to be part of their daily workflow. Companies relying on outdated manual processes struggle to appeal to a workforce that values efficiency, automation, and data-driven decision-making.

Manufacturers can position themselves as forward-thinking employers that invest in both their people and their technology by demonstrating a continued commitment to innovation.

However, skilled labour shortages are not just about recruitment; retaining experienced workers is just as crucial, and employees who feel valued and see opportunities for growth are more likely to stay. ERP platforms streamline processes, reduce frustration, and provide structured training pathways, helping manufacturers retain their workforce. Upskilling programs supported by ERP systems can help employees transition into new roles, letting manufacturers keep the talent they need to remain productive.

“The industry is changing rapidly, and manufacturers that fail to evolve risk being left behind,” said Andrew Mamonitis. “Investing in ERP is as much about creating an environment where employees feel supported and can develop their skills as it is about improving efficiency and productivity. Staff that see that technology is there to help them, rather than replace them, are more engaged and open to change.”

ERP systems also address a major issue in manufacturing: production planning. Many manufacturers struggle with scheduling due to unpredictable stock levels, machine availability, and workforce constraints. ERP platforms integrate these factors into a single system, making it easier to manage production timelines and prevent bottlenecks. This lets manufacturers make informed decisions based on real-time data rather than relying on outdated spreadsheets or siloed information.

This level of visibility is essential for long-term business resilience, giving manufacturers scalable solutions that can adapt to changing demands as the industry becomes increasingly complex. However, an ERP system is not a one-time implementation; it’s one that requires ongoing updates and optimisation to evolve alongside changing business needs. Manufacturers that view ERP as a strategic investment will be better positioned to navigate future challenges compared to their counterparts that see it as a shortterm fix.

“An ERP system is not a set-and-forget solution. Businesses evolve, and their systems need to evolve with them,” Andrew Mamonitis said. “Those that continuously refine their ERP setup, train their staff, and integrate new capabilities will be the ones that thrive in the long run. Manufacturers that bridge the skills gap through automation, upskilling, and process optimisation will reduce reliance on hardto-find talent while making their operations more attractive to new workers, securing their future.” ecisolutions.com

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Itron Australia’s water future with AI and ML. Itron's Area Vice President, ANZPI & Strategic Markets, Alex Beveridge explains.

Australia, the driest inhabited continent, is grappling with increasing challenges in securing its water future. A volatile combination of climate change, increasing incidence of extreme weather events and rising demand for water is putting the nation’s resources under immense strain. As droughts intensify and rainfall become more unpredictable, urgent action is needed to ensure long-term, sustainable water security for a country that is the world’s secondhighest per capita consumer of water.

Globally, water demand will surge by 73% by 2050, from 1,500 to 2,650 gigalitres. Australia’s manufacturing sector, the largest consumer of water, used 626 gigalitres in 2022 – the latest year for which such figures are available. The stakes are rising with the sector expected to grow at a compound annual growth rate (CAGR) of 1.54% between 2025 and 2029. This increasing demand heightens the pressure on the nation’s already strained water resources.

The manufacturing conundrum – Balancing growth with sustainability Manufacturing is a crucial pillar of Australia’s economy, contributing 5.38% to the nation’s GDP in 2023. According to the Jobs and Skills Australia November 2024 report, the sector employs close to 900,000 people. However, its water-intensive processes, such as cooling machinery, washing raw materials, and chemical processing, present significant challenges. These are exacerbated by ageing infrastructure, inefficient water use and reliance on natural sources vulnerable to climate extremes. As the sector grows, balancing rising water demands with limited supply and climate change is vital. How can manufacturing thrive and continue to drive the economy while conserving water?

Australia’s government has recognised the urgency of this issue, committing $519.1m over eight years through the Future Drought Fund to support climate-resilient water infrastructure.

Beyond infrastructure investments, collaborative initiatives like the Australian Water Partnership (AWP) bring together over 240 partners to address sustainable water management challenges, fostering shared solutions that integrate innovation and climate resilience. Manufacturers can implement water-efficiency and waste-reduction programmes using accurate data, ensuring compliance and sustainability. Effective water management is increasingly dependent on technologies like artificial intelligence (AI) and machine learning (ML). Itron, a global leader in smart resource management, helps manufacturers via their water utility to optimise water usage and improve sustainability by integrating these technologies into their operations. By raising awareness and providing tools for sustainable management in Australia, the company plays a key role in promoting water conservation across its diverse climate regions. Through intelligent networks, innovative metering systems and real-time data analytics informing water utility management, these interoperable solutions enable manufacturers to monitor consumption, detect inefficiencies, and manage distribution systems with remarkable precision.

A significant challenge is the loss of treated water in distribution systems, where up to a third is wasted due to leaks. This inefficiency places additional pressure on operations, especially in water-scarce areas like Australia. In response, AI and ML-powered systems help manufacturers swiftly detect leaks and take immediate corrective actions to minimise water waste. Itron’s Advanced Metering Infrastructure (AMI) and smart water meters provide the manufacturing industry real-time insights received via their water utility, empowering manufacturers to optimise water usage across

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production processes. By integrating predictive analytics, its technology helps manufacturers analyse massive volumes of data to forecast water demand trends, enabling better planning during peak periods, mitigating risks, and improving operational efficiency while reducing costs and preserving essential resources.

These innovations are already making a difference. According to Itron’s 2024 Resourcefulness Insight Report, 82% of Australian utilities believe AI and ML are vital for overcoming water management challenges, while 67% have begun adopting these technologies.

Predictive maintenance, demand forecasting, and real-time anomaly detection are among the most widely implemented applications.

AI user cases for securing water in Australian manufacturing AI is smart and will be smarter tomorrow. Its transformative role in water security is evident across several critical areas. Australia’s manufacturing hubs, particularly in flood-prone areas like New South Wales and Queensland, face escalating risks from extreme weather events. Traditional risk assessments often rely on outdated data, missing the complexities of future climate patterns. AI’s predictive modelling can analyse weather, topography and climate variables, enabling manufacturers to adapt operations, protect facilities and minimise flood disruptions.

Recycling water is essential for manufacturers aiming to meet sustainability targets and comply with stricter water regulations.

AI-driven systems monitor water quality in real-time, ensuring wastewater treatment meets reuse standards. A chemical manufacturer could use AI to ensure treated water is suitable for reintroduction into production cycles, reducing reliance on freshwater.

AI also optimises asset management and water allocation in manufacturing. It helps prioritise infrastructure maintenance and reduces waste by monitoring water usage. In mining operations, AI tracks water use during mineral processing, conserving resources without compromising production.

Driving a sustainable, water-efficient future with AI The era of AI for utilities has arrived, with its strategic use vital for enhancing safety, boosting consumer engagement and achieving lasting sustainability. AI and ML provide a powerful solution to Australia’s water scarcity challenges by enabling industries to optimise water usage and adapt to shifting climate realities.

By embracing innovation and harnessing smart, data-driven technologies, utilities can lead the way in next-generation resource management. This commitment will secure industries, preserve vital resources and pave the way toward a resilient, water-efficient economy for generations to come. aunz.itron.com

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Manufacturing meets AI DMS manufacturing supply chain maturity score: Aligning technology with supply chain maturity.

Elton Brown, DMS Senior Business Consultant explains.

Artificial Intelligence (AI) is revolutionising supply chain planning, but a one-size-fits-all approach doesn’t work. AI isn’t just for highly advanced supply chains; regardless of maturity, every company can benefit. The key is aligning AI adoption with current capabilities rather than rushing into advanced solutions without a solid foundation.

However, blindly implementing AI—without understanding your supply chain maturity or selecting the right technology partner—can be risky. AI success depends on choosing tools suited to your needs and ensuring proper integration.

The Five Levels of Manufacturing and Supply Chain Maturity and AI Readiness A Supply Chain Maturity Model helps businesses assess where they stand and determine what AI can offer at each stage. While various models exist globally (Gartner, Oliver Wight, Deloitte, PwC, SCOR), the DMS Manufacturing Supply Chain Maturity Score is tailored to Australian and New Zealand manufacturers. This model evaluates people, processes, technology, strategy, and collaboration, helping businesses identify strengths, weaknesses, and AI opportunities.

Here’s how AI fits into each maturity stage: 1. Disjointed Manufacturing Supply Chains (Low Maturity) Limited processes, poor visibility, reactive decision-making. At this stage, supply chains operate in silos, with minimal data integration, leading to inefficiencies. AI adoption should focus on basic automation and data cleansing to improve visibility and reduce manual work.

AI Focus: Data standardisation, rule-based automation, entrylevel reporting tools.

Risk if ignored: Implementing complex AI without a strong data foundation leads to poor recommendations and inaccurate insights.

2. Rudimentary Manufacturing Supply Chains (Basic Maturity) Some digital tools, manual forecasting, limited data-driven decision-making. Companies at this level often use ERP systems but lack integrated planning tools, relying on spreadsheets. AI should focus on proven statistical models for demand forecasting and replenishment, reducing reliance on intuition.

AI Focus: Predictive analytics, demand forecasting, replenishment automation.

Risk if ignored: Without AI-driven forecasting, companies struggle with stockouts and excess inventory, increasing carrying costs.

3. Defined Manufacturing Supply Chains (Intermediate Maturity) Structured processes, better visibility, improving collaboration. These supply chains have well-established processes and some digital integration but lack agility. AI can optimise inventory, automate purchasing, and enhance visibility.

AI Focus: Machine learning for inventory optimisation, nearreal-time demand sensing, automated exception management.

Risk if ignored: Without AI-powered automation, supply chains remain slow to react to disruptions, missing efficiency gains.

4. Dynamic Manufacturing Supply Chains (Advanced Maturity) End-to-end digital integration, data-driven decisionmaking, agility in responding to changes. Companies at this stage use real-time data for decision-making but still rely on human intervention. AI should now enable scenario modelling, automated decision-making, and prescriptive analytics.

AI Focus: Digital twins, advanced prescriptive analytics, AIdriven scenario planning.

Risk if ignored: Without AI decision-support tools, companies may struggle to scale efficiently and stay competitive in fastchanging markets.

5. Visionary Manufacturing Supply Chains (Best-in-Class Maturity) AI-driven, autonomous operations, proactive risk management. At this level, AI isn’t just a tool—it drives decision-making. Supply chains operate autonomously, responding to live data and market conditions.

AI Focus: Autonomous planning, continuous network optimisation, intelligent order response.

Risk if ignored: Companies failing to reach this level risk falling behind AI-native competitors using AI for full decision automation.

Avoiding the Pitfalls of Poorly Aligned AI Adoption AI delivers value at every maturity level, but misalignment can backfire. Common pitfalls include: • Investing in AI that doesn’t match maturity: Deploying an AIpowered digital twin when data is fragmented won’t yield results. • Lack of integration with existing systems: AI should enhance ERP, WMS, and TMS systems - not operate in isolation. • Resistance to AI adoption: AI success requires executive buy-in and workforce upskilling. Companies failing to train teams on AI adoption are 2.5x more likely to struggle with implementation (Oliver Wight, 2023).

Selecting the right technology partner is as critical as selecting the right AI. The best partners tailor AI adoption to your current state while building a roadmap for future advancements.

Finding the Right AI Strategy for Your Manufacturing and Supply Chain AI is for everyone—but not all AI is for everyone. Success lies in matching AI solutions to your current capabilities while preparing for the next level of maturity. Instead of asking, “Is my supply chain ready for AI?” - the better question is: “What kind of AI is right for my manufacturing and supply chain?”

With the right AI solution - aligned to your maturity level and supported by the right partner - your supply chain can increase efficiency, reduce risk, and build long-term resilience.

Final Thoughts AI is no longer a futuristic vision - it’s here and accessible to all supply chains. By assessing where you are today and implementing AI aligned to your maturity level, you can unlock its full potential while avoiding misalignment and wasted investment.

So, where does your supply chain sit on the DMS Manufacturing Supply Chain Maturity Score? The answer could shape your AI journey for the future. manufacturingmaturityscore.com

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TECH NEWS

USA: Scientists observe water molecules flipping before they separate, pointing out how to produce more affordable hydrogen fuel.

Scientists have observed water molecules splitting in real time to form hydrogen and oxygen. Just before they split, the molecules did something entirely unexpected: They flipped 180 degrees. This micro acrobatic stunt requires energy, which explains why splitting water demands more energy than theoretical calculations indicated.

The researchers suggest that further study could provide vital insights into enhancing the efficiency of splitting water molecules— paving the way for more affordable, clean hydrogen fuel.

Hydrogen possesses several key properties that render it an attractive source of green energy. This energy-rich fuel can power trucks and even cargo ships, and it stands as the sole alternative to fossil fuels in industries such as steel and fertiliser manufacturing.

When burned, the fuel emits water instead of carbon dioxide.

Australia: Animal strength in medical robotics University of Queensland researchers have created shape-shifting liquid metal robotics with musculoskeletal qualities inspired by animal physiology. Dr. Ruirui Qiao and her research team at the Australian Institute for Bioengineering and Nanotechnology (AIBN) have used the technique to make medical rehabilitation components and devices with superior strength and flexibility. “We set out to mimic the locomotion, flexibility and control of mammalian movement,” Dr. Qiao said.

The AIBN team created a gallium-polymer composite by combining ‘soft’ spherical liquid metal nanoparticles with ‘rigid’ rod-like gallium-based nanorods during 3D printing. This composite mimics the interconnected structure of bone and muscle, enhancing animal efficiency and strength. It holds potential for advanced medical rehabilitation products, including high-precision grippers for prosthetic limbs. Similar to Dr. Qiao’s previous studies on liquid metal, the newest advancements can take on and retain different shapes and functions when exposed to stimuli such as heat and infrared light. Dr. Qiao notes numerous manufacturers draw inspiration from the movement mechanisms observed in nature's soft-bodied animals.

“But making hybrid structures is very challenging due to limitations in material selection as well as the complex, multi-step processes involved in traditional manufacturing methods,” she said. “We developed a new method to mimic animal physiology to benefit our own technology using a quick and simple manufacturing process.”

However, the steep energy requirements for hydrogen production significantly limit the scale at which the fuel can be produced.

According to the International Energy Authority, 322 million tonnes of hydrogen fuel must be generated annually to satisfy global energy needs. Yet, in 2023, only 97 million tonnes were produced at a monetary cost 1.5 to six times higher than fossil fuel production— and the vast majority of it was also made using fossil fuels.

Hydrogen fuel is produced by adding water to an electrode and then splitting the water with an applied voltage into hydrogen and oxygen. This process is most efficient when the chemical element iridium is used as a catalyst for the oxygen evolution reaction, which cleaves oxygen from water molecules. However, iridium only arrives on our planet through meteorite impacts, making it expensive and rare. However, even when using iridium, the process is less efficient than scientists believe it ought to be. “It ultimately consumes more energy than what is theoretically calculated. If you do the sums, it should require 1.23 volts. However, in practice, it needs closer to 1.5 or 1.6 volts,” noted study lead author Franz Geiger, a professor of chemistry at Northwestern University. “Covering that extra voltage incurs a cost, and that's why water splitting hasn't been done on a large scale.”

To better understand the energy requirements of this process and why it is less efficient than theory suggests, the researchers placed water on an electrode inside a container and measured the positions of the molecules using the amplitude and phase of laser light directed at them.

When the scientists applied a voltage across the electrode, they observed that the molecules flipped and rotated rapidly so that their two hydrogen atoms in contact with the electrode faced upwards while the oxygen atom faced downwards.

Science Advances

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Dr. Qiao stated that soft-rigid polymer composites, due to their ease of fabrication and possible uses, have the potential to transform the hybrid soft materials field and speed up advancements in soft robotics. “We would like to see research that advances 3D printing technologies and design strategies, focusing on increasing the proportion of metal-based nanoparticles within the 3D-printed composite,” she said. “This will further enhance responsive properties and ultimately improve the performance of hybrid soft robots.”

Advanced Materials

Australia: AI-powered breath test could detect silicosis early A new diagnostic tool developed by physicians and scientists from UNSW Sydney that analyses a person’s breath for signs of silicosis has the potential to catch the disease earlier rather than wait for irreversible lung damage to appear. Researchers Professor William Alexander Donald and Conjoint Professor Deborah Yates present a rapid, AI-powered breath test that could revolutionise the diagnosis of silicosis. This test merges mass spectrometry—a scientific technique used to analyse molecules—with AI to quickly detect silicosis from breath samples, offering a fast and non-invasive diagnostic tool for workers at risk.

TECH HEADING NEWS In the years ahead, DNA data storage could quietly reshape how digital information is preserved. Large cloud providers may shift to DNA for deep storage, reducing data centre footprints and energy usage. Your data, from family photos to medical records, could one day be stored safely and permanently in a fingernail-sized vial.

Perhaps most importantly, DNA storage offers humanity a chance to preserve knowledge, history, and culture for centuries to come in a medium that will never become obsolete.

Fifth Quadrant

Australia: New liquid catalyst transforms chemical manufacturing

Unlike traditional methods such as X-rays and CT scans that detect silicosis at later stages, the UNSW-developed test provides results in minutes. Silicosis, a lung disease caused by inhaling tiny crystalline particles of silicon dioxide, poses a significant occupational health risk in Australia, with cases now extending beyond just engineered stone workers to those in tunnelling and construction.

The Australian government has implemented a ban on engineered stone; however, with new cases arising in other high-risk industries, there is an urgent need for improved diagnostic tools.

“Our study shows that the AI-driven model accurately distinguished silicosis patients from healthy individuals based on their breath profiles, providing a reliable tool for early detection, “ lead researcher Prof. Donald from UNSW’s School of Chemistry said. “This suggests that breath testing could be a practical tool for large-scale worker screening and early intervention.”

The study analysed breath samples from 31 silicosis patients and 60 healthy controls, confirming the test’s high accuracy in distinguishing between affected and unaffected individuals.

Participants exhale into a bag that is then tested for silicosis using the new technology. The breath content is subsequently pushed into a mass spectrometer, which detects the various molecules present. “In human breath, there are thousands of organic molecules that you breathe out,” Prof. Donald said. “Our instrument can profile someone’s breath, and then we feed that into an artificial intelligence algorithm that finds patterns. In this case, it’s looking for patterns in the organic compounds present in people's breath in the early stages of silicosis. And we’re getting very high accuracy, like over 90%, for just such a simple, non-invasive breath test.”

Journal of Breath Research

Researchers at Monash University, the University of Sydney, and RMIT University have developed a liquid catalyst that could revolutionise chemical production across various industries – from pharmaceuticals and sustainable products to advanced materials materials. The team, led by Associate Professor Md. Arifur Rahim from Monash University’s Department of Chemical and Biological Engineering, created a self-regenerating catalytic system with unprecedented efficiency by dissolving palladium in liquid gallium.

The new catalyst displayed exceptional performance in SuzukiMiyaura cross-coupling reactions – a Nobel Prize-winning method for forming carbon-carbon (C‒C) bonds, which are crucial in pharmaceuticals, agrochemicals, and materials science.

"This advancement is poised to revolutionise chemical manufacturing, providing faster, safer, and more sustainable production across industries, ranging from pharmaceuticals to advanced materials," quotes senior co-author Professor Kourosh Kalantar-Zadeh.

Their breakthrough, published in Science Advances, could revolutionise the production of essential products across industries, ranging from life-saving pharmaceuticals and eco-friendly agrochemicals to advanced materials such as plastics, polymers, and electronic components.

“This new catalyst takes advantage of the unique fluid-like behaviour of palladium atoms in a liquid gallium mixture, making it exceptionally effective at speeding up reactions – accelerating them up to 100,000 times faster than the best existing palladium catalysts,” Associate Professor Rahim said. "We found that palladium atoms would sit just below the liquid surface, activate the gallium atoms above, and the reaction would happen there,” senior co-author from RMIT Dr Andrew J. Christofferson said. “This is completely different from a solid-state catalyst."

The researchers aspire for their work to inspire additional innovations in catalyst design, paving the way for greener and more efficient industrial processes globally.

Science Advances

Australia: An answer to the data crisis Since 2010, the world has been facing a growing data crisis, with the amount of digital data produced globally far outpacing our ability to store it. Recent estimates suggest that over 402 million terabytes of data are generated daily. To put this into perspective, the volume of data we generate every three days equals the total amount of data that had ever existed in 2010. With IT leaders expecting their organisations’ data storage needs to double by the end of 2026, leading cloud service providers – Amazon, Microsoft, and Google – are battling to futureproof their energy supply by investing heavily in scalable clean energy solutions.

As data generation continues to outstrip storage capacity and consume enormous energy, an unexpected solution may be found in one of nature’s oldest technologies.

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PRODUCT NEWS

Static meter New digital static meter offers precise measurement and simple usage.

Static electricity isn’t just a nuisance; it’s a serious threat to manufacturing efficiency, product integrity and workplace safety.

Unchecked static can lead to costly downtime, product defects, material jams and even hazardous shocks to employees. If static interferes with your processes, EXAIR’s upgraded Model 7905 digital static meter offers an essential first step in identifying and eliminating the problem.

With just the press of a button, this easy-to-use, handheld device pinpoints the highest voltage areas in your facility, helping you diagnose static issues before they escalate. The digital static meter detects surface voltage and polarity on objects up to ±20 kV, providing immediate LED-illuminated readings for quick and accurate troubleshooting. The new digital static meter features an infrared beam to ensure measurements are taken from the optimal one-inch distance for precise readings. Certified for accuracy by the National Institute of Standards and Technology (NIST), this highly sensitive instrument guarantees accurate static measurements, allowing you to take proactive steps toward eliminating costly disruptions in your operations.

EXAIR offers a full range of static eliminators, including super ion air knives, Intellistat® ionizing air guns for clean rooms, ionizing bars, ion air cannons, and ion air guns – all designed to neutralise static and improve process reliability. caasafety.com.au

Kaeser M250E portable compressor Mobile e-power up to 132 kW with the M250E portable compressor.

Exhaust-free and quiet compressed air production – wherever you need it. That's what you get with the Mobilair electric-drive portable compressors by KAESER Compressors.

The drive units of the 132 kW M250E portable compressor consists of a highly energy-efficient IE4 electric motor and a Sigma Profile airend that has consistently proven itself in industrial rotary screw compressors. Depending on the combination and pressure range, the M250E delivers flow rates of up to 25 m³/min at 8.6 bar and 16.2 m³/min at 14 bar.

“What sets these units apart from the industrial rotary screw compressors typically installed in closed compressor rooms, is the defining features of a MOBILAIR compressor by Kaeser,” said Ronald van Wyk, KAESER Australia’s Mobilair Sales Manager.

“These compressors are purpose-built for outdoor installations, meaning they can withstand wind and weather without any issues – whether it's the body or the controls.”

True to its MOBILAIR roots, the M250E is also built to be moved quickly and easily from place to place. The galvanised skids with forklift slots, fitted as standard, and the crane lifting eye are a big help when loading and unloading. The narrow footprint is optimised for transport. Two units can be placed side by side on a truck bed, and the rigging eyelets ensure that they arrive safely.

The M250E can be used for a wide variety of applications, from temporary use in industry to handle breakdowns or peak production periods, to permanent outdoor installations. Van Wyk says the unit’s versatility sees it being used, “for almost anything!

From sandblasting to tunneling, everywhere from mines to inner city sites where sound restrictions apply.”

The closed floor pan, supplied as standard, is there for all eventualities to protect the environment against spills. The aftercooler with centrifugal separator, supplied as standard, extracts moisture from the air. And the optional filter combination

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The M250E provides exhaust-free and silent compressed air production at any desired location.

for oil-free compressed air is installed within the compact body of the unit. All controls, maintenance points and connection points are conveniently accessible. Power is easily connected via quick-lock sockets and for safety, there is also an external isolator switch.

A connection to a master controller is also provided – making the MOBILAIR M250E a team player. The unit can be equipped with a modem for connection to Industrie 4.0 systems. This can be connected directly either to the KAESER Sigma Air Manager, or to an in-house Telematics system, including the precise physical location of the unit. The system also provides valuable data such as duty-cycle analysis, maintenance planning and remote diagnostics. au.kaeser.com

PRODUCT NEWS

Air leak detection Teledyne Tech’s FLIR Si1-LD acoustic imaging camera for compressed air leak detection.

This new acoustic imaging camera helps professional inspectors locate smaller compressed air leaks.

FLIR, a Teledyne Technologies company, has introduced the Si1LD, an industrial acoustic imaging camera that provides faster and more accurate compressed air leak detection for those on a modest condition monitoring budget. The new FLIR Si1-LD offers enhanced detection and quantification capabilities compared to the existing FLIR Si124-LD Plus, as well as a higher upper frequency limit.

Compressed air systems typically lose 25–30% of their air due to leaks, leading to proportionally higher energy bills, costly unplanned production stoppages, shorter compressor lifespans, the need to purchase additional compressor capacity, and increased maintenance expenses for the extra equipment.

Leveraging the advantages of ultrasonic technology, the new FLIR Si1-LD pinpoints leaks with enhanced imaging sensitivity at an affordable price. It offers several stand-out capabilities and features: •

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An array of 96 microphones (2–100 kHz) enables the automatic detection, location, and measurement of compressed air and vacuum leaks from a safe distance of up to 130 metres. It is supported by a 12MP colour camera with 8× digital zoom and an LED lamp to easily capture visual details.

Bandpass filtering enables inspectors to filter out confusing or incorrect ultrasound sources without the need for manual tuning. It is particularly effective for challenging leak detection applications where user input is beneficial. On rare occasions, the inspector can manually adjust the bandpass filter to tune the required frequency range and display the source of interest as needed.

The lightweight and compact FLIR Si1-LD ultrasonic imager features singlehanded operation and industryleading AI, making it easy to use with minimal trainingperfect for fastpaced inspections across large facilities.

The touch-screen interface displays highresolution images for easy identification of issues. It also quantifies leak volume flow rates and annual leak costs in real time on the device.

Users can leverage this data to prioritise repairs. Additionally, the data is suitable for inclusion in sustainability reports to reflect energy reduction initiatives.

Wireless data transfer enables seamless reporting and analytics options, utilizing either the online FLIR Acoustic Viewer or the offline FLIR Thermal Studio for effortless data backup and organisational team sharing, while also serving as the

backbone for Over The Air (OTA) firmware updates.

The software allows users to create reports using pre-built or fully customisable templates.

“Many manufacturing and process plants are experiencing rising energy bills due to leaky compressed air systems, which increase OPEX [operational expenditure] and erode margins,” said Darrell Taylor, Global Acoustic Business Development Manager at FLIR. “If you wish to locate leaks quickly and easily with minimal technician training, our new Si1-LD industrial acoustic imaging camera offers a fast and precise solution that supports sustainable manufacturing.

In addition to reduced energy consumption, the new device helps you save on maintenance, repair, operation, and capital/OPEX costs, all while enhancing worker safety. With its minimum detected leak rate [MDLR] of 0.01 L/min at 2.5 m, our Si1-LD provides the market’s best combination of performance and ease of use at its price point.”

The new acoustic imaging camera includes two batteries, an additional battery cover, a battery charger, a camera neck strap, a hard case, a USB memory stick, access to both free online and offline acoustic analysis and reporting software, and a twoyear warranty. A new accessory is the data transfer cable. This convenient cable enables users to connect directly from the camera to a PC or laptop, facilitating easy file access in organisations that prohibit the use of WiFi and USB drives. Users can upload their acoustic images into the FLIR Thermal Studio software or the FLIR Acoustic Viewer. flir.asia/Si1-LD/

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AMW2025 REVIEW

AMW2025 Melbourne

Melbourne turned it on for the manufacturing industry all week in early May. What a week. We knew the Melbourne show would be huge, but the sense of scale only really hit us when ‘bump-in’ began late the previous week. Shane Infanti, bringing his long experience of show preparation, told us later he walked 157kms over the week.

Ultimately, 381 companies joined the show’s diverse range of exhibitors, with 12,531sqm of floorspace sold in record time, and 1,148 people downloaded the AMW Expo App. 12,572 visitors created My Show Planner profiles to save over 1.9m AMW features of interest to their Show Planners.

11,588 carpet tiles were laid for the show, and 3,823 wall panels were installed, and over 10 tonnes of recyclable material were generated and around 17km of three-phase electrical cable was installed for the event.

AMTIL CEO Lorraine Maxwell

asking this very question. Ask ten different people, and you’ll receive ten different responses—each shedding light on a different facet of our reality.

“The diversity of opinions reflects the dynamic environment in which we operate. Some argue that our technology is not just surviving but thriving—a testament to relentless innovation and the pursuit of excellence. Others caution that while adoption of advanced technologies is transforming production processes, the sector remains in a state of profound flux, grappling with global competition, skills shortages and supply chain uncertainties.

CEO’s welcome

“These disparate views remind us that manufacturing technology is a living, evolving entity—constantly adapting to market forces, regulatory shifts, and economic pressures. I contend that the industry is undergoing a transformation. Parts are growing, parts are contracting. Some parts are automating, while others never will.

AMTIL CEO Lorraine Maxwell introduced the Hon Colin Brooks, Victorian Minister for Industry and Advanced Manufacturing, to officially open AMW2025. Maxwell spoke briefly beforehand about the vital community of manufacturers she has come to know over her first year in the job. “When asked, ‘Is manufacturing technology in Australia thriving, surviving, transforming, growing, or even declining?’, experts and practitioners alike offer varied answers,” she said. “Since joining AMTIL, I’ve been on a listening tour and

“Skills are in shortage, and we are in competition not with each other but with other industries for those skills. The stereotype of manufacturing has undergone a significant transformation. Large production lines and commoditised manufacturing are in decline – and have been for more than a decade. Instead, high-value-added, small-run, high-tech, clean tech is the new norm. At the heart of it all, it’s also about creating a shared vision and a narrative that is future-focused and not anchored in the regrets of the past.”

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AMW2025 REVIEW

16,105 ATTENDEES

38 6 ZONES SPEAKERS FUTURE SOLUTIONS SPEAKER PROGRAM 2700+ ATTENDEES

ALMOST 400 EXHIBITORS

Minister Colin Brooks “It's great to be here to officially open Australian Manufacturing Week for 2025 with nearly 400 exhibitors at the show here this week,” said Minister Brooks. “I was reliably informed that this is the biggest manufacturing week ever. Our government is proud to sponsor this event and provide a vital platform for the manufacturing sector.

We are holding this advanced manufacturing event in the nation's manufacturing capital. Of course, there’s coffee for our culture and our great sporting events, but we are, of course, also home to the biggest employing manufacturing sector in the country, made up of more than 23,000 businesses and employing some 273,000 people. The manufacturing sector is the driving force for the state's economy. It contributes 6% to our gross state product and exports nearly $26bn worth of goods. Manufacturers are thriving in Victoria, with employment in the sector growing by some 10% in the two years to the end of 2024. As a new minister in this portfolio, I’ve been travelling around visiting numerous manufacturing facilities.

I've heard loud and clear about the challenges in the sector and how the government can do more. I will be taking action on those fronts. We know in an uncertain world that resting on our laurels is never an option. Therefore, the Victorian government released Victoria's economic growth statement last year, which seems to be a clear signal for reviewing this.

“I challenge each of you, whether you are a precision manufacturer, a technology innovator, or a policymaker, to view these diverse insights as opportunities. Every perspective provides a lesson on where we have been, where we are, and where we can go together.

The Hon. Colin Brooks MP Minister for Industry and Advanced Manufacturing

Let us harness our collective expertise, resilience, and unwavering commitment to excellence. By investing in transformative technology, nurturing our most valuable asset—our people—and forging robust partnerships, Australia’s manufacturing technology sector can not only survive and thrive but also be healthy for the generations to come.

The actions we take today will define the legacy we leave tomorrow.

Together, we can transform challenges into breakthroughs and uncertainty into groundbreaking innovation.” australianmanufacturingweek.com.au

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AMW2025 REVIEW

MELBOURNE

Machine Tools Welcome to the Machines! The largest and the original Zone at Australian Manufacturing Week.

Combining fabrication, rolling, cutting and everything inbetween.

The range and scope of hardware being shown and demonstrated in the Machine Tools zone at AMW2025 is Visitors to Hi-Tech Metrology’s stand experienced firsthand how the Creaform HandySCAN BLACK 3D scanner delivers unparalleled results for quality control, reverse engineering, and product development. It is recognised for its exceptional accuracy, speed, and portability. Also on display from Creaform is the HandySCAN MAX 3D scanner.

Designed to meet the needs of industries handling large components, this innovative scanner features improved performance, faster scanning speed, and a wider field of view. The Micro-Vu Vertex optical CMM distinguishes itself as both a non-contact and contact measurement solution that sets new standards in precision measurement.

With its ability to capture intricate details with utmost accuracy, the Micro-Vu Vertex fulfills the growing demand for reliable and efficient quality assurance processes.

Adding another layer to Hi-Tech Metrology's portfolio, the IP54-class Hexagon Absolute 80-series Arm with AS1 laser scanner is designed for flexibility and ease of use. This advanced tool allows manufacturers to conduct accurate measurements directly on the shop floor. Coupled with worldleading PolyWorks point-cloud software, users can streamline inspection processes and enhance overall production efficiency.

Beyond the impressive product lineup, HiTech Metrology engaged expo attendees with expert-led demonstrations that gave professionals and enthusiasts a deeper understanding of how these technologies seamlessly integrate into manufacturing processes, optimising efficiency and ensuring unparalleled precision.

Chain Systems Australia is a key player in the Australian and New Zealand markets, and Craig Stokes and Amy Saunders are thrilled to have this opportunity to connect with industry leaders, share their expertise, and showcase the products that set Chain Systems apart.

Chain Systems Australia specialises in the Brevetti Stendalto brand with cutting-edge cable and hose management solutions.

With a presence in both Perth and Sydney, they maintain extensive stock holdings in both locations to ensure rapid delivery across the region. Our commitment to quality, customer service, and technical excellence makes us a trusted partner for industries ranging from heavy machinery to automation and robotics.

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“These nylon energy chains are designed for applications where strength, reliability, and weight-saving are critical,” said Stokes.

“They are corrosion-resistant and perfect for use in dynamic environments, such as automated machinery and robotics.

At Australian Manufacturing Week, Chain Systems Australia exhibited their leading product lines, nylon and steel energy chains.

These products represent the pinnacle of durability, flexibility, and design, suitable for a variety of industrial applications.

“Built for heavy-duty applications, our steel energy chain offers unparalleled durability and strength,” he added. “They are ideal for industries requiring robust solutions that can withstand harsh conditions, such as mining, construction, and heavy manufacturing.

Both product lines are engineered to protect cables and hoses from wear and tear, extend their lifespan, and minimise the risk of unexpected downtime.

“Our team brings decades of experience, offering solutions that protect critical cables and hoses in demanding environments in durability, flexibility, or advanced engineering,” Amy Saunders added.

Australian Metal Casting is developing new materials and high-performance alloys, greatly enhancing the performance and durability of cast products.

Today, the Australian metal casting industry is a mature high-tech industry embracing cutting-edge technologies and supplying to markets in mining, engineering, marine, aeronautics and automotive, among others.

Innovative mould-making techniques have improved the quality and precision of castings. Additive manufacturing such as 3D printing, has transformed the casting process by allowing the creation of complex designs and reducing production times. 3D printing of sand moulds and wax or plastic patterns for investment casting allows for more complicated designs.

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Today, advanced computer simulation and modelling technologies, such as computational fluid dynamics (CFD) and finite difference calculations (FD), are commonly used to simulate mould filling, solidification, and defect prediction.

The integration of smart technologies and Industry 4.0 principles has brought significant advancements to the metal casting industry. Internet of Things (IoT) sensors and devices monitor equipment and processes in real time, while big data analytics and machine learning streamline processes and predict defects.

These innovations enhance product quality and streamline production processes, making manufacturing more sustainable and cost-effective. As such, embracing these cutting-edge technologies is crucial for staying competitive in today’s fastgrowing market.

Jenny Castles from Koenig Machinery reminds me her company is primarily into laser cutting, but the technology has changed in that the higher-powered options are much more affordable than they used to be. “So, we're finding customers are ready to move to higher-powered machines that can cut much thicker materials,” she said.

“AMW gives us an excellent opportunity to meet your customers, explain to them how we offer service all across Australia, and introduce them to our technicians who are all here on the days. We don't have salespeople here; we're all technicians and can all support the service. We've also had the opportunity to show some new equipment, so we've got a 61 machine here, which is actually a fibre welder combined with a CO2 laser and CNC metal cutting, and it's a very affordable entry-level machine. We've also introduced a range of

finishing machines to line up with your laser, allowing you to have a full machinery range for a nice final product.”

AMT spoke to Lance Watson, Director at Total Rollforming, about how the market is changing. Watson said the past year has seen a significant shift in the market towards automation and alternative supply options.

Manufacturers are increasingly looking beyond incumbent suppliers, who might have grown accustomed to recognising that innovative and competitive solutions are available elsewhere. “This has led to a rise in inquiries for automation solutions, particularly for our folding systems from our Swiss partner Thalmann and rollforming automation from our Turkish partner Etcoma, who has an exceptional track record in this space,” he explained. “As the demand for greater efficiency grows, we continue to see automation as a key driver of industry evolution.”

Automation is at the forefront of innovation in rollforming and flashing production.

One of the most exciting advancements is integrating software that connects multiple machines, enabling autonomous

or semi-autonomous operation. Watson reckons he’ll begin to see multi-decoiling solutions that can automatically change coils, slit blanks, and feed materials into and out of long folders—minimising manual handling which both improves safety, and lowers the cost per part. “Additionally, we are developing an AI-powered tool to assist our technicians in the field, ensuring fast, efficient service and troubleshooting.

These advancements are paving the way for safer, more efficient, and cost-effective manufacturing.”

“AMW 2025 presents an incredible opportunity for brand expansion and engagement with the manufacturing community,” he added. “We are excited to showcase our highly automated solutions from our international partners, including Thalmann, whose innovations haven’t been seen live in Australia for years. Our primary focus will be connecting with new and existing customers, demonstrating the value of our automation-driven approach, and engaging in meaningful discussions about how we can support the evolving needs of manufacturers.”

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Manufacturing Solutions Every manufacturer needs services and solutions to ensure that their work reaches the customer in good shape.

Exhibitors in this Zone bring their solutions to market with the manufacturer and the end product in mind.

Recycling Tech Group saw a big rise in enquiries and sales of commercial metal briquette presses last year at the Sydney show.

“This happened because we have shown customers successful projects with great ROI and higher scrap yields,” explained Lachlan Esplin, the director of sales and marketing at RTC. “We’ve recovered cutting fluid, and customers are increasingly aware of recycling options.”

Recycling Tech Group unapologetically aims to lead waste-toenergy solutions in Australia. Esplin is upbeat about the future. With top-notch briquetting equipment and exceptional customer service, RTG is set to boost waste recovery yields for metal processors nationwide, from defence contractors to CNC machine operators.

In the future, RTC is looking beyond shredders and briquette presses. “Recycling Tech Group is advancing through extensive R&D in biochar, green steel technology, gasification, and energy generation,” explains Esplin. We hope AMW2025 is successful and runs smoothly, reaching defence contractors and top metal processors across Australia to showcase the high-yield potential of metal briquette presses.

Over the past year, Travis MacLachlan has observed significant shifts in the energy market that reshape how businesses approach electricity procurement. MacLachlan is a Commercial Solutions Manager at Flow Power, managing a portfolio of large, complex customer retail contracts. Additionally, he consults on holistic energy strategies, aiding businesses in navigating the evolving energy landscape.

Average wholesale energy prices have risen across the board, driven by coal generator outages (as many units are nearing the end of their life cycle), transmission constraints, and broader economic factors. Increasing electricity costs have become a key discussion point in the lead-up to this year’s election, and there is growing public concern over energy affordability. For manufacturing businesses, where electricity is frequently one of the largest operational expenses, this has generated increased interest in wholesale-linked electricity plans that reward flexibility and offer opportunities for cost optimisation.

Businesses are increasingly recognising the value of flexibility in achieving better pricing outcomes. Thanks to the higher penetration of renewable energy in the grid, companies can leverage dynamic pricing structures to take advantage of lower electricity prices during the day. In some instances, this flexibility can also extend to network charges, which, in certain states, can account for up to 50% of a business’s electricity bill. This shift enables businesses to unlock savings on wholesale electricity and across their entire energy spending, significantly impacting profitability.

“AMW2025 presents an invaluable opportunity to listen to and learn from manufacturers,” said MacLachlan. “We aim to comprehend their unique challenges, pinpoint their pain points, and hear directly about the strategies they are employing to reduce energy costs— both now and in the future. These insights will aid us in refining our solutions and ensuring we continually deliver value that aligns with the industry's evolving needs.”

“At Australia Manufacturing Week we've partnered with Kite Magnetics,” said Paul O’Shaughnessy from LEAP Australia.

The stand had some hardware they built using Euphoria Studio with an AR experience, showcasing many aspects of the design and the technology. Chic Magnetics uses Creo for 3D design and simulation. So the AR really shows what's unique about this technology and we've infused that within the augmented reality experience.” Through VR glasses, anything is visually possible.

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“With the AR, we can see inside using in a virtual x-ray vision of some of the internal components, which is useful to explain the mechanism better. This year we're also using the new advanced model tracking, which means we can approach the physical model from any angle and the augmented reality will still attach to the geometry. In addition, we can overlay information about the performance characteristics, general information around what this product does on the simulation side, they've conducted low frequency, electromagnetic simulations, and you can actually see this overlaid on the physical model here using the AR experience.”

Thomas Warburton demonstrated the CPS Global Kanban systems, streamlining production with reliable, just-in-time delivery, and the CPS Vend vending solutions, providing secure access to the consumables that manufacturing teams need.

“Thomas Warburton isn’t just showing products,” said Michael Hardman from Thomas Warburton. “We’re showcasing possibilities and our innovative solutions that many Australian manufacturing business already have in place.”

These Digital Inventory Services include 3D printing and additive manufacturing offerings, now supporting engineering teams with custom component solutions built for speed, strength, and precision. "We have had the best experience for this year's show to date," said Hardman. "It really was a great show, with many great leads that we hope to turn into new customers and strongly believe it lived up to the promoted 'biggest show yet'. Well done for a great show. May the next Melbourne event be even bigger than this one!"

AMT spoke with Andrew Mamonitis, VP of Manufacturing for ECI Solutions. He told me the manufacturing sector has significantly transformed over the past year, particularly in the small to medium business space. “Manufacturers are increasingly seeking ways to control fluctuating costs, gain greater visibility into their production efficiency and remain competitive as they try to do more with less,” he said.

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Thank you for visiting Dimac at AMW 2025 This has driven the need for greater agility in supply chain management and production processes, as well as the adoption of technologies such as AI. “At ECI, we've seen the heightened need for manufacturing software solutions as manufacturers prioritise sustaining their sales pipeline and focusing on diversifying their offerings to attract new markets. This trend aligns with the upcoming launch of our Manufacturing Execution System (MES) and Advanced Production Scheduling (APS) modules, which will address these evolving needs by enhancing factory floor productivity and enabling smarter scheduling capabilities.

The crew at ECI say AMW2025 represents a pivotal moment for them to showcase how technology can transform manufacturing processes. “My hope is that this event highlights the critical role small and medium manufacturers play in driving innovation, they represent the largest group of manufacturing businesses, making it the backbone of the industry,” Mamonitis added.

“For ECI, it’s an opportunity to demonstrate how our manufacturingspecific solutions can empower these manufacturers to achieve new levels of efficiency and resilience.”

At the Sandvik Coromant stand, Manny Valenza serves as the Cluster Manager for all the South East Asian sales teams, including Australia, New Zealand, Singapore, Malaysia, Thailand, Indonesia, Vietnam, and the Philippines. Sandvik Coromant shares its stand with other software companies that are part of Sandvik Machining Solutions, specifically Mastercam and Vericut. Instead of showcasing tools, they have advisors available to engage in meaningful conversations with visitors looking to optimise their machine investment and address their manufacturing challenges.

“At Sandvik Coromant, we’ve aligned our products, services and advisory approach around these habits,” Valenza expands.

“Our goal is to work closely with customers to perform a kind of ‘health check’ on their operations, and then support them in embedding those habits into their everyday practices. This is how we help manufacturers optimise performance and build long-term, sustainable success.”

PFMWorks has rebranded itself, as described by CEO and Founder Trevor Calder, to “be better aligned with the product that we're selling. It's a big creature that we've put together now, which can be moulded to the client’s production and supply chain.”

PFMWorks updated its approach to the technology presented for planning, scheduling, and execution. “Yes, we've got a totally different model which is called the ‘dynamic production method’, which is pretty much the polar opposite to ‘finite capacity scheduling’ that every ERP system out there uses,” said Calder.

“We want to change the way that manufacturers manufacture so they deliver things on time, every time.”

We enjoyed meeting likeminded industry innovators and look forward to discussing how our CNC solutions can enhance your operations.

Connect with us to keep the conversation going.

dimac.com.au | 03 9771 6121 sales@dimac.com.au Dandenong South, VIC 3175

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Additive Manufacturing Echoes of progress are a shrill addition to 3D printing. Last year, metals were being demonstrated as the next big thing in additives. Scale and precision in 3D production are two areas in this year’s demonstration range. Immensely impressive.

AXT has brought the whole box and dice to AMW this year. Metal powder production is centre stage, but also powders and ceramics are entering the fray as well.

“Amazemet rePowder opens up many possibilities for metal AM producers,” explained Dr Cameron Chai from AXT. “You can take control of your process with the ability to transform just about any metal, recycled powder, and failed parts into powders with customised properties.

Utilising unique ultrasonic atomisation technology, it can also be used to create custom alloy compositions. You can then confirm alloy composition with the Exum Instruments Massbox, which uses pioneering LALI-TOF-MS technology to rapidly measure every element in the periodic table at every location.”

When it comes time to print metal parts, Aconity3D can provide LPBF systems to meet your requirements. With flexible and modular designs, multi-laser configurations, multi-material capabilities, and inline process monitoring, they can customise a system for you, ranging from academic research to industrial-scale printing.

AXT has an extensive portfolio of AM solutions for metals, polymers, and ceramics. “If you are looking to go beyond the limits of FDM, we offer 3D printers from UpNano, Boston Microfabrication (BMF), and Miicraft,” added Chai. “These systems can achieve micron and submicron resolutions. We provide Aconity3D LBPF systems with multi-laser and multimaterial capabilities for those interested in printing metals. Amazemet’s rePowder can produce highly spherical metal powders with customised alloy compositions and particle sizes. For quality control and product development, we offer Hirox 3D digital microscopes. For complete 3D non-destructive inspections, we also have Computed Tomography (CT) instruments from Diondo and Rigaku.”

Kevin Price from 3D Systems has found Australian manufacturering SMEs have spent the last few years using low-cost 3D printers that have clear limitations. The industry has now changed. “The range of bespoke materials from high-temperature up to 300 degrees, carbon-fibre strength, flexible and metals including copper, titanium, nickel alloys are of high interest for specific applications enabling ROI on more production-based systems. Cost is less of a consideration when there is a clear offering for client applications or to deliver on available tenders.,” he said.

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“3D Systems has some of the brightest minds in the industry based out of our development facility at Berkeley UC, and they continue to innovate in 3D printing, allowing for greater accuracy and higher speed, such as what is coming from the P-SLA projector-based resin 3D printing.”

Price is hoping for more brand awareness at AMW2025. “3D Systems didn’t do any promotion for the past four years, so a lot of people are not aware of our full product range from fine detailed jewellery to batch plastics, to large format and complex metal additive. 3D Systems has great service, materials and software but not many people know we are the second largest 3D printing company in the world, having started in 1986.”

Ben Matthews from Titomic is talking up the many projects the company is into at the moment. Most of which he can’t talk about, of course. “AMW is a great opportunity to show off our technology and to meet industry members who we know will understand the technology,” he said. “Some of the composites we use in our applications are pretty complex but the customers we’ve seen are clued up already, or willing to learn, which is great.”

“While our US team is over there introducing Cold Spray to the oil & gas community in Houston, we’re here in Melbourne discussing how this gamechanging technology is redefining coatings, repairs, and even large-scale additive manufacturing – at rates of 5–6 kilograms per hour. Cold spray uses kinetic energy, not melting, to build thick, dense metal layers, including titanium, steel, and Inconel,” explained Matthews. “The result is faster, more durable, and more sustainable manufacturing and repair solutions.”

Over the past 12 months, Craig Alexander at Formero has seen a noticeable improvement in business activity and overall confidence in the market. He feels demand is steadily returning, and the increase in complex projects is heartening, particularly in the defence sector. “This trend suggests that Australian manufacturers are moving forward with innovation-focused and technically challenging work, something we’re well-equipped to support,” he added.

Formero is growing in terms of its capabilities and the industries it works in.

“We’ve recently added our third SLS printer to meet growing demand, and we’re in the final stages of launching a new SLA printer,

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further expanding our capacity and range.

As additive manufacturing becomes more integrated into production workflows, we’re committed to staying ahead of the curve and supporting our customers with the most advanced solutions available.”

“In the coming months, we’ll add Vapour Polishing to our in-house capabilities, enhancing the surface finish of parts, particularly those made using MJF and SLS,” said Alexander.

“AMTIL always puts on a strong event, and we’re confident AMW2025 will be no exception. We’re connecting with new and existing customers, discussing their projects, and sharing insights into how our technologies can support their goals. Events like AMW offer a valuable opportunity to engage with the broader manufacturing community, spot emerging trends, and better understand what the next 12 months might bring.”

Down at the Convention Centre end of the hall, there are some real attractions, so the walk is worth it. AML3D has a few examples of the 3D-printed and machined cogs for the naval jobs they’ve been doing lately. “Yes, we’re doing a lot of work in the defence space at the moment, and we're looking to progress into general manufacturing, as our technology is becoming accepted throughout the industry,” said Global Business Development Manager Stuart Banks down at AM605 where they’re showing their work with ARCEMY. AML3D has recently just opened a facility in Ohio in the US. “That's been operational since the first of November, and it's proving to be a great boon for our plans in the many sectors we’re working in.”

AMW is a chance for AML3D to bring its

technology home and make it available for the local markets. “We've done an awful lot of work in other sectors, and we're looking to progress further into industrial markets.”

Some of the parts that AML3D has on display are large, flat bow parts. “Typically, this would have about a four to six month lead time forecasting of forgings, but we've

managed to produce this in two weeks and we're showcasing this technology and the capability so they can help Australian producers to overcome some of the bottlenecks around supply chain issues that they're having at the moment,” Banks added.

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Australian Manufacturers' Pavilion The Australian Manufacturers Pavilion proves Australia excels at creating tangible products people use all over the world.

RJS Tech Group is an Australian-owned leader in manufacturing solutions, boasting nearly 40 years of expertise in the woodworking, metalworking, and industrial sectors. As the parent company of PPE Tech, Prestige Precision Tools (PPTools), NanoTech, Whitelaw Machinery, Wood Tech, Metal Tech, and Rogers Industries, the stand at AMW highlights how Australian-made innovations are pushing the boundaries of efficiency, durability, and performance in modern manufacturing across various mediums. “We were quite impressed with the number of leads and traffic coming through to our stand every day,” said Chris Rowe, the Marketing Manager at RJS Tech Group. “Particularly, we noticed on both Wednesday and Thursday. So we were quite happy with that. The overall setup of the show was truly impressive. The layout looked really impressive.”

The RJS Tech Group merges advanced technology with local manufacturing to deliver precision and reliability. From Australianmade products to innovative import solutions, we are committed to empowering industries with sustainable and customer-focused solutions. “We’re looking forward to next year, as most of our offices are located in Brisbane, with our head office also based there.

We’ve other subsidiaries operating in other States,” Rowe added.

“But Brisbane next year will be a very convenient location.”

At the OSAAP Australia stand, Queensland Gaskets were piggybacking. “There was a real buzz in the air this year,” said OSAAP Australia’s Manager. “Innovation, energy, and a shared belief that Australian manufacturing is not just alive, but evolving fast.”

“It was great to meet so many new faces, reconnect with longtime industry friends, and catch up with those we hadn’t seen in years,” he said. “These moments, those quick chats, deep dives, and shared laughs make events like this so valuable.”

“We love showing how smarter tool control and LEAN-focused thinking can unlock real gains in efficiency and workflow.”

Ian Cubitt and his wife Latinka were taking turns holding the stand at AMW this year, such was the workload for them at the moment.

Catten Industries is a leading precision sheet metal manufacturer, delivering high-quality solutions across various industries. Their state-of-the-art facility features a dedicated engineering team that supports design, development, and project management. “We have had a constant stream of visitors to the stand, and genuine requests for work,” Latinka told AMT. “We cater to industries such as building, electrical and electronics (including switchboards), transport, shopfitting, display and point of sale, communications, furniture, material handling, general engineering, and defence. From prototypes to full-scale production, we ensure precision, reliability, and innovation in every project.”

The Elexon Electronics stand was swamped when I was going to visit, so an hour later, I approached, and Marketing Manager Sandra Simpson was holding the fort. Elexon Electronics is a 100% Australian-owned electronics design and manufacturing company, specialising in high-mix, low-volume production of advanced electronic solutions for harsh environments. Serving industries such as mining, agriculture and defence, Elexon manages the entire product lifecycle, delivering custom-engineered electronics with exceptional precision and reliability. Operating from a newly constructed Industry 4.0 facility, capabilities include prototyping, production, and advanced testing, adhering to ISO 9001 and AS 9100D quality standards. “The industry is chasing commitments to achieving zero defects, zero delays, and zero warranty returns, and Elexon2Zero is our continuous improvement program,” Simpson explains. “This focus on quality and performance ensures our electronics meet the most demanding operational requirements, setting new benchmarks in innovation and reliability.”

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Jack Thompson Engineering is a 100% Australian-owned company, providing bespoke engineering solutions for projects of all sizes. Lucas Cant, Director at JTE was pretty happy with the show and the result. The big pile of leads and interest from the show was excellent. “The AMW show is the perfect platform for RJS Tech Group to demonstrate how our businesses are driving progress across advanced manufacturing, tooling, surface coatings, machine tools, and materials processing. I remember five or so years ago, the NMW wasn’t even filling up the main hall, but AMW has turned it around very nicely. The proudly Australian-made Parken Engineerings has been manufacturing for over 85 years and provide high-quality industrial machines to the Australian market.

Proudly Australian-owned, operated with a reliable ongoing local support network.”

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Nick Fergus from JTE was especially happy with the outcomes of the show because the team was looking for an understanding of the channels through which they market their products. “That’s primarily why we went to the show too, as well as showing the products to the people who passed by, but it was primarily to understand the appetite in the market for the products, and how we go about distributing them down the road. We’ve now established that, because we went to that show, it was an excellent opportunity for us.”

The great people at the MOSS Products stand have been busy all week. AMT caught up with Graham Wilson the Director at MOSS and he was very pleased with the number of leads and clients coming through to check out the materials they had on offer. The company has been designing and manufacturing components and assemblies from plastics and metal for over 70 years. Moss Industrial specialises in the following areas: Injection Moulding / Plastic Components; Zinc Diecasting; Assemblies; Design & Project Management; Prototype Development.

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Weld & Air Solutions Welding has changed substantially over the last few years. Software applications, robotics, safety regs and especially the automation of many welding technologies has altered the practical science of metallurgy and fabrication.

Down from Ballarat, KO Welding Tables & Supplies is a small, family-owned Aussie business. These guys design and supply precision, durable, customisable welding tables with over 100 accessories tailored for professionals in the welding and fabrication industries. “Even though we have quite a small stand, we’ve a huge range of tables and accessories. Our products are engineered for precision, stability, and versatility, accommodating a wide range of welding techniques and projects,” said Alex Kweifio-Okai. KO Welding Supplies manufactures and supplies welding equipment, consumables, and accessories for professionals and hobbyists alike.

“The traffic has been pretty constant, and all those who stop want to check out the details. People who weld understand what they are looking at, and they ask good questions.”

AMT spoke with the CEO of Kemppi Oy, Kalle Suurpaa and the VP of Markets, Heidi Hannonen. They come across to visit AMW every year because they agree it is the biggest show on this side of the planet. “We come back every time,” said Heidi Hannonen. “We see AMW as a great opportunity to showcase our latest welding machines, software and automation solutions. And perhaps more importantly, the fair allows us to connect with our existing customers, meet new ones and, of course, to close deals, which is rare. We no longer see this in Europe at fairs, where we can close deals, as fairs have shifted towards showcasing products and building brand awareness rather than serving as commercial events.”

I asked them about the range of Kemppi products available here in Australia. “There has been quite significant improvement and renewal of our basic product line,” said Suurpaa. “There have been improvements in our models from the usability point of view, which is a key focus area for us.

For instance, we have a very interesting new welding machine that also features an integrated cleaning solution. It’s quite unique and we believe it's a good solution for users, as it saves them both precious time and money. To date, feedback on the Minarc T223 ACDC GM has been quite positive, and the machine has been very well received. We will continue to incorporate features that empower the welder.”

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Kemppi cooperates with different educational institutions that offer training in welding. “In every country in which we are present, we believe that it's very beneficial to learn to weld with a quality machine that has all those features that a quality machine should have,” said Suurpaa. “In Australia, we work closely with TAFE, training welding teachers on our machines and software, so that they can pass on best practices to students and help prepare them with the correct skill set.”

At ABICOR BINZEL you will discover the ideal torch along with welding accessories and peripheral systems tailored for your welding needs. We also offer welder protection for manual, semi-automation, or full automation applications. With ABICOR BINZEL Australia as your welding specialist, you gain access to advanced equipment designed to help you achieve the perfect seam. The fume extraction torches and lightweight MIG, TIG, and plasma torches are here to comply with welding standards

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while prioritising the health of welders.

These days, welding torches and related equipment must adhere to stringent safety, quality, and functionality criteria. Ensuring the health of welders through effective fume extraction and lightweight torches is just as crucial as maintaining the high quality of our products.

Orbimax is Australia's leading supplier of smart and simple pipe and welding equipment, including Collaborative Welding Robots, MIG, TIG and MMA Welders, Pipe and Tube Cutting Equipment, Tube Facing, Bevellers and Orbital Welders. Mark Wall is on site here for the company in the Weld & Air Zone. “We've been run off our feet,” he said straight away. “There’s a lot of activity, a lot of leads, a lot of demonstrations set for the next couple of months. A lot of quotes and leads, which is what we're here to do. It's excellent. A good kind of crowd as well. I've found that they're not so much after information, but they are after actual prices and quotes. It's not the DIY type of customer, it's actual business-to-business, which is great.”

Wall continues to stress that the work is out there. “There is a lot of innovation in the industry, such as lasers and automation, but a lack of legislation around some of these new laser technologies is concerning,” he told AMT. “The welding industry is the backbone of the country, as it is essential for the construction of infrastructure.”

Rolling through the aisles, I stopped to speak with David Wilton, MD of Lorch Welding. He has brought OTC Asia and Daihen into the country from Germany. The Lorch range of welders is only now available here in Australia and David is excited about the Lorch iQS, the fully digital connected system with a broad portfolio of advanced processes. He also set aside a MicorMIG Mobile, which can be positioned to weld just about anywhere with the same quality and output as the MicorMIG kits.

“These mobile units are the next generation of welders,” said Wilton. “They are two of the most technologically advanced MIGMAG (GMAW) and FCAW systems on the planet right now. They have Speed Processes for both solid and flux cored wires, and they come wih I4.0 connectivity and the best big data management system with Lorch Connect.”

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Robotics and Automation The ideas of having a business run by robots used to be pure fiction. Automating of mundane tasks was first, and then automating precision manufacturing is bringing the impossible into the realm of inevitability.

“The demand for robots and cobots has definitely increased,” said Trinton Smith of Automation & Robotics Services, down on the floor of AMW2025 on a busy first day. “The demand for robots and collaborative robots (cobots) has been experiencing significant growth, indicating a buoyant market. This is driven by increasing automation adoption across various industries to enhance productivity, safety, and efficiency.”

So, what technologies are breaking ground in this part of the industry?

“Collaborative AI for robot code generation,” Smith flagged immediately.

“The integration of AI into collaborative robots could transform the robotics landscape, particularly in the areas of code generation and programming. Some companies have developed AI Accelerators, which are tools designed specifically to facilitate the development of AI-powered applications for cobots.”

Trinton Smith is, of course, hoping to see AMW2025 successful and busy for all involved. “I’m hoping to meet potential clients and partners who are serious about automation and robotics investments,” Smith said. “Making sure we are connecting with the right people who can decide on the future of their manufacturing facility.”

At MSA, we deliver a comprehensive, TÜV-certified solution for industrial manufacturing, guiding your projects from initial risk assessments through to successful implementation and safety validation. Our turnkey, end-to-end approach guarantees full compliance with industry standards, boosts productivity, minimizes downtime, and prioritises a safer work environment. Our team of expert safety engineers manages all complexities, ensuring that your safety systems are meticulously assessed, designed, and executed with precision. Trust MSA to streamline your processes and uphold the highest safety standards.

CNC Design is a local leader for motion control-based automation systems, with 170 people located across Australia, New Zealand, Indonesia, Thailand, Malaysia & Singapore. We have been in business since 1984. Our technology partners Siemens & Güdel provide industry-leading technologies in their respective fields. CNC Design has partnered with Siemens for more than 35 years, and this strong relationship allows us to support customers both in our region and worldwide. We are the exclusive representative for Siemens Machine Tool

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products, solutions and service in Australia and SE Asia, supporting machine OEM’s, End Users & Machinery Dealers. Service for SINUMERIK CNC Systems, SINAMICS Drives and SIMOTICS servo motor and

spindle motors is a key part of our business.

For FANUC, it is all about robotics, automation, combining robots with machine tools. Gaby Ghabach, is Managing Director of Fanuc Oceania. “Artificial Intelligence is a

AMW2025 REVIEW big part of our development in Japan at the moment,” adds Gaby, who’s been coming and exhibiting at AMW for many years. “All our product development with the future is all based around AI. So, AI is very important machine learning as well as smart factories.”

“AMW is an opportunity to promote Fanuc, a giant name in the robotics industry,” he said. “We are 100% made in Japan and the company has been active in the country since 1976 for sales of service.” Ghabach feels manufacturing in Australia is a little bit unrecognised. “I think the show here puts us on the map and hopefully governments can take us more seriously about what we do here with robotics in Australia.”

“At AMW we get the exposure, we get the branding out there and we let people know that we're change our business model in a way that we can now be a direct OEM to suppliers in the country.”

“The future looks promising because we are in the right place for Australian manufacturing. Can I say the future looks good because it is all about automation, AI, machine learning, smart factories and IOT? All in the one package.”

‘MMAPing’ your products will determine & enforce your brand’s new automated standard for: eCommerce product information product data, product quality control, access, storage, distribution & AI

implementation. MMAPT is an Australian tech start up that uses patented hardware & software to create digital product libraries. Through automation & robotics we create both Data & Assets for B2B & B2C products, ensuring businesses can cross functionally utilise these outputs from a centralised cloud.

Mobile Automation is a leader in industrial electrical and automation solutions, specialising in the manufacturing sector.

We deliver a comprehensive range of electrical services tailored to the industrial environment, along with advanced

automation solutions designed to enhance production efficiencies and reduce waste.

Committed to supporting the future of Australian manufacturing, we work closely with our clients to ensure their businesses remain competitive and sustainable in Australia long term. With a team of over 45 skilled professionals—including engineers, electricians, and fitters—we leverage cutting-edge technologies to provide customised, high-quality solutions that meet each client’s unique needs and deliver measurable results.

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Get to know our comprehensive range of industrial robots, autonomous mobile robots (AMR), and intelligent automation solutions.

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A NEW FRONTIER…

A U S T R A L I A N M A N U FA C T U R I N G W E E K . C O M . A U

For the first time ever, Australia’s premier manufacturing solutions event Australian Manufacturing Week will take place in Brisbane in 2026.

Save the date and join us for an amazing event in the sunshine state.

MAY 12-14, 2026 BRISBANE CONVENTION & EXHIBITION CENTRE, BRISBANE

Want to hear the latest updates?

Simply submit your information

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ADDITIVE MANUFACTURING

Studio Kite and CADzilla CADzilla is set to produce low-cost and durable houses from recycled consumer waste. AMT Editor Paul Hellard speaks to Studio Kite founder Steve Rosewell.

Studio Kite is at the forefront of 3D printing technology, having built two massive 3D printers, fittingly named CADzilla. As the name suggests, these printers are designed for large-scale fabrication and have been fully operational for the past seven years, producing props, sculptures, public art, and prototypes, all on a grand scale. With 25 years of experience in 3D printing and 35 years in cinematic special effects, sculpture, and model making, Studio Kite now plans to start massproducing affordable homes from plastics destined for landfill. Introducing Jindi, a building solution that Studio Kite says “doesn’t cost the earth. " “Over the last few years, we have vigorously fine-tuned the shapes to optimise the materials as best we can; these forms have been rigorously tested to enter the housing and construction market. We’re 3D printing using 100% recycled consumer waste, which is challenging and costly to recycle consistently. We 3D print an optimised sacrificial formwork that gets coated with a thin shell of basalt fibre-reinforced cement,” said founder Steve Rosewell.

‘Jindi’ is the Yugambeh-Bundjalung word for ‘nest.' The Bundjalung Nation is the custodian of the northern coastal area of NSW, Australia.

“The inspiration for building houses came from the extraordinary success of 3D printing nest boxes for endangered species,” explained Rosewell. “We proved we could economically 3D print a comfortable Wild B&B from waste plastic that will far outlast the existing materials like plywood and hollowed logs. That's when there was a clear light bulb moment: why can’t we do this for humans too?”

Using plastic waste Converting waste plastic back into fuel or oil to produce more plastic is costly and energy-intensive. Due to polymer degradation, most types of plastic cannot be endlessly reprocessed to perform the same function. Meanwhile, housing construction costs are rising far beyond inflation, making housing unaffordable for a significant portion of the population.

The construction industry alone contributes to approximately one-quarter of Australia’s emissions. Each year in Australia, twenty million tonnes of building waste end up in landfill.

“Two years ago, we built an example of what is possible,” says Rosewell. “During this process, we’ve learned a lot about how to make Jindi strong, bushfire-

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proof, comfortable, and potentially last for centuries. Southern Cross and Adelaide universities have been great champions of the vision, facilitating and executing extensive engineering tests to a point where we’ve passed the structural requirements to meet the Australian construction code, and our first formally accepted building is going up.”

Jindi is a system that promises a lowcarbon and more affordable building form and offers endless opportunities for exciting new house shapes. It starts with a cellular structure that is 3D printed from recycled plastic. Various types of plastic can be utilised, and they don’t need to be perfectly clean— a small amount of contamination won’t significantly impact the outcome. The idea is to make use of the mass of consumer waste polyfins, primarily polypropylene, which is typically found in laundry detergent containers, higher-quality takeaway food containers, and plant pots, in addition to HDPE, another standard food container, and finally LDPE, the familiar plastic wrap or ‘scrunchy material’ we all know well. We incorporate

a small amount of glass fibre into the plastic to help stabilise and enhance printability. These 3D printed shells are assembled on-site and coated with basalt fibre-reinforced cement. This basalt fibre is created by melting a common type of rock and spinning it into a fibre, providing strong rust and rot resistance without the use of chemicals; its tensile strength is ten times stronger than steel by weight!

There’s no need for steel or timber in Jindi houses. If we utilised all the plastic currently sent to landfills to construct homes, we could diminish the demand for wood by 30%—imagine the forests we could save.

The closed cells in the walls create a superior thermal barrier, preventing heat and cold from easily passing through. To endure extreme weather conditions, the walls can be constructed to any desired thickness and filled with various insulation materials.

Curves and self-supporting roofs create an expansive and uplifting living space in Jindi. This design provides a far better sense of space compared to boxy

ADDITIVE MANUFACTURING

rooms. A significant feature of Jindi is that frameless glass doors and windows can be installed directly into the reinforced 3D-printed structure, eliminating the need for window frames and their associated costs. Additionally, storage cupboards can be integrated directly into the printed walls, further lowering fit-out expenses.

Remote and isolated locations No matter where people live, plastic waste is abundant. In remote areas like central Australia and the Pacific Islands, durable building materials are hard to come by due to transportation costs. In the outback, you can simply dig a hole and pile the plastic in, but there is limited space to dig such holes on the Pacific Islands. With the threat of cyclones, the risk of this waste ending up in the ocean is exceptionally high. The plan is to build a containerised recycling and 3D printing plant that can be moved to the islands where the houses are needed. Once it is operational, people in these areas will have a good reason to sort and adequately store these soon-to-be valuable materials.

Temperature control The energy a building consumes over its lifetime is as important as the resources required for its construction. Jindi features a unique system for extracting or harnessing heat from its walls. As the 3D-printed cells in the walls extend from the ground to the ridge, heat build-up can be expelled quickly using a small extraction fan.

Additionally, in winter, any warm air that accumulates in the cells can be redirected back into the building, helping to maintain warmth during the evening. This vital function stabilises the temperature, creating a more comfortable environment without incurring high energy bills.

Four horses Subjecting a section of the Jindi wall to fire testing surpassed the requirements of the Australian bushfire Flame Zone Tests. After 40 minutes of a fan-forced fire with surface temperatures reaching 800°C, there was no damage. “I know where I want to be when a bushfire approaches; it’s in one of these homes,” said Rosewell.

continuous reinforcement rods run around the building. This makes it nearly impossible to dismantle, even against the worst fury a cyclone could unleash. Furthermore, no amount of shaking could cause it to collapse due to its low weight and flexibility, making Jindi resilient even during the most severe earthquakes.

The materials used in a Jindi are waterproof; there’s no wood to rot or steel to rust. In the event of flooding, a Jindi house will simply need a thorough hosing out.

When asked how long they would last, Steve Rosewell stated it would be about 1000 years, “but you’ll need to recoat it with cement every century or so. Hopefully, with the promise of longer-lasting geopolymer materials, cement will become a thing of the past. These low-carbon cement-like options are an important step forward for housing like this, and I’d love to start using them.” jindi3d.com

Thanks to Jindi’s solid construction, pesky vermin are kept at bay since there are no gaps of any size, aside from open doors and windows. Thus, there is nothing for white ants to eat. The walls are fully integrated with the floor and roof, and

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ADDITIVE MANUFACTURING

Fashion in AM Tides Studios’ shades of identity produced on demand by 3D People.

Additive manufacturing (AM) technologies have proved time and again that they are capable of making things and making things better. This has proven true once again with the polymer powder bed fusion (PBF) AM process for the production of stylish and original eyewear.

As a case in point, Tides Studios, based in London, has built a successful business by focusing on eyewear, specifically sunglasses, utilising polymer PBF AM and some key finishing techniques alongside a made in London business model that contributes to its sustainability goals.

Founded by Joseph Alpert, Tides Studios is a sustainable design company that originally focused on make-up and brand packaging, until it expanded into eyewear and launched its own brands and full collection of sunglasses. It also produces bespoke, made-to-order sunglasses, or ‘Shades of Identity.’

The premise that the studio adheres to is that “sunglasses go beyond their practical role of sun protection; they tap into human desires for privacy, mystery, and control over perception. Ultimately eyewear has been a large part of popular culture from the stage to dancers in the crowd and we want to be part of that evolving story.”

For Tides Studios this evolution goes even further beyond the practicalities and the style – to the means of manufacture.

Eyewear is not a unique application for AM in 2024, but unique is absolutely a word that can be attributed to the Tides Studios collection as well as commissioned, bespoke sunglasses for customers that are fully enabled by additive technologies and an ecosystem of efficient finishing technologies.

“The nature of additive technologies is a key enabler for how we design and empowers us to experiment freely, pushing boundaries to create eyewear that fits a diverse range of styles, faces, and preferences,” said Alpert.

“Thus, for us, and many of our customers, eyewear isn’t just an accessory—it’s a platform for self-expression, reflecting both cutting-edge technology and the individuality of its wearer.”

Alpert and his team had been observing the maturation of AM technologies for several years and utilising them frequently for product development. The concept for the sunglasses had emerged 2-3 years ago in collaboration with the fashion brand La Maskarade, but the early prototypes were heavy and not at all user-friendly. The idea of using 3D printing technologies to hollow out the heavy frames was proposed and

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tested, resulting in functional prototype runs that led to the first model for the studio.

Subsequently, Tides launched the first models and garnered “a ton of interest,” according to Alpert. “It really blew up and exceeded our greatest expectations and we transitioned to an eyewear business

full-time about a year ago.” The business is fully enabled by 3d printing, with Alpert’s convictions that additive technology, specifically PBF, could produce Tides’ original designs paying off. “Although it wouldn’t have happened without an old man in engineering collaborating with

ADDITIVE MANUFACTURING

young people in fashion,” he quipped. The development phase also took time, and Alpert and his team collaborated with 3D People during this period.

“We did send prototypes out to other AM bureaux early on, and there were some good results with the prints themselves.

What sold us on 3d People, though, was their willingness to accommodate our vision and find solutions that would enable us to develop the collection and move into production with them. While the PBF production process is vital, we needed more. Specifically in terms of bespoke colour options and a superior finish to every pair of glasses.”

Polymer PBF AM processes provide the best strength and flexibility for eyewear while allowing for the cost-effective production of complex, unique, and intricate designs.

However, finishing PBF parts that come off the machine is an essential post-processing step for any application that will be in direct contact with the skin. PBF parts tend to have a sandpapery feel and can be rough, particularly on the sensitive skin around the face. Smoothing and strengthening the surface finish is essential.

Indeed, 3D People provided Tides Studios with a unique finishing solution to meet their needs cost-effectively. They combined their in-house vibro polishing and vapour smoothing capabilities to achieve the ultimate finish. This, along with the widest palette of colour dye options in the UK, gave Tides exactly what they required. As a result, 3D People are now completing batch production runs for Tides Studios every month, with up to 500 items each time.

“Working with Alpert and the Tides team has really cemented for us how important

finishing options are for production applications of additive techs like MJF and SLS, which we run in-house at our facility in London,” explained Felix Manley, CoFounder of 3D People. “It is why we place as much emphasis on finishing systems as we do on the 3D printing systems. By focusing on the application, we can deliver the best possible finishing results, which, when you look at the Tides Sunglasses, speak for themselves.”

The London connection is an important one. All of Tides Studios’ sunglasses are sourced and made locally in London. This is with the single exception of the lens base,

with the only factory to manufacture them based in China. However, that is sourced raw and is then cut and assembled at Tides’ Whitechapel operations. As “‘Made in London’ isn’t just a label,” Alpert said. “it’s a commitment to sustainability, authenticity, and accountability in every pair of glasses we create.”

Tides Studios designs and manufactures sunglasses for customers from all over the world, including some recognisable names such as Beyoncé for her Renaissance tour and British stylist Betsy Johnson.

3dpeople.uk

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AXT and VisiConsult partnership Partnership driving digital transformation in NDT with AI, automation, and advanced imaging for mining, defence, and additive manufacturing.

AXT, a leader in Australia’s X-ray technology landscape, has announced a strategic expansion of its portfolio through a new partnership with the German-based X-ray systems manufacturer VisiConsult. This collaboration marks a significant step forward in delivering high-performance, intelligent Non-Destructive Testing (NDT) solutions tailored to Australia’s unique industrial and research environment.

VisiConsult brings over 25 years of experience in designing and manufacturing advanced X-ray systems under its VCxray brand.

Already trusted worldwide in the aerospace, defence, energy, and electronics sectors, its technology integrates automation, robotics, and AI-powered software, such as Automated Defect Recognition (ADR), to enhance efficiency, accuracy, and readiness for the digital future. Through this partnership, AXT and VisiConsult aim to deliver a comprehensive, end-to-end NDT solution portfolio for the Australian market. This includes standard catalogue systems and fully customised platforms for sectors such as defence and mining, complemented by a robust software ecosystem that supports the entire journey from conventional to fully digital inspection processes.

At the core of this transformation is VisiConsult’s commitment to enabling the shift from traditional RT film inspection to modern digital workflows. This evolution is powered by high-resolution Digital Detector Array (DDA) systems, supported by VC.acquire—VisiConsult’s

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robust digital acquisition platform—and enhanced further by the AI-powered solution Compass, which autonomously detects flaws in digital images, significantly accelerating inspection processes and improving reliability. The partnership also brings the Diondo CT product line to Australian labs and research institutes, providing high-resolution computed tomography (CT) systems ideally suited for additive manufacturing, quality assurance, and advanced materials research.

“We are thrilled to be working with VisiConsult,” said Richard Trett, Managing Director at AXT. “Their technologies perfectly complement our offerings and will allow us to break into new markets, particularly in defence and advanced manufacturing.

We’re already collaborating on major projects and see strong demand nationwide.”

“Our goal is to support Australian customers at every stage of their digital NDT journey—from initial system acquisition to full AI-enhanced inspection workflows,” said Jason Robbins, Division Lead Commercial at VisiConsult.

“AXT’s established presence in NDT, research, and additive manufacturing makes them the ideal partner to drive this transformation.”

With this collaboration, AXT and VisiConsult are positioned to become key enablers of innovation in the Australian NDT landscape—empowering industries to modernise, scale, and meet the highest quality standards. axt.com.au

ADDITIVE MANUFACTURING

Amazemet Novel system for upcycling metal powders. An advanced fabrication technique explained by Dr. Cameron Chai and Peter Airey from AXT. Australian manufacturers are turning to advanced fabrication techniques such as additive manufacturing.

Processes like Laser Powder Bed Fusion (LPBF) enable the production of complex metal components from metal powders, providing designers greater freedom than traditional fabrication techniques. Typically, only a small amount of the powder is used in this process, leaving most of it to be reprocessed.

For the optimisation of the LBPF process, feed powder needs to be consistent and controlled over properties such as particle sizes, particle morphologies, powder rheology, and chemical composition. Re-using powder from previous runs does run the risk of degrading powder properties, and disposing of powders can be an environmental nightmare.

Amazemet, an innovator in metal powder production, has just introduced a new solution that enables you to reprocess your metal powders into usable powders with tailored properties, providing a sustainable solution. The new system, dubbed Powder2Powder or P2P, was launched at Formnext in November. It allows you to take pre-used powders and out-of-spec material and re-process it into usable satellite-free powder with excellent sphericity and narrow particle size distribution. Based on their ultrasonic atomisation

technology, the system allows you to change processing parameters such as sonotrode vibration frequency and amplitude to control the output powder properties optimised for your specific LBPF process. It also has the advantage that you can use it to produce custom alloy compositions with precise compositional control that might not be available or too expensive, where it can be equally applicable in industry or research environments. Extensive trials using +200μm oversize and irregular Ti alloy powders have shown exceptional results with the P2P system.

Operating at a frequency of 40kHz, the system consistently achieved a powder morphology with an aspect ratio (D50) exceeding 0.95.

The particle size distribution (PSD) was precisely controlled, producing powders with D90 < 80μm and yielding particles <63μm at ≥80%. Nearly 97% of the resulting powder was suitable for AM processes, including LPBF), Directed Energy Deposition (DED) and Electron Beam Melting (EBM), highlighting the system’s potential to enhance sustainability in metal powder production.

This patented technology addresses two critical challenges in the AM industry - upcycling of powder waste and custom powder production - delivering advanced functionality that surpasses traditional recycling methods. axt.com.au

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Objective3D Building the Most Comprehensive Additive Manufacturing Solutions Provider in ANZ. Objective3D, Australia and New Zealand’s leading provider of additive manufacturing solutions, has officially merged with TCL Hofman (Australia) and TCL Hunt (New Zealand), both part of the Ravago Group. This strategic merger creates the region's most comprehensive additive manufacturing solutions provider, operating under the unified Objective3D brand.

This merger combines unparalleled expertise and technology offerings, including polymer, metal, and ceramic 3D printing, advanced 3D scanning, and additive manufacturing software. In addition to the extensive range of cuttingedge solutions from Stratasys, Lithoz, Artec3D, and Materialise, Objective3D will expand to incorporate other additive manufacturing technologies including both Formlabs and Nikon SLM solutions.

This positions Objective3D as a driving force in the Australian manufacturing landscape, empowering industries to embrace innovation, enhance efficiency, and strengthen local manufacturing capabilities.

What sets Objective3D apart is not only the scale of its operations but also the authenticity of its approach. Its Additive Manufacturing Centre in Carrum Downs, Victoria, is one of the largest of its kind in the country. Unlike others who merely sell 3D printers as part of a broader portfolio, Objective3D employs the same technologies it supplies.

Objective3D’s 3D Printing Service Bureau produces over 300,000 parts annually for more than 2,000 companies across Australia and New Zealand, including industry leaders such as Boeing, Ford, PACCAR, Northrop Grumman, Resmed, CSIRO, BAE Systems, and the Department of Defence.

One such industry partner, Walkinshaw Andretti United Motorsports, relies on the Stratasys Fortus 450mc to 3d print parts critical to the team’s motorsport performance. “Every second counts not only on the track but also in the workshop” said Bruce Stewart, Team Principal at Walkinshaw Andretti United. “We use 3D printing to prototype and produce parts much faster than we could through traditional methods. At the same time, the high-performance standards of Stratasys industrial printers and materials means these parts also perform exceptionally well, despite the extreme heat, dirt, and vibration that go with Supercars racing. As such, Stratasys and Objective3D make great partners for our team.”

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The service bureau boasts an expansive fleet of industrial-grade machines that cover all key technologies: FDM, PolyJet, SLS, SLA, SAF, DLP, and DMLS. These include flagship models such as the Stratasys Fortus 900mc, Fortus 450mc, H350, J55, J826, Formlabs Fuse 1+, and Form 4, as well as the EOS and Concept Laser Mlab100R metal printer.

This capability allows Objective3D to produce prototypes, tooling, and end-use parts with unmatched speed and consistency—simultaneously demonstrating the machines' abilities to potential buyers. This ‘practice-whatyou-preach’ approach builds customer confidence and offers tangible proof of performance.

Integrating Formlabs and Nikon SLM additive manufacturing technologies into the Objective3D portfolio has significantly broadened its reach and relevance.

Formlabs, with its robust and cost-effective Form 4 and Fuse 1+ systems, enables small to mid-sized manufacturers to perform SLS and SLA printing in-house.

These systems are particularly popular among medical device manufacturers, dental labs, and product designers seeking high-resolution prototypes and lowvolume production without compromising precision. The introduction of Nikon SLM metal technologies highlights Objective3D’s commitment to serving high-end, regulated industries. Nikon’s SLM systems facilitate the production of high-strength, lightweight metal components using titanium and other alloys, making them ideal for all advanced manufacturing sectors.

These two brands enhance the existing portfolio, which includes Stratasys (FDM,

SAF, PolyJet, DLP), Lithoz (ceramics), Artec3D (3D scanning), and Materialise (software), solidifying Objective3D as the region’s most diverse additive manufacturing provider.

Objective3D’s Additive Manufacturing Centre (AMC) assists customers throughout the product lifecycle—from prototyping to production. This encompasses part manufacturing and design for additive manufacturing (DfAM), inspection, postprocessing, and assembly.

Whether a defence contractor needs a titanium prototype or an automotive aftermarket company requires jigs and fixtures with quick turnaround times, Objective3D delivers results that are industrially certified and compliant with ISO9100:2015.

Objective3D’s inclusion in the Stratasys Global Manufacturing Network ensures that parts printed in Carrum Downs meet the same quality standards as those produced in North America, Europe, or Asia—crucial for multinational customers seeking consistency across locations. In times of production overflow, Objective3D benefits from this global network, which guarantees seamless scalability and uninterrupted supply to address urgent or high-volume demands.

Objective3D doesn’t just sell 3D printers— they use, test, master, and help their customers do the same. With a suite of industrial-grade technologies, a proven track record, and the added strength of the TCL Group merger, Objective3D is more than a supplier; it is a dependable manufacturing innovation partner. objective3d.com.au

ADDITIVE MANUFACTURING

UpNano Industrial scale 3D printing of microparts now a reality with UpNano NanoOne Green.

3D printing is often referred to as rapid prototyping due to its ability to quickly and affordably manufacture small volumes of components, particularly those with complex geometries. With no need to produce expensive tooling or moulds, 3D printing is significantly more economical, especially during the development phase, when compared to processes such as injection moulding. However, making the transition to industrial-scale production has been a challenge… until now.

For those needing to fabricate parts with high-resolution (better than ~0.3mm) and a surface finish akin to injection moulded parts, resin-based 3D printing using light-based technologies is the solution.

At the top end of the scale is the UpNano NanoOne Green which can achieve feature sizes as fine as 100nm using 2-photon polymerisation (2PP) technology, making it the ultimate tool for rapid prototyping.

Even with it’s industry-leading printing speed, print times can be relatively long and production volumes are limited.

economical for producers by offering the first fully integrated 2PP-based service for the production of micro parts. Now designers can directly translate their refined designs and processes from the NanoOne platform to the NanoPro VT and utilise the NanoPro service for production without the capital outlay required to buy the system.

Peter Gruber, CTO of UpNano explained that using the NanoPro VT, “makes it possible to print a million identical parts, or a million parts with individual modifications.

In addition, the printer's resolution allows structures and tolerances below 100nm.

The ability to print the entire surface of 200x200mm substrates is also unique. An automatic lens changer increases flexibility

and enables optimised production cycles with the extremely robust NanoPro VT, which operates under ISO 5 cleanroom conditions, is temperature-stable and vibration-isolated.”

The NanoPro service enters the market when the miniaturisation of production parts has often reached the limits of existing technologies such as DLP, μSLA, SLA, MIM, or FDM. In addition, the global economy is driving fierce competition, making economies of scale through highvolume production even more necessary than ever. NanoPro offers scalable solutions that can’t be found elsewhere on the market. upnano.com/nanoone-green/

UpNano recently unveiled the NanoPro VT, the world’s first 2PP 3D printer built for industrial-scale production, offering high-volume microparts on a scale that has never been possible. The NanoPro VT utilises the same 515nm green laser used in the recently released NanoOne Green that yields 30% higher precision compared 780nm lasers, as well as the ability to work with an even broader range of materials, including transparent materials.

The machine uses extremely efficient and cost-effective mechanisms, finally allowing 2PP 3D printing of polymeric microparts at a mass-production scale.

Having led the industry in terms of speed and resolution, UpNano has also made the path to commercialisation more

Volume printing of microfluidic nozzles.

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PLASTICS, COMPOSITES & ADVANCED MATERIALS

BOY Electric: Proven machines rethought The BOY Electric offers all the advantages of an all-electric injection moulding machine regarding high dynamics and parallel movements.

The electromechanical universal injection unit has been redesigned and significantly enhanced for the BOY Electric series. The new type of back-pressure measurement is unique in injection moulding machines. A patent has already been granted. The force transmitted to the screw is recorded at the injection mechanism employing a force sensor and analysed in the machine control system.

The electromechanical drive technology offers additional advantages in the form of even more precise position detection, dynamic movement sequences and shorter cycle times thanks to parallel clamping force build-up for injection.

The proven two-platen clamping unit with the oil and lubricant-free mould installation space is supplied by the established and energy-saving servo-hydraulics. With the pressure intensifier and differential pressure technology, hydraulic pressure is converted dynamically into the clamping platen movement and energy-efficiently into the clamping force. The new electromechanical ejector exceeds the dynamics of its hydraulic counterpart: thanks to its even more precise position detection and very direct control, parallel, precise, and highly

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dynamic movements can be realised in conjunction with clamping platen or handling movements. These not only save cycle time in individual cases but also protect the product, mould, gripper, and machine. The electromechanical ejector also has a major advantage with extremely slow movements, as the stick-slip effects that can occur in the hydraulic system are avoided.

The BOY Electric series has also been given a new machine design, which is not only characterised by its new look. The drive and inverter technology is integrated into the smallest possible space and allows numerous expansion options. A new, compact, low-maintenance safety technology is also finding its way into the BOY injection moulding machines.

This OSSD technology (Output Signal Switching Device) enables very userfriendly monitoring at the highest safety level. By systematically integrating the high-performance technology into the BOY Electric, BOY remains true to its philosophy of minimising the machine footprint. paktec.com.au

PLASTICS, COMPOSITES & ADVANCED MATERIALS

Raymax and HySpex Hyperspectral data collection and analysis – now all at once.

Breaking ground for mining and more industries, a European collaboration has developed integrated hardware and software that enables simultaneous hyperspectral data collection and analysis.

This will transform research for anyone using hyperspectral imaging and data, drones, or remote sensing technologies – with instant processing and analysis done as data is collected.

The collaborators are HySpex by NEO (Norsk Elektro Optik), NORCE Norwegian Research Centre, ReSe Applications LLC, and Prediktera AB. Each collaborator has made incremental innovations on their IP; together, they have achieved an architectural innovation that will benefit many industries.

Imagine a drone collecting hyperspectral data at 500MB per second while, in real time, HySpex’s integrated system will instantly and accurately: • • • •

Generate surface models; Geo-reference hyperspectral data; Perform atmospheric corrections; Run application-specific analyses (mineral maps); • Visualise everything in 3D on the ground station as a mesh.

Dr Cedric Chaminade, Technical Director of Raymax Applications, which distributes HySpex in Australasia, believes there’s a huge bonus for end-users, thanks to the elimination of rasterisation and unnecessary overheads with data post-processing.

“This significant advancement in integration offers a turnkey solution that provides accurate results instantly,” says Chaminade. “Anyone using this integrated

system would reap the benefits of the highest data quality captured by HySpex hyperspectral imaging systems, alongside how it democratises remote sensing by combining hyperspectral imaging, direct geo-referencing, and data analysis – all in real time and in flight.”

HySpex sees the potential as virtually limitless and identifies the most obvious applications as: •

Agriculture: Precision crop monitoring and management • Forestry Immediate detection of forest health or damage • Environmental mentoring Real-time tracking of pollution or climate changes • Defence: Rapid situational awareness and decision-making The HySpex team is grateful to its partners in the m4mining group’s Horizon Europe project and to the European Commission for funding m4mining. This group aims to

improve material characterisation during exploration, extraction, re-mining, and environmental impact monitoring through real-time mineral classification via UAV, giving decision-makers seamless 3D visualisation.

Norsk Elektro Optikk, or NEO, was established in 1985 as a privately owned research company working on electrooptics. NEO’s hyperspectral imaging activities started in 1995 with the Hyperspectral Imager for Small Satellites project for the European Space Agency.

HySpex is now an industry leader in airborne and ground-based hyperspectral imaging, and its sensors are renowned for stability, flexibility, and data quality.

HySpex distributor Raymax has more than thirty years of experience customising and proving results with lasers and photonics equipment in Australasia. Call the Raymax experts at 02 9979 7646 to discuss your imaging needs. raymax.com.au

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engineering plastics online epol.net.au 1800 215 216 sales@epol.net.au

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Reinventing amalgem There’s more to manufacturing dental materials than meets the eye. AMT Editor Paul Hellard opens wide.

Occupying half a nondescript side street in an industrial area of Bayswater, a sprawling medical device research and manufacturing facility buzzes with activity. Inside this complex is SDI Limited, primarily involved in researching and developing, manufacturing, and marketing specialist materials for the dental profession.

Founded in 1972, SDI is fast becoming a world leader in specialist dental materials, and has been recognised with multiple export and international awards.

History Over 50 years ago, the company's Chairman, Jeffery Cheetham OAM, founded SDI Limited. SDI expanded into composites in the 1990s, and whitening and glass-ionomer cements in the 2000s, now making a wide range of materials for clinicians.

SDI Limited’s products compete in the highly regulated medical device market and have full accreditation in each country, including the EU MDR, so they will continue this practice for the foreseeable future. SDI Limited is classified as a medical device company. Those brave enough to visit the dentist every six months will have seen their range of dental products in use.

Technology The high-tech devices are mainly products which the clinician can apply to the patient in situ. SDI is increasingly expanding its technology with composites, adhesives, etchants, glass ionomers, sealants and all kinds of accessories Dr Leon Prentice is the Chief Research & Development Officer at SDI Limited, and was as excited about the products as I. “We work in both the materials space and the manufacturing space – both are really, really complex,” he said. “This is high tech, with strict demands on our materials. And then the production processing side is phenomenal.” The composites made onsite at SDI have five main types of ingredients. Prentice explained that “typically dimethacrylate monomers are mixed with fillers, which are mostly glass or amorphous silica that are functionalised to react to the monomers.”

“Around half of our composite materials are glass,” explains Prentice.

“There's a lot of technology in the glass because it is radiopaque.”

This means the mixture is a paste that sets, or cures when exposed to a strong blue light. “It's typically a strontium or barium glass.

Then, there are initiators to trigger the curing reaction. Usually photoinitiators like camphorquinone and co-initiators. We also add pigments to create lifelike tooth-coloured materials.”

The other technology within the cured material extends to mimicking the aesthetics of naturally translucent teeth. “We need the translucency to get the curing,” he explained. “So there's a whole lot of technology around tailored translucency shades, and even complex opalescence and fluorescence, which natural teeth have.”

Additionally, there are some inhibitors that will prevent premature curing. “Each element involves significant technology because we want these compounds to light cure in 10 to 20 seconds while the patient is in the dentist’s chair.”

Manufacturing The SDI plant has furnaces for producing specialised metals, silver alloys and dental glass. The reasoning behind it was pretty clear.

“We used to have some items made overseas,” explained Jitesh Katoor, Operations Manager at SDI. “But after a few issues, this fueled the drive to start from scratch because we had much tighter control. Now, we can even change the formulation; we can change recipes as the market changes and technology matures. When we perhaps hear from R&D that we need to make another kind of glass,

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SDI Limited founder and chairman, Jeffery Cheetham OAM.

we can change this formulation ourselves, and it can take about a week to produce that glass in a powder form.”

All grinding and surface treatments occur on-site as well, and this process is unified to create the final materials. “There are perhaps four companies in the world doing what we do,” said Prentice. “We also do our own injection moulding of the capsules, syringes, and other delivery systems, to ensure they are as clean as possible. We have 18 injection moulding machines working all the time.”

All encapsulation machines are also made onsite. “Now every part in the line is made here,” explained Katoor. “So the resin, the fillers, the glass, and the plastic parts are all made here. That's about as ‘Australian Made’ as it gets.”

There is also a large contingent of robots at SDI, active in filling, picking and packing their final products. SDI is also actioning a long pipeline of automation projects, trying to get into that heavily automated business. “We have a diverse product range, so we're working with the many local machine manufacturers and robot suppliers to design new assembly lines,” explained Katoor.

Stela The latest product is Stela, a high-performance self-cure composite.

Developed in partnership with UNSW and the University of Sydney, and helped by a CRC-P Government grant, Stela offers an unlimited depth of cure and low-stress polymerisation with a gap-free interface. There is no need to an acid etch or light cure. Instead of photoinitiators, it cures on mixing two resin components, plus adds a primer. “Conceptually, a bit like a twin tube applicator for Araldite, but very much stronger, and very different,” Prentice qualified.

Stela achieves its ground-breaking properties through a tailored combination of BPA-free resin monomers, SDI’s bioactive proprietary ionglass hybrid glass fillers, and specially surface-modified amorphous silica. Stela’s outstanding mechanical properties come from a rapid curing reaction. The Stela monomers form tiny polymeric chains and, simultaneously, these chains are rapidly and densely cross-linked to each other, creating a complex web that strongly binds the ionglass filler and the amorphous silica, resulting in a strong and resilient restorative material. The Stela snap set fast

PLASTICS, COMPOSITES & ADVANCED MATERIALS

cure is due to an innovative hydroperoxide-based initiation system.

This ensures fast-setting characteristics, good colour stability and an excellent conversion rate.

Riva Riva is another SDI product, manufactured for the minimally invasive dentistry area or MID. This is more tooth-like chemistry,” Prentice explained. “It's a polymer-reinforced cement. It's at least three times stronger than your street cement and sets in about four minutes.

It sticks straight to the tooth structure and releases fluoride and strontium ions, synergistically enhancing tooth bio-remineralisation to strengthen your teeth. We love simple preventative dentistry. We hope our materials mean you never need anything more serious than a filling!”

Riva Self Cure replaces dentine by imitating several of its natural features. The ionglass technology utilised in Riva Self Cure replicates the hydrophilic characteristics of dentine and its coefficient of thermal expansion. No etching or adhesive is required to ensure the restoration process is efficient. This significantly reduces chair time

for the dentist and minimises the risk of sensitivity for the patient.

Strength These materials need to be incredibly strong. They are strong enough to withstand significant grinding, as one might imagine.

Natural tooth enamel can be tough, with a 300-400 megapascals compressive strength. SDI’s composites boast similar strength.

“Stela is in that window, integrating well with natural tooth structure.”

Trade SDI manufactures all of its products in Victoria and sells them through distributors in over 100 countries worldwide. SDI also has offices and warehouses in the USA, Germany, and Brazil. A new 24,000sqm property in Montrose is allowing SDI to expand production. The established warehouse was refurbished to meet medical device standards and became fully operational in September 2023. A new manufacturing plant is planned to commence building in 2025, followed by all manufacturing in Bayswater moving in 2027. sdi.com.au

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Swisslog Four 2025 trends shaping warehouse automation and intralogistics. By Dan Ulmamei, Managing Director, Swisslog Australia and New Zealand.

As we roll through 2025, warehouse automation and intralogistics will be shaped by technological innovation, evolving consumer demands, labour challenges, space scarcity, and a continued drive to optimise performance and efficiency.

Organisations are increasing investments in proven automation technologies and unlocking new efficiencies through software orchestration and artificial intelligence.

These advancements are transforming the intralogistics landscape and setting the stage for industry changes. Let’s explore four key trends expected to shape the industry in 2025.

Brownfield Warehouse Automation and the Importance of Scalability With industrial land prices continuing to rise in Australia and New Zealand, particularly in and around major cities, it is becoming increasingly important for companies to make the most of their existing space with retrofits, modernisations, or upgrades to new technologies that bring greater efficiencies.

There are numerous reasons for modernising or upgrading a warehouse automation system. These are typically centred around optimising current operations and investing in cost-effective enhancements that deliver long-term benefits.

Scalability is crucial when considering any automation investment. If your business expands, you want your warehouse to be able to handle additional or different SKUs and greater volumes. The quicker it can adapt, the quicker the business can reap the benefits of its growth.

Micro-fulfillment centres (MFCs) are the next step in creating a harmonious omnichannel supply chain. They have grown in popularity, particularly in the past five years, and the trend will continue in 2025.

An MFC model is a form of hub-and-spoke strategy in which a centralised fulfillment centre (the hub) stores a large amount of stock, and each spoke holds some stock that is replenished efficiently from the hub.

The spokes are often stored themselves, but they can also be delivered directly to home delivery centres, for example.

Hub-and-spoke models are particularly popular with top grocery companies, where freshness and efficient deliveries are paramount.

Automated MFCs allow companies with or without a brick-and-mortar footprint within a particular area to move fulfillment closer

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to customers. This reduces transportation costs and enables shorter delivery times, benefiting both the retailer and the customer. Companies can build a microfulfilment centre as a standalone facility or integrate it into an existing location to expand fulfilment capacity.

The mutual benefits of MFCs are likely to drive their continued expansion this year as supply chains look to increase their efficiency and profitability further. It reduces labour and transport costs, avoids clogging retail stores with pickers and supports higher-order demand levels. In other words, MFCs create a more efficient supply chain.

Software orchestration To achieve peak performance and maximise returns in warehouse automation and intralogistics systems, the right software can make a significant difference.

Companies looking to take operations to the next level in 2025 will use software orchestration to optimise performance for both greenfield and brownfield warehouse automation projects.

Swisslog’s SynQ Warehouse Management System (WMS), modules can include realtime monitoring and full 3D visualisations of the warehouse, with “click-and-solve” functionality. This means, for example, that an operator can access any pallet

within the automated warehouse and make changes to it directly—such as sending it to the reject station or to a clearing station to be checked if something doesn’t look right.

Nearly every industry is discussing artificial intelligence (AI) and robotics, but the intralogistics sector has been reaping tangible benefits from these tools for years now, and they are continually becoming smarter and more capable.

AI-powered systems can facilitate accurate demand forecasting, predictive maintenance, real-time inventory management, and seamless integration with warehouse automation solutions.

These insights streamline order fulfilment, optimise material flow, and enhance overall supply chain performance, allowing warehouses to meet rising demands with precision.

Swisslog is seeing these trends not just across Australia and New Zealand but globally as well. Swisslog can draw upon its extensive local and global knowledge to design and implement solutions in our region that are fit for purpose and designed to deliver optimum returns. Intralogistics is evolving rapidly, and companies that adapt to these trends will thrive in an era of futuristic, highly optimised warehouses.

Swisslog.com

INDUSTRY 4.0

VEPRM Beyond automation: Is manufacturing ready for its next evolution?

For centuries, industrial revolutions have reshaped economies, elevated industries, and redefined human progress. Each shift— whether mechanisation, electrification, automation, or digitalisation—has driven society forward, unlocking new levels of productivity and economic expansion.

However, as we enter the era of Industry 5.0, one question lingers: Have we truly optimised the potential of past revolutions, or have we been too quick to settle for "good enough"?

and automation with human intelligence.

For decades, manufacturing has pursued efficiency—automating processes, integrating IoT, and refining data-driven decision-making. Industry 4.0 promised a future where factories operated autonomously, powered by smart sensors and AI-driven analytics. Yet, despite these advancements, something fundamental has been missing: human ingenuity at the core of industrial progress.

Imagine factories where automation is not rigid but fluid—where machines learn from human operators and adapt in real-time.

Picture a supply chain where sustainability is not an afterthought but a built-in principle, with AI-driven systems constantly refining production methods to minimise waste and maximise efficiency. Consider a workforce that no longer fears displacement but thrives in collaboration with intelligent systems, using advanced tools to amplify their problem-solving capabilities rather than replace them.

This next revolution is about course correction—about revisiting the decisions made in the rush for progress and asking if they still hold up in the face of new possibilities. It’s about balancing efficiency with adaptability, scale with customisation,

The future: Where machines empower, not replace Industry 5.0 envisions a world where technology is not just about optimisation but about empowerment. AI is no longer just an analytical tool but a co-pilot in innovation, assisting humans in designing new materials, optimising energy usage, and unlocking once unimaginable manufacturing processes.

Industry 5.0 isn’t just about improving production lines—it’s about redefining value. It’s about shifting from an era of mass

production to one of mass personalisation.

It’s about making manufacturing faster, smarter, more sustainable, and more human-centric. The question isn’t whether Industry 5.0 will change the manufacturing landscape—it already is. The real challenge is: Who will be bold enough to lead this transformation?

The time to act is now. Manufacturing is at the threshold of its most transformative era yet. Will we seize the opportunity, or will we let history repeat itself—only to ask decades from now, What if we had done things differently?

References 1. Industry 5.0 (no date) Research and innovation. Available at: https://researchand-innovation.ec.europa.eu/research-area/ industrial-research-and-innovation/industry-50_ en (Accessed: 26 March 2025).

2. Industry 5.0: A survey on enabling technologies and potential applications, Journal of Industrial Information Integration, Volume 26, 2022, 100257, ISSN 2452-414X, https://doi.org/10.1016/j. jii.2021.100257. (https://www.sciencedirect.com/science/article/ pii/S2452414X21000558) 3. (N.d.). Retrieved from https://www.energy.gov. au/business/equipment-guides/industry-40

veprm.com

Opportunities The data revolution in carbon markets: opportunities for IoT and emerging tech.

By Sam Sneddon, CEO and Co-founder WollemAI. Carbon markets are entering a new phase of growth, catalysed by global policy shifts like the COP29 agreement on Article 6, which creates clearer standards for international carbon trading. As these markets expand, the demand for accurate, transparent, and real-time environmental data is intensifying—and this presents a significant opportunity for IoT, data, and AI innovators.

Australia’s own regulated carbon market, powered by the Australian Carbon Credit Unit (ACCU) Scheme, is a key part of national emissions reduction strategy.

Alongside it, global voluntary markets offer corporates new avenues to meet manage climate reporting requirements and, ultimately, climate and nature-related financial risk. However, both systems face a critical challenge: a persistent data gap that undermines confidence, pricing, and transparency.

irrigation, to drones that capture vegetation cover and methane leaks, IoT solutions are making carbon and nature data more granular, verifiable, and decision-ready than ever before. This is particularly relevant to emerging biodiversity markets—such as Australia’s Nature Repair Market—which rely on real-time, location-specific data to validate restoration outcomes. The role of IoT and AI in creating robust, auditable records is central to the success of these new markets.

Enter the Internet of Things

Companies like WollemAI are showing what’s possible by using machine learning and geospatial data to assess agricultural emissions, model land-use impacts, and provide scalable MRV (measurement, reporting, and verification) systems.

Their approach highlights how tech solutions from the IoTAA ecosystem can support climate goals while opening new commercial opportunities.

IoT devices, when integrated with Earth observation and machine learning, are transforming how we monitor and measure environmental outcomes. From soil sensors that track carbon levels and

For IoTAA members, this is market opportunity. Integrating IoT and AI into carbon market infrastructure supports transparency, enables dynamic pricing of natural capital, and enhances investor

confidence. It also positions Australian tech companies at the forefront of global climate risk management.

Now is the time for collaboration between environmental stakeholders, regulators, and IoT innovators. With the right digital infrastructure, Australia can lead the world in building climate-aligned, data-driven markets that are transparent, trustworthy, and scalable. wollemai.com

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AspenTech on AI Many industries are dipping their toes into AI use. Many still think the water is too cold. Ron Beck, Senior Director, Solution Marketing at Aspen Technology addresses some doubts.

Artificial Intelligence is not yet being used in some industries.

Asset-intensive industries, such as refining, LNG, hydrogen chemical, mineral processing, and power generation assets, have slowly embraced AI in key processing and optimisation business functions. The reasons for this are pretty logical. These industries maintain a ‘safety-first’ mindset, closely followed by a focus on operational excellence. Design or operational mistakes can incur multi-million-dollar penalties, and process plant issues can create safety risks and “cascading impacts. " Our foundational software systems are heavily relied upon today for these design and operational decisions. This trust results from the hundreds of man-years of first principles chemistry and physics built into the simulation, control, and optimisation systems. Therefore, to address this AI reluctance, AspenTech has focused on delivering AI within the framework of these engineering model-based systems, which we call INDUSTRIAL AI. The domain expertise embedded in industrial AI provides robust “guardrails” that ensure the AI delivers reliable, trustworthy, and explainable results. We expect this approach to accelerate the adoption of AI in areas that have lagged in acceptance, overcoming safety and operational concerns.

AspenTech has incorporated AI into our industrial software solutions since the 1990s. Today, we have a uniquely strong pipeline of industrial AI research in our software development pipeline, with over 25 capabilities productised to date and many more in development. AspenTech brings three unique strengths for rapid innovation around the use of AI to the table. First, the company has a strong team of AI researchers, drawn from the North American AI hotbeds in Massachusetts (MIT and Harvard Universities) and Montreal. Second, AspenTech has deep-domain expertise in the asset-intensive industries, namely energy, chemicals, mining and electric power. Third, the company also has expertise in modern data fabric, which brings together the worlds of OT and IT, contextualising data for use in AI applications.

AspenTech also brings the foundation of our position as an industrial software powerhouse, with widely adopted software systems such as the Aspen HYSYS modeling system and Aspen DMC3 adaptive control system. These solutions are in use in virtually every large global industrial sector, and certainly in Australia, and therefore provide an adoption “anchor” for companies and technical experts to begin to feel comfortable with AI in conjunction with the systems they are used to relying on, and therefore take AI further and faster in creating value for companies.

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AspenTech offers a solution called Aspen Hybrid Models. This software, built on several patented capabilities, combines rigorous simulation models with AI to increase agility and accuracy in matching plant data (the reality on the ground) with the model (the way the plant should run). This approach yields a lot of different use cases, including diagnosing how to reduce energy use and carbon emissions in processes and how to learn faster from pilot plants in introducing new technology such as plastics recycling and green hydrogen.

We also have a collaboration agreement with Saudi Aramco that led us to introduce a new generative AI-powered software product last year called ‘Strategic Planning for Sustainability Pathways.’

This solution uses generative AI to ideate the best pathways within an existing production environment for introducing new, innovative technologies. For example, suppose you have an existing chemical plant or steel plant, and four startup companies come to you with new carbon capture technologies. This tool allows you to quickly conceptualise where these inventions would most effectively fit into your existing plants and processes, as well as rank which would yield the most profit and the greatest carbon reduction. If you attempted this without AI, it would require more experts and significantly more time and effort to arrive at the same resulting strategic options for capital investment.

What is certain is that companies that understand and identify strong value use cases for industrial AI today will be tomorrow’s winners. The immense pressure on the energy and resource industries to become sustainable can only be effectively addressed through digital innovation. I believe that much of this over the next five years will be driven by those assisted and supercharged by industrial AI.

Which area of manufacturing in Australia is adopting AI fastest?

Interestingly, the mining sector is a very strong sector for us in adopting our prescriptive maintenance software. The mining and mineral processing sector is characterised by rigorous environments, utilising extremely large and sometimes one-of-akind equipment. This makes forecasting and predicting equipment degradation a highly valued activity. This is also an area, where autonomous monitoring and operations that take people out of dangerous and rigorous environments has a high value. aspentech.com/en

INDUSTRY 4.0

MFRP Manufacturing Futures Research Platform (MFRP) is a key pillar of Swinburne’s research and industry engagement.

Manufacturing is a key capability at Swinburne University of Technology. We have collaborated with various industry sectors for several years. Our focus is to support our institutes and platforms in delivering successful outcomes for our partners. Strategically positioned at the intersection of design, business, engineering, and information systems, the Manufacturing Futures Research Platform employs advanced manufacturing integration within the global value chain to capture the advantages of design, Industry 4.0, robotics, and sustainability in securing Australia’s industrial future.

Digital Twins for food processing As a leading food supplier to the aged care sector, EzyChef produces a range of food products that support the elderly, and the production of safe and quality products is critically important.

Ezychef and Swinburne Digital Innovation Lab, supported by funding from MFRP, undertook a research project to develop a Digital Twin solution. The Digital Twin solution, underpinned by the Industrial Internet of Things (IIoT), enables real-time data capture and process monitoring. The solution is currently deployed on a production line at EzyChef’s Broadmeadows plant. The key outcomes of this project include real-time visibility of the production process (process, machine, and product data), which has enabled EzyChef to improve manufacturing efficiency.

Composite Testlab The Swinburne-CSIRO Industry 4.0 Testlab is a flagship R&D and training facility within the Swinburne Manufacturing Futures Research Platform (MFRP). By leveraging cutting-edge software and advanced production systems, the Testlab—along with Swinburne’s AIRHUB—has successfully developed and implemented highrate stamp forming capabilities for unidirectional carbon fibrereinforced thermoplastic (CFRTP) composites. This capability is unique within Australia, positioning the Testlab as the only facility in the country capable of conducting such advanced research and development at scale. Mirroring the principles of sheet metal stamp forming used in the automotive industry, this process enables the rapid and cost-effective production of lightweight, geometrically complex CFRTP components. It presents a compelling opportunity for industries seeking to enhance or replace existing metallic and plastic structural components with high-performance composite alternatives. While this technology is new to Australia, it has already seen early adoption in aerospace and space applications abroad.

Unlike conventional composite moulding processes, which can take several hours, stamp-formed CFRTP parts can be manufactured in minutes from flat, OEM-supplied blanks. This positions the Testlab as a national leader in enabling local industry to translate conceptual lightweight solutions into manufacturable, structurally compliant products. Additionally, the Testlab is driving innovation in scalable and cost-effective tooling and processing technologies to support this transition. Combined double-diaphragm forming and consolidation. The Double Diaphragm Former (DDF), housed within the Industry 4.0 Testlab, presents a compelling solution for the high-rate production of thermoplastic composite parts. Designed originally for pre-forming bindered dry-fibre tapes, the DDF operates at temperatures up to 230°C and has successfully processed thermoplastic blanks made from CF-PP, and CF-PC, demonstrating its versatility for industrial applications. Its multi-part forming capability boosts throughput, making it a scalable alternative to stamp forming, particularly for materials with lower glass transition temperatures. By automating the draping process—typically one of the most labour-intensive stages in composite manufacturing— the DDF significantly reduces production time and labour costs, especially for resin transfer moulding (RTM) workflows.

For thermoplastic forming, which often relies on matched metal tooling and autoclaves, the DDF offers a streamlined alternative. It utilises a single side tool with integrated active heating and cooling, enabling consistent, high-quality forming without the need for highpressure systems.

Lemma18: Advancing Australia’s Renewable Energy Innovation MFRP is spearheading an ambitious initiative, Lemma18®, designed to enhance Australia’s capacity in the design and manufacture of advanced renewable energy devices. Backed by MFRP seed funding and Rebus Corp. Pty. Ltd., this multidisciplinary project tackles key challenges in developing innovative solutions for energy generation, storage, and conversion.

Aligned with Swinburne’s strategic focus on research-led innovation, Lemma18® is accelerating the development of cuttingedge design, prototyping, and manufacturing approaches for the next generation of renewable energy technologies. The project aims to deliver a compact, reliable, and economically sustainable hybrid green energy solution capable of harnessing solar, wind, and thermal energy. Unlike conventional systems, Lemma18® is designed to ensure grid stability and a continuous power supply, even under variable environmental conditions, addressing the ‘no sun, no wind’ challenge that limits many traditional green technologies.

The project contributes to national objectives by enhancing Australia’s sovereign capacity to deliver locally developed solutions and reduce reliance on imported technologies. By fostering close collaboration with industry and government stakeholders, Lemma18® supports the rapid translation of research into practical outcomes, laying the groundwork for a more sustainable and selfsufficient energy future. It exemplifies Swinburne’s commitment to bridging the gap between fundamental research and real-world impact, reinforcing its position as a leader in energy-focused manufacturing innovation. swin.edu.au

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Embracing Automation Addressing ASEAN's Manufacturing Challenges. By Lim Boon Choon, President, Hexagon Manufacturing Intelligence for Korea, ASEAN, and the Pacific.

The ASEAN manufacturing sector is at a critical juncture, teetering on the edge of unprecedented growth and formidable challenges. In 2023, foreign direct investment (FDI) inflows soared to a recordbreaking $230bn, a remarkable 24% increase from the annual average of $190bn between 2020 and 2022, according to UNCTAD’s latest Global Investment Report.

This surge in investment is a testament to ASEAN’s magnetic appeal to global investors, yet it also casts a spotlight on the pressing issues that could impede its progress.

Quality assurance, workforce shortages, and cost efficiency are central to these challenges. As the region confronts these obstacles, the demand for automation has become louder and more urgent than ever.

Experts argue that automation is not just an option but an essential strategy for ASEAN to overcome these barriers and solidify its position as a global manufacturing powerhouse.

Manpower shortages: The growing talent gap Nowhere is the need for change more evident than in Vietnam, where realised FDI reached $14.15bn in the first eight months of 2024, with nearly 80% directed into manufacturing (Vietnam Ministry of Planning and Investment). Despite this growth, a severe shortage of skilled workers persists.

A ManpowerGroup survey in 2023 ranked manufacturing as one of the hardest-hit sectors in Vietnam’s labour market.

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This trend isn’t limited to Vietnam.

Across ASEAN’s six largest economies— Indonesia, Thailand, Malaysia, the Philippines, Singapore, and Vietnam—the talent gap is projected to reach 6.6 million skilled workers this year. This scarcity has pushed companies into a “talent tug-ofwar,” destabilising production lines as newer factories poach experienced workers from established ones. For instance, the automotive sector in Thailand has been particularly impacted, with companies like Toyota and Honda struggling to maintain production schedules due to shortages of skilled labour.

Quality and efficiency: Automation as a competitive advantage As global competition intensifies, ASEAN manufacturers must prioritise consistent quality. However, reliance on manual processes often results in variability, product defects, and customer dissatisfaction.

Automation addresses these issues by ensuring precision, uniformity, and efficiency.

For example, Hexagon’s advanced sensor technologies allow less experienced workers to perform complex tasks accurately, addressing the expertise shortage while maintaining high production standards. In Malaysia, electronics manufacturers like Intel and AMD have successfully integrated automated quality control systems, significantly reducing defect rates and improving product reliability. Automation also reduces waste and downtime, making

it a key driver for cost efficiency. According to Hexagon's Advanced Manufacturing Report, companies that have adopted automation technologies report up to a 30% improvement in efficiency and a 50% reduction in product defects. These gains underscore the transformative potential of automation in enhancing both quality and efficiency within manufacturing processes.

Overcoming resistance to change Despite its advantages, the adoption of automation remains slow among small and medium-sized enterprises (SMEs), frequently due to cost concerns. A phased approach—"Start Small, Scale Fast”—can assist in overcoming these barriers.

For instance, a pharmaceutical company in Indonesia that is struggling with high error rates in packaging could implement automated quality management systems in specific production areas. Once the initial investment demonstrates its value, the company can scale its automation efforts across other operations. This approach has been successfully demonstrated by companies like Kalbe Farma, which started with small-scale automation projects and gradually expanded them, leading to significant improvements in efficiency and product quality .

Government support is also crucial.

Singapore’s industrial parks, such as Jurong Island, serve as a model for encouraging technology adoption. By establishing integrated ecosystems and providing financial incentives, governments

INDUSTRY 4.0 Lim Boon Choon, President, Hexagon Manufacturing Intelligence for Korea, ASEAN, and the Pacific.

crucial for survival in a rapidly evolving industry. Companies like Vietnam’s Vingroup have already started this transition by investing heavily in automation for their VinFast automotive manufacturing plants, positioning themselves as significant contenders in the global market.

can assist manufacturers in modernising and staying competitive. Automation stands out as a practical solution to this urgent challenge.

Innovating for the future ASEAN manufacturers can learn from the transformation of South Korean giants like LG and Samsung. These companies transitioned from cost-focused operations

to global innovation leaders through sustained investments in quality, innovation, and automation. This shift allowed them to command premium prices for their superior products.

Similarly, ASEAN manufacturers must go beyond competing solely on cost.

Automation and smart factory technologies are no longer merely aspirational; they are

The ASEAN manufacturing sector has the potential to become a global powerhouse; however, this will require bold investments in automation and innovation.

Manufacturers that act now will overcome current challenges and position themselves for long-term success.

By starting small, scaling fast, and leveraging government support, ASEAN companies can transform today’s pain points into opportunities for growth and technological leadership. hexagon.com

The best of SLA meets the best of light projection – for real production.

• MAXIMIZE ROI Streamline workflows with minimal reliance on specialized personnel. Its cost-efficient design ensures a quick payoff while delivering high-quality results.

• SPEED & VERSATILITY Enhance your production capabilities with a large build area, 5x faster layer cure times versus laser technology, and material changeovers in minutes.

• PREMIER PARTS Leverage the breadth of the Figure 4 Materials Portfolio for professional prototypes, functional end-use parts, and indirect production applications.

Discover the PSLA 270 at www.3dsystems.com/3d-printers/psla-270 © 2025 by 3D Systems, Inc. All rights reserved. Specifications subject to change without notice.

3D Systems and the 3D Systems logo are registered trademarks of 3D Systems, Inc.

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BUSINESS MANAGEMENT

Strategy to execution Why good plans fail and how to fix them. Anthony Hengel is a partner at Mattingly.

Many businesses invest significant time and resources into crafting ambitious strategies, only to see them falter during execution. A plan that looks great in the PowerPoint deck often falls apart when faced with real-world challenges. The gap between strategy and execution isn’t just a minor hurdle—it’s the primary reason why many well-intentioned initiatives fail to deliver results.

For businesses to succeed, execution must be embedded into the strategy from the start. It’s not just about having a good idea; it’s about ensuring that idea is realistic, actionable, and supported across all levels of the organisation. So, why do good plans fail, and how can businesses bridge the execution gap?

The Strategy-Execution Gap: Why It Happens Many organisations fall into the trap of treating execution as a secondary concern, leading to several key issues: •

Execution as an Afterthought – Strategies are developed in boardrooms, but little thought is given to how they will be implemented on the ground.

• Unrealistic Plans – Lofty goals are set without considering operational constraints or organisational resource challenges.

• Lack of Clear Ownership – No one is explicitly responsible for ensuring the strategy moves from paper to reality, creating confusion and inertia.

• Disconnect Between Strategy and Operations – Employees don’t see how the strategic vision relates to their daily work, leading to disengagement.

• Rigid Plans That Can’t Adapt – Businesses fail to adjust to changing conditions because their strategies don’t allow for flexibility.

These gaps lead to frustration, wasted resources, and missed opportunities. The key to fixing them lies in designing strategy with execution in mind from day one.

Designing strategy with execution in mind To ensure a strategy is implementable, businesses need to build execution into their planning process. Ideally this is done through both top down and bottom-up processes. This means: •

Execution-First Thinking – Before finalising a strategy, ask: "How will we make this happen in reality?" Execution should not be an afterthought but a core part of strategic discussions.

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•

•

•

•

Cross-Functional Involvement – Engage frontline teams, operational managers, and other key stakeholders early to validate the feasibility of the strategy and how it will be implemented.

Simple, Actionable Goals – Break down broad strategies into clear, measurable steps that teams can execute – not just lofty statements.

Clear Ownership and Accountability – Assign leaders and teams responsibility for specific aspects of execution.

Real-Time Feedback Loops – Implement regular check-ins and performance metrics to track execution and allow for real-time course corrections.

How to Bridge the Gap Turning strategy into reality requires a structured approach. Businesses can close the execution gap by following these key steps: 1. Start with Execution in Mind When developing a strategy, immediately identify the people, processes, and resources required for execution. If a plan can’t be implemented within existing operational frameworks, it needs to be reworked before finalisation.

2. Align Strategy with Operational Reality Ensure that the strategy accounts for existing capabilities, potential constraints, and market conditions. The best plans fail if they are detached from the realities of the business environment.

3. Communicate with Clarity A strategy only works if everyone understands it. Avoid vague directives and ensure teams know exactly what needs to be done, who is responsible, and how success will be measured.

4. Embed Workflows

Execution

into

Daily

Don’t treat execution as a separate phase—integrate it into everyday business operations. Align performance metrics, incentive structures, and decision-making processes with strategic objectives.

5. Track, Adapt, and Refine Execution isn’t a one-time event—it’s an ongoing process. Businesses must continuously monitor progress, identify bottlenecks, and be willing to refine their approach to stay on course.

A well-crafted strategy is meaningless if it doesn’t translate into action. Businesses that succeed understand that strategy and execution are inseparable. By embedding execution into the planning process, ensuring alignment between leadership and frontline teams, and maintaining flexibility, organisations can close the strategyexecution gap and drive real results.

The challenge for leaders isn’t just to develop a strategy—it’s to make sure it happens. That starts with asking the right question from the beginning: How will we make this work?

Anthony Hengel is a partner at Mattingly.

They are specialists in Strategy to Execution: Consulting Done Differently. mattingly.com.au

BUSINESS MANAGEMENT

Manufacturing in an AI world Julie Harrison is CEO and Director of Harrison Manufacturing Company.

Before Christmas 2024, Ian Bremmer, founder of the Eurasia Group, predicted that within three to five years, our most important relationship will be with our AI (probably in our phones), and this personal AI will ‘know’ us better than anyone else.

And by anyone else, he meant family, spouse and employer.

Bremmer’s forecast means that in ten years the role of government becomes not only disintermediated – as individuals and businesses increasingly use their AI to interact with each other – but paradoxically the citizen-government relationship also becomes more centralised as the control and regulation of IT and data occurs in ever-fewer places.

In this paradigm, the traditional role of ‘government’ is not needed so much for regulation of interaction between people – AI does it. And this opens an opportunity for bad actors, especially foreign governments who – for instance – want to influence voters in an election. But whatever AI portends – positive or negative – how does its rise affect Australian industry?

Change agent The good news is that Artificial Intelligence systems are already being used in Australian industry. They are deployed to drive efficiencies, aid design, achieve decarbonisation and control energy use.

AI is embedded in existing ERP systems where machine learning, predictive analytics and natural language processing (NLP) are used. Australian industry uses AI in supply chains, in particular the automating of complex ordering/receiving and freight logistics, and management of complex energy systems: for example, where a factory has solar, battery and gas turbine and the owner is managing the optimum power output for the least carbon emitted. AI can speed back-office functions such as finance and HR and because it can be trained and customised, it can drive efficiencies in manufacturing processes.

Harrison Manufacturing and SPARC At Harrison Manufacturing and our R&D company, Harrison SPARC (Special Projects and Advance Research Centre), we use a Microsoft pretrained Large Language Model based on SharePoint and OneDrive data. We are able to source enormous amounts of data, but we do it by separating the systems into two distinct entities: on-premises, and cloud-based (AI) language models. Our on-premises model handles sensitive internal operations within our secure environment, whereas we leverage cloud services like Microsoft's

co-pilot for general-purpose, nonsensitive tasks. These systems operate independently for security reasons and to minimise sensitive information leaking into the public realm. We use retrievalaugmented generation (RAG) to enhance our models' responses, by grounding them in our internal documentation and knowledge base, which we are constantly growing. By using RAG our on-premises AI can collaborate with our researchers, giving them the up-to-date information on the latest trials and experiments being performed.

The future of AI The Economist says 75% of AI use is currently personal, ChatGPT etc. The rest is corporate which is the category we fall into. Clearly while consumers blaze the trail, it will be businesses and governments that put AI to the most powerful uses in the future. Ian Bremmer says AI will fill the intermediary roles currently conducted by governments, giving rise to the ‘Gzero’ scenario where – rather than the G20 or the G7, or COP – governments won’t need to meet and align on policy directions.

Global relations will become more regional and fractured, and assisted by AI the countries will group themselves by national interest and perhaps on an issue-by-issue basis. Is this a useful trend? We have to suppose that it will be old-fashioned human judgement that decides that question.

AI downside AI is not neutral. The people who build, control, and train AI programs can slant them in the direction they prefer. What could go wrong? Well, you might rely on an AI app to show you an image from history, but if you used Google’s Gemini AI in early 2024, you’d be struck by the fact that it would not return a picture of a European person. This concentration of data at one vendor might be powerful for a business owner or manager looking for operational improvements, innovations, and new IP; such industrial breakthroughs require intense focus and the ability to mine all relevant data. However, this may not be beneficial for a consumer society that depends on IT platforms to search for ‘facts’ but is instead served non-facts. If consumers are asked to rely on AI, then it must be reliable.

Consumers also need protection because most of them use AI without realising that the machine is ‘learning’ from the user and nudging them into behaviours and purchases they are not consciously aware of. The world’s most innovative people –

inventors, engineers, scientists, writers, academics, musicians, directors, and artists – are quite vulnerable. They have much more to offer AI vendors than regular consumers, and many of these individuals have already had their IP and creative ideas taken by AI training models without their consent.

Finally, while AI significantly enhances our document processing and decision-making efficiency, it is important to acknowledge that increasing our usage of AI over time contributes to the well-known energyconsuming and heat-producing aspects of Artificial Intelligence. This places us in an ethical dilemma: AI has the ability to summarise long documents, allowing us to extract salient points and accelerate our processes and decision-making; but at what cost to the energy grid and the physical environment?

Conclusion AI is great for data retrieval, concept synthesis and sorting through large sets of information to get answers. We use these AI strengths in our manufacturing and our R&D operations. But AI is not the same as a thinking human brain – our critical thinking, our reasoning, is still the most powerful thing. We see it like this: AI can improve human productivity gains when working in tandem with a team of great employees.

That’s the quality we prioritise at Harrison – ‘Real Intelligence’ (RI). Artificial Intelligence is a tool for humans – it doesn’t replace them.

An Industry feature story about Harrison Manufacturing is on page 66-67, in the AugSep 2023 issue of AMT magazine. harrisonmanufacturing.com.au

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BUSINESS MANAGEMENT

OFS launches Mayvn AI OFS’s Australian-built generative AI already improving the figures in manufacturing.

Australian-built generative AI software trialled by iconic American confectionery company Tootsie Roll could provide hundreds of millions of dollars in savings to the manufacturing industry.

The software includes real-time insights that facilitate a greater connection between the C-suite and operational teams.

Australian manufacturing efficiency software company OFS has launched Mayvn AI, a first-of-its-kind artificial intelligence platform designed to improve productivity and strengthen communication between manufacturing executives and operational teams.

“The reality is that most manufacturing executives lack adequate visibility into what’s occurring in their factories. Various factors mean many don’t spend as much time as they’d like visiting, and when they do, they are rarely equipped with the necessary information to engage in meaningful conversations with those responsible for running them. This includes the workers on the front line who operate the production lines every day.”

The Australian-designed and engineered software, Mayvn AI, offers real-time information and insights into what’s happening operationally in manufacturing facilities. This can encompass current issues delaying production all the way through to preparing a business case for capital investment and the related return on investment (ROI).

“We know from experience that the more people engage in conversations about operational performance, the more likely it is that overall engagement will increase, leading to improvements in both performance and profits. The impact is significantly greater when engagement begins at the very top. Mayvn AI takes this a step further by allowing executives to question how much the faulty flow wrapper is costing the business, if there’s a return on investment for replacing it, and even to identify the necessary capital investment.”

Mayvn AI has been trialled with major Australian and global manufacturers, including the iconic US confectionery maker Tootsie Roll Industries, which has reduced specific data-related procedures by over 90%.

Magee also states that this type of AI innovation will support the Government’s Future Made in Australia plan aimed at strengthening Australia’s manufacturing in sectors like renewable energy, industrial innovation, and technology.

“There are things we ‘knew’ were a problem, but Mayvn AI validates and quickly provides us with data to effectively demonstrate the impact of those problems,” said Eric Bader, Manufacturing Systems Manager at Tootsie Roll Industries.

“Reinvigorating such a globally competitive industry can’t happen without modern technologies, and it certainly can’t happen without complete alignment between the boardroom and the manufacturing floor,” he said.

“We’ve seen all levels of our team use Mayvn from our COO to VPs right through to the factory floor. The speed at which it can give us concrete, actionable data and its prompting suggestions to dive deeper into that have been particularly useful. It also supports our wider vision to leverage data mining and analysis to improve our operations.”

Mayvn AI has a global patent pending focused on how OFS has utilised new manufacturing-based data models, significantly enhancing the quality of the insights delivered.

Bridging the gap with AI-powered insights “Times have changed; business leaders today face an overwhelming amount of information from multiple functions—finance, operations, supply chain, compliance, and beyond,” said OFS CEO James Magee. “They are time-poor, constantly making high-stakes decisions, and determining where best to focus their attention.

The pressures of leadership can make it difficult to step away from strategy and spend quality time on the factory floor.

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Following its successful trials with Australian and US manufacturers, the Melbourne-founded company will also launch Mayvn AI further afield as part of its expanding international business, including in the UK, Asia-Pacific, and its new Latin American headquarters set to open in Argentina later this year.

The OFS software Mayvn AI is now available for deployment. It places the performance data of thousands of manufacturing lines across 29 countries front and centre for operators, supervisors, and managers. Asahi Beverages, Dulux, Bega, nudie, AstraZeneca, Twinings, Electrolux, and many other well-known brands depend on OFS to efficiently produce and package their products. ofsystems.com

BUSINESS MANAGEMENT

The forgotten majority Where the future of manufacturing lives. By Paul Lutkajtis, CEO and Co-Founder of Factory.

Walk into almost any industrial area across Australia - or anywhere in the world - and you’ll find the same thing: small, hardworking manufacturing businesses quietly powering our economy. They’re running CNC machines, cutting steel, welding frames, building products, and solving problems.

They represent over 90% of the manufacturing industry, yet they’re often treated as the minority. And nowhere is this disconnect more obvious than in technology.

A misunderstood market For decades, the tech industry has built software for the top end of town - enterprise manufacturers with big budgets, full-time IT teams, and layers of management.

But small manufacturers? They’ve been left to fend for themselves.

The result is a wide gap - not just in tooling, but in understanding.

Too many in the tech world still hold outdated beliefs about small manufacturing businesses: • That they’re not ‘digital enough’ to adopt software; • That they prefer doing things the ‘old-fashioned way’; • That they’re too small to matter.

These assumptions are not only wrong—they’re harmful. They ignore these businesses' core strengths and what makes them exceptional.

The truth about SMB manufacturers My family has run fabrication businesses for over 30 years, and I’ve spent my career building tech products that solve real-world problems. That dual perspective has shown me how entrepreneurial, innovative, and adaptable small manufacturers truly are.

What the broader world often misses: •

They are expert problem-solvers. Every day, they handle unique requests, shifting deadlines, and material constraints and still deliver; • They are fast and inventive. They move quickly and think on their feet; • They are builders. Not just of physical products but of businesses, families, and generational legacies.

What they’re not is resistant to technology. They just haven’t been given the right kind.

The real challenges In speaking with hundreds of small manufacturers, the same themes come up repeatedly. They’re not all dreaming of AI or predictive analytics - they’re looking for practical ways to work better and waste less.

Their biggest challenges include: •

•

•

Quote accuracy and margin control Quoting is often manual and inconsistent. A small miscalculation can wipe out a job's profit. They need tools that help them quote with ease and confidence.

Disjointed systems and double-handling Too many businesses still operate with information scattered across whiteboards, spreadsheets, inboxes, and people’s heads. This creates delays, duplication, and stress. A single source of truth is no longer a luxury - it’s a necessity.

Poor visibility and communication When the team lacks visibility over what’s happening—what’s urgent, what’s ready, and what’s waiting on a supplier—things fall through the cracks. This leads to confusion, frustration, and late nights.

•

Customer communication gaps Manufacturers pride themselves on service, but staying on top of customer updates, timelines, and changes is tough without the right systems. Dropping the ball here damages trust and relationships.

• Work-life imbalance Many owners wear five hats—quoting at 6 a.m., delivering at noon, and invoicing late at night. Without better processes, this is unsustainable, and burnout is inevitable.

These problems aren’t just operational - they’re deeply human.

They affect mental load, job satisfaction, and the ability to grow with confidence.

What needs to change The narrative needs to shift. We need to stop treating small manufacturers like they’re behind the curve and start recognising them as the competent, forward-thinking operators they are.

That means: •

Meeting manufacturers where they are, and growing with them; • Providing tools that adapt to them, not the other way around; • Solving today’s problems, while enabling tomorrow’s growth.

These businesses aren’t asking for a digital revolution. They’re asking for digital respect - tools that understand how they work, fit into their day, and help them move faster, smarter, and more confidently

The opportunity The future of manufacturing doesn’t lie only in massive factories and full automation. It lies in the thousands of small shops nationwide - making, fixing, welding, cutting, and building behind unassuming roller doors. They’re not the exception. They are the industry.

If we equip them with the right tools that enhance accuracy, visibility, communication, and work/life balance, we’re not just boosting productivity. We’re strengthening the foundation of modern manufacturing worldwide.

I’ve witnessed firsthand how transformative the right software can be when it’s developed with a deep understanding of the industry.

It’s not about digitising for the sake of it; it’s about helping good businesses operate better, with less stress and more control.

That’s been my mission from day one, and others who’ve experienced both sides—the shop floor and software—share it.

It’s time to stop ignoring the 90%. It’s time to build for them. factory.app

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ELECTRONICS

Made in Australia Electronics: How to compete The fundamental principle of being competitive is to compete where you can, not where you can’t. Ray Keefe, Managing Director at Successful Endeavour.

When it comes to manufacturing, Australia operates in a highcost business environment, much like Germany. This means we’re not the ideal place for producing low-grade, low-value, and easily replicated products. This is especially true in the electronics sector.

So, if you can’t compete on raw transactional costs, what can you compete on?

Eighteen months ago, we relocated to a larger design office and a separate electronics manufacturing factory in Dandenong South.

Now, we have an SMT pick and place line, enabling us to produce higher volumes of products at a reduced unit cost. However, we are not aiming to become a Contract Electronics Manufacturer (CEM), and we still collaborate with established Australian CEMs such as Precision Electronic Technologies, Duet Electronics, and Entech Electronics. We are not looking to compete with them in volume manufacturing; instead, we specialise in high-quality, high-mix, lowvolume manufacturing for prototypes, field trial units, and niche opportunities. While this is not the core business for the CEMs, it represents a critical area for startups and early-stage opportunities.

When I tell people we have a factory the first question I am usually asked is, “So you are cheaper”? To which the answer is, “No”.

Which leads to the obvious second question of, “How can you compete if you are not cheaper”? Which implies the only thing that matters is price.

Since the core assumption above is wrong, I explain what we compete on. Here is our list of things we can compete on: •

Time – you can have a quote tomorrow and your electronics in two weeks; • Ease of doing business – we have a full design team behind the factory; • Single business relationship – if we designed the product for you then making it for you is very straight forward and you only need the one account; • Test – we can design and build the test systems and because we can build them quickly this also saves time; • Total Cost of Ownership – raw transactional cost is not the only cost, you also need to factor in the rest of them.

We also assist our clients in becoming more competitive by taking into account the needs of all stakeholders. A successful product

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must adequately address the requirements of every stakeholder.

Therefore, it’s essential to consider this. Production is a stakeholder, and to manufacture a product cost-effectively, you need to ensure the design is suitable for manufacturing. In Australian electronics manufacturing, this entails minimising labour content, reducing rework or scrap, and incorporating as many features as possible in software to lower the hardware bill of materials. Considering production assembly and testing from the outset of a project will provide it with the necessary priority.

Other areas are also important, including how the product is sold; the installation, configuration, or commissioning process, if applicable; its usage; field support; and service management. Below is a bit of a map outlining the typical stakeholders involved in getting the product ready for market. There are additional stakeholders beyond this, including some of those mentioned above.

You will notice that Funding and Development Capability impact the most areas. Which leads to the following considerations: •

How are you funding the project and is that enough to get you to a successful product?

• Are you working with the right Design Partner?

The second question also intersects with funding because you can save money by choosing a Design Partner who can’t do the job, but you really didn’t save money because you didn’t get to the finish line. This does not mean that spending more automatically gets you better results. Just that you need to spend the right amount. We find there is usually a primary pressure point on the project, and it is either: • •

Cost – either development budget or unit cost?

Time – how quickly do you need the product ready for market?

• Performance/Features – how well does the product need to work?

The usual rule applies. You can optimise a project around one of these as the primary priority, but not all of them.

I encourage you to think more broadly about being competitive and all the levers available to you. And then compete where you can best compete. successful.com.au

ELECTRONICS

IND Technology RMIT spin-off launches new manufacturing hub in the heart of Melbourne.

The company that produces an early fault detection (EFD) system designed to help prevent bushfires and blackouts worldwide has established a new manufacturing hub in Richmond, Victoria.

IND Technology has commercialised this innovation from RMIT University and installed it across the USA and Canada, New Zealand, Malaysia and Australia.

The EFD technology acts like a smoke alarm for the power network, covering up to five kilometres of powerlines with two devices that listen to radio frequency signals travelling up and down power lines.

Some radio frequency signals are generated by failing assets on the power lines. The EFD system uses the radio frequency information collected by the sensors to determine where and which equipment is failing. With the EFD system, network owners can monitor every network asset around the clock, including during extreme weather when asset failures are likely to first occur.

Professor Alan Wong, who invented the EFD system at RMIT, is the founder and CEO of IND Technology. He said the new facility would generate millions of dollars of export income for Victoria and Australia. The EFD system comprises parts made almost entirely in Melbourne. “We are strengthening Australia’s advanced manufacturing sector, creating high-tech local jobs and showcasing homegrown innovation,” Wong said.

“Our EFD systems have already prevented more than 500 potential fires, primarily in North America where it has been widely adopted.

The demand for our product in North America has fuelled the expansion of our manufacturing facility in Melbourne. The facility will allow us to produce more than 10,000 EFD devices each year to meet the growth.” With this new hub, IND Technology seeks to work closely with regulators and governments to ensure the EFD system is also rolled out across Victoria and the rest of Australia.

In November last year, the company submitted a report to the Department of Energy, Environment and Climate Action on the FireSafe Early Fault Detection trial. “Our trial examined this bushfire safety technology across rural Victoria,” Wong said. “Many of Victoria’s worst bushfires, like those on Black Saturday, were ignited by faults in these old powerlines. These powerlines are still in use to provide electricity to remote areas today, and the risk remains very real.”

Distinguished Professor Calum Drummond AO, Deputy ViceChancellor of Research and Innovation and Vice-President at RMIT University, stated that IND Technology’s trajectory exemplifies the university’s mission to translate academic research for the benefit of society. “IND Technology is on a strong growth trajectory, selling 60 devices in 2020 and 4,000 in 2024,” he said. “Not only has this meant local job and wealth creation, it has also meant lives and property are being saved through the translation and roll-out of this technology born at RMIT.” ind-technology.com rmit.edu.au

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ELECTRONICS

Making Australian manufacturing awesome Can Australian manufacturing set itself up to thrive under fierce international competition through autonomous manufacturing? By Dayalan Gunasegaram and Christian Ruberg (CSIRO Manufacturing).

Emerging AI technologies coupled with a digitally savvy and a highly educated workforce are giving Australia the opportunity to reinvent its manufacturing industry as a high-value, niche enterprise capable of supporting high-end jobs.

The transformative change will manifest as autonomous manufacturing, in which machines independently make decisions, boosting productivity, ensuring quality, enhancing safety, minimising waste, optimising energy consumption, and so forth. The relevant technologies that support these capabilities are already accessible, as evidenced by autonomous vehicles. Australian mines have been early adopters of these technologies, with self-driving trucks operating in several local mines.

The algorithms that facilitate decision-making are trained through machine learning, enabling machines to emulate human cognition.

This capability allows machines to perceive their environment, reason, and make rational and safe decisions—with the advantage that machines can perform these tasks consistently and faster than humans due to their superior data processing capacity. Engineers and data scientists collaborate to guide the algorithms.

As the nation’s premier research organisation focusing on translational applied research, CSIRO is committed to helping Australian businesses transition into an advanced future. In line with this commitment, it recently held a two-day Cutting Edge Science Symposium in Melbourne under the theme of ‘Real-time control decisions using machine learning – for the adaptive control of processes and devices.’

The event was a tremendous success, attracting nearly 150 researchers and engineers from industry, universities, defence, and CSIRO sites nationwide. The enthusiastic participation at the Symposium underscored the growing recognition in Australia that its high-wage economy must embrace advanced digital technologies to remain globally competitive by extracting maximum value from its extensive natural resources and the high education levels of its workforce.

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On DAY 1, inspirational keynote addresses were delivered by several world experts: 1. MACHINE LEARNING – Prof Amanda Barnard, AM (Australian National Uni.) 2. ROBOTICS – Prof. Michael Milford (Queensland Uni. of Technology) 3. FLOW CHEMISTRY – Prof. Richard Bourne (Uni. of Leeds) 4. ADDITIVE MANUFACTURING – Dr. Stephen DeWitt (Oak Ridge National Lab.) 5. ENERGY – Assoc. Prof. Ján Drgoña (John Hopkins Uni.) 6. SPACE/AEROSPACE – Dr. Seema Chopra (Boeing India) and Dr. Nicholas Mulé (Boeing US).

High-quality short talks addressed the practical, and applied end of the spectrum: 1. QUANTUM MACHINE LEARNING – NEC Corporation (Australia) and D-Wave (Canada) 2. AI IN INDUSTRIAL SOFTWARE DEVELOPMENT – Abhijeet Verma (Siemens) 3. CASE STUDIES – Ananth Prakash Jayakumar (Microsoft) 4. SUPPORTING RESPONSIBLE AI THROUGH STANDARDS William Giacometti (Standards Australia) 5. OVERCOMING THE BARRIERS TO INDUSTRIAL ML – Steven Harding (Optrix)

On Day 2, attendees took part in a software coding session and visited several CSIRO laboratories.

If you wish to discuss the application of autonomous technologies in your business with CSIRO’s engineers, scientists, and data scientists, please get in touch with Dr Dayalan Gunasegaram via Dayalan.Gunasegaram@csiro.au csiro.au

ELECTRONICS

Liquid Instruments Introducing more ways to simplify FPGA code development.

With eight new precompiled IP cores and expanded Verilog support, it’s easier to build and deploy custom FPGA code to your Moku device with Moku Cloud Compile.

Hardware at first glance, software at the core. Moku devices combine sleek, compact hardware with an intuitive software interface, delivering 15+ instruments in one easy-to-use solution.

Choose from three versatile options: Moku:Pro for technology development, Moku:Lab for research, or Moku:Go for a portable design and test solution.Moku is a reconfigurable suite of test and measurement instruments integrated into a single, FPGA-based device that removes the friction in multi-instrument test setups.

Unlike conventional fixed-function instruments, Moku allows you to configure and reconfigure complex test scenarios, develop and deploy custom capabilities, and update functionality to meet evolving needs.

With Multi-instrument Mode, you can use up to four instruments at the same time and connect them seamlessly to build a customised test system. Instruments running in this mode can be linked to build sophisticated signal-processing pipelines. For advanced capabilities, drop in custom features designed in Moku Cloud Compile to maximise flexibility.

Choose from three efficient hardware options, each with dedicated specifications, to unlock an unparalleled combination of performance, speed, and flexibility anywhere you need to test.

A software version of a Waveform Generator, Spectrum Analyser, a Neural Network, Phasemeter, Oscilloscope, etc., with Moku, you get a suite of powerful scientific instruments and advanced customisation capabilities to level up your workflow in the lab.

We regularly add new instruments and features, so your device becomes even more powerful over time.

It’s easy to implement custom digital signal processing by writing VHDL code and deploying it your Moku device’s FPGA. Simply access this cloud-based tool directly from a browser. Then develop, compile, and deploy custom algorithms to your Moku device — no software download required!

Available exclusively with Multi-instrument Mode, your code is compatible with any of your device’s professional-grade instruments. liquidinstruments.com

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COMPANY PROFILE

Applied Jenera Jenera’s investment in high-powered fibre lasers from Applied Machinery further expands its fabrication capabilities.

Established in 1974 and trading as Jenkin Bros. Engineers until last year’s 50th anniversary, the new trading name Jenera pays homage to the company’s founders, Bob and Graham Jenkin, while looking forward to a new era in its evolution.

Some key developments in the company’s history occurred with a buyout of management in 2004 by a group including Frank Taranto and Jamie Macaulay, the current business directors and owners. The acquisition of Arthur Ward, a fabrication business, in 2009 significantly boosted the company’s capabilities. The transfer of around two million dollars worth of Kenworth parts business from Australian Engineering (previously Elliott) in 2013 significantly increased turnover. Simon Bowen is the current CEO, and staff numbers today are around sixty.

Operating primarily in Melbourne, Jenera’s key services include precision CNC machining, laser cutting, welding, bending, thread rolling, folding, and painting. A dedicated finished assembly area connects manufactured components, providing customers with a one-stop shop for all their sheet metal needs.

Its machining centre features nine CNC lathes, five VMC mills, and two CNC saws. On the fabrication side, its equipment includes press brakes, welders, laser cutters, brazing, and painting capabilities.

The company operates under the ISO 9001:2015 certified quality management system and has experience across numerous industry segments, including transport, defence, mining, construction and energy. Its specialised products for the defence industry include vehicle roll bars, handrails, valves, brackets, and pipe fittings, with a commitment to delivering these projects to specifications, on time and within budget.

Understanding the mining industry and the requirement for products that can endure the harshest environments has led Jenera to be contracted to manufacture a number of metal engineering services, including fabrication, repair, and refurbishment.

However, Jenera’s main business is metal fabrication services for specialised products in the transport and logistics industry.

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As a wholly Australian-owned and operated company, Jenera is dedicated to collaborating with and supporting local businesses.

This commitment is evident in the company’s long-standing and successful partnership with Kenworth Australia, a subsidiary of Paccar's global truck manufacturer. Kenworth is Australia’s leading heavy-duty on-highway truck manufacturer, built at its manufacturing facility in Bayswater, Victoria. Jenera supplies Kenworth with around

INDUSTRY FEATURE

2,000 parts, including body and cabin panels, chassis parts, specialist engine components, engine mounts, gearbox supports, clutch levers, and more.

Nearly a decade ago, purchasing a 2.5kW CO2 laser allowed for faster cutting speeds, combined with the precision and accuracy only a laser can offer. This expanded the company’s ability to do more complex and extensive metal fabrication, such as whole cab sections for Kenworth. The performance of the initial machine led the company to upgrade to a 6kW fiber laser and, more recently, purchase a high-power 12kW Yawei HLF series machine.

“We conducted extensive research before deciding on the Yawei brand, particularly the high-powered 12kW HLF model,” stated Senior Engineer Kevin Youliang Yi. “It was a significant investment for us, and we wanted to ensure the laser we selected would meet our current requirements and remain suitable in five years.

“Applied Machinery took us to China to view the Yawei plant and see the fibre laser in action. The impressive machine and Yawei’s willingness to provide an extended warranty really gave us the confidence to proceed. Yawei’s very competitive price was obviously an important factor for us, too.”

“Dealing with Applied Machinery has been a pleasure. Daniel Fisher, their Sales & Marketing Manager, is extremely knowledgeable, very helpful and, most importantly, understands things from a customer perspective. Likewise, Applied’s technicians have been quick to respond to any issue or question – that’s one of the benefits of having a relationship with an Australian-based supplier who has been around for many years,” Kevin added.

The number of options available for the fibre laser's laser source and cutting head also significantly attracted Jenera, who chose the German brand Precitec for the auto-focus cutting head.

“Given laser cutting is such an important part of our business, we also wanted to protect ourselves against downtime for planned or unplanned maintenance. The new Yawei gives us that security and ensures we can maintain delivery times and not let our customers down,” Kevin said.

After just a few months, the new Yawei fiber laser has demonstrated its value by reducing cutting times, enhancing productivity, and enabling Jenera to further broaden its product portfolio and capabilities.

Over the past 50 years, Jenera has undoubtedly significantly impacted the precision machining and fabrication sector. With a focus on customer service and investment in cutting-edge equipment, Jenera’s new era is assured. jenera.com.au appliedmachinery.com.au

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Handheld laser welding Programming laser welding cobots: basics and overview.

Welding cobots are designed to work in proximity with human welders to offer many of the advantages of robotic automation in a more cost-effective and easier to integrate package. One of the most important ways welding cobots make automation more approachable is by simplifying programming.

How are laser welding cobots programmed?

Every welding cobot is different, particularly when distinguishing between arc welding cobots and laser welding cobots. Although the specifics may differ the concepts remain similar, however. Going forward we will use the LightWELD Cobot System as reference.

The LightWELD Cobot System is designed with an ABB GoFa collaborative robot which uses a similar programming style to Google's Blockly. Blockly and other similar visual programming languages use drag-and-drop blocks to represent more complex coding concepts. By eliminating typical coding hurdles like syntax, blockbased programming is user-friendly and accessible, especially for those new to programming.

The LightWELD Cobot System uses custom interlocking pre-defined blocks that represent a variety of cobot commands.

Each program comprises a series of steps, motions, and welding parameters. This intuitive representation of code integrates seamlessly with the ease of robot teaching offered by welding cobots.

Here is an example of a common series of programming steps written in an easy to understand list: 1. Move to a safe starting position 2. Move rapidly to a point above the weld starting point 3. Orient the weld tip & move slowly to the weld starting point 4. Set the weld speed 5. Teach the weld start position, weld schedule, and weld end position 6. Move to a position above the next weld and repeat steps 3 through 5 OR return to safe starting position

Manual teaching The most common method of teaching for most cobots, manual teaching, also called teach-by-touch or lead through, allows the operator to move the cobot arm to the desired position by physically guiding the arm through its range of motion. Operators can program air moves by pressing the Arm Side Interface (ASI) button on the top of the cobot. Welding cobot user interfaces also include preprogrammed functions for

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controlling when welding starts, continues, and stops.

Jogging As an alternative to manual arm manipulation, the LightWELD Cobot System also has joystick control to teach the desired cobot paths. The modes of operation are: •

Joint: allows jogging of the major and minor axes separately • Linear: allows X, Y, and Z movements of all axes • Reorient: allows all axis movement around a point The linear and reoriented options are beneficial for programming exact movements and positions. Linear jogging allows the operator to lock one or two axes for movement in just a single axis.

Reorientation of the weld tip in jog mode can enable excellent control over the welding torch position.

How are laser welding parameters controlled?

Beyond controlling cobot motion and welding on/off, creating excellent welds requires the configuration of laser parameters. When physical dials or an external interface configures handheld welding, LightWELD laser sources. The LightWELD Cobot System includes access to all parameters and options on the cobot controller.

Changing laser parameters is as simple as selecting the type of operation (fusion welding, wire welding, tack welding, cleaning), selecting the material, and defining the thickness of the material. This loads in optimised LightWELD presets for

the operation. However, operators can adjust the presets as needed to suit their application better and save them for later use.

How long does programming a welding cobot take?

Welding cobots are explicitly designed with ease of programming in mind. How long it takes to program a welding cobot depends on the task.

Programming complex jobs with many motions or that address multiple parts at once will take longer than programming simple jobs like individual welds. Creating a program for the first time, which can include testing and optimising parameters, also takes longer than running an already defined job. Ultimately, programming a welding cobot often takes just a few minutes.

Is robotic programming experience required?

Cobots, whether for welding or other industrial applications, require no experience with robots or programming robots. Welding cobots like the LightWELD Cobot System can be programmed and in use as soon as the day they are installed.

Getting started with a laser welding cobot solution Implementing a laser welding cobot solution can seem intimidating, particularly for those without automation or laser welding experience. Fortunately, the laser welding experts at IPG are ready to help. Getting started is easy — send us a sample, visit one of our global application labs, or just tell us about your application. ipgphotonics.com

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Nederman fume extraction Changes to Australian Workplace Exposure Standard (WES) for welding fumes.

Safe Work Australia has recently brought in significant changes to the Workplace Exposure Standard (WES) for welding fumes after the Work Health and Safety Ministers endorsed a decision to change Australian legislation.

The new law establishes air quality standards for an eight-hour weighted average at just 1mg/m³, an 80% reduction from the previous limit of 5mg/ m³. This change represents a significant step towards ensuring worker safety by reducing their exposure to harmful welding fumes. The new limit applies to welders and anyone who works near them.

Worker protection in the welding industry has recently faced scrutiny, as serious health issues have been linked to extended exposure to welding fumes, a recognised carcinogen. The quick implementation of this reduction will ensure workplaces actively mitigate the negative health effects associated with welding activities. This decision will also ensure that workers remain committed to their roles without worrying about potential long-term health impacts from their chosen careers.

Implications of the WES changes to welding workers and business owners The recent update to the Workplace Exposure Standard (WES) for welding fumes holds significant implications for both welding workers and business owners.

Here's a run-down of how it may impact you.

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Health Protection for Workers: The WES’s reduction to 1mg/m3 from 5mg/m3 is evidence of an industry shift towards prioritising the health and well-being of welding workers.

This stricter standard aims to minimise the risk of adverse health effects associated with prolonged exposure to welding fumes.

New Compliance Standards for Business Owners: Business Owners or Persons Conducting a Business or Undertaking (PCBUs) now have stricter compliance laws regarding air quality standards in the welding industry. This will entail reviewing your current compliance measures and ensuring your control measures meet the new standards. It may also involve purchasing new extraction products to ensure your workplace practices align with the new stricter standard.

Enhanced Work Environment for the Welding Industry: The reduced WES for welding fumes necessitates

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the implementation of more stringent control measures by PCBUs. By ensuring compliance, businesses will not only prioritise health and safety but also foster an enhanced workplace with increased productivity and employee morale.

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Meeting the Challenge: Nederman's Solutions for WES compliance in welding As the landscape of welding workplace safety evolves, businesses must ensure their workplaces comply with new WES standards and that employees are protected by these regulations.

Nederman is a global expert in air extraction and workplace safety and offers a range of solutions for the welding and metal fabrication industries that help businesses meet the WES guidelines.

Here are just a few ways Nederman can help as you navigate the Australian WES for welding fumes: •

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Experts in welding safety: Nederman profoundly understands welding processes and their associated hazards. With 80 years of experience, they ensure comprehensive knowledge and support for welding businesses seeking to enhance safety control measures to meet new WES guidelines.

Premium air-extraction solutions: Nederman offers a suite of extraction systems specially designed to capture and filter welding fumes. These systems help you create a compliant, safe, and efficient work environment for you and your staff.

Energy-efficient and sustainable options: Nederman solutions recognise the importance of

sustainability and offer energy efficiency, ensuring your business minimises operating costs while aligning with safety laws and sustainability goals.

Access to Australian offices and specialists: Whilst operating on a global scale, Nederman are committed to offering local Australian specialists to ensure that their clients adhere to Australian standards and cater to the specific needs of our Australian clientele. They combine our global expertise with local knowledge to deliver a premium product to the Australian market.

Welding Industry Solutions – Nederman’s Extraction Products for WES Compliance Nederman provides a number of options specifically designed for the welding industry and will ensure compliance with the new WES for welding fumes. Some of these include:

FE 860 – An On-Torch Solution • •

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Portable source capture for on-torch extraction.

Designed explicitly for on-torch applications, extracting fumes directly at the source.

Features a knob for setting suction level, automatic start/stop function, and improved motor performance.

Suitable for maintenance welding applications and compliant with ISO 21904 (W3).

Equipped with warnings for malfunction and filter status, highefficiency Nanofiber filter, and designed for torches requiring max 18kPa at connection point.

WELDING

FilterCart • •

MCP-12S-APT – Air Purification Tower • • •

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Self-contained cartridge dust collectors for ambient air cleaning.

Ideal for factories with welding fumes or suspended dust.

Can be used standalone or in a network, suitable for various workshop sizes and layouts.

Compact and efficient design with high-capacity cartridge filters and patented Nanofiber media.

Flexible configuration with low and high models, quiet fan operation, and user-friendly controller for automation.

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Mobile filter unit for light welding and extraction applications.

Includes an extraction arm with an integrated spotlight for better visibility.

Easy to manoeuvre with a long-lasting disposable filter and optional HEPA 13 filter for enhanced efficiency.

Available in Original and Advanced versions with varying filter efficiencies.

FilterCart Carbon • •

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Specially designed for extraction of odours and gas contaminants.

Equipped with an Extraction Arm Standard and optional HEPA filter for maximum efficiency.

Easy to manoeuvre with optional carbon filter for organic vapours, ensuring a safer working environment.

Embracing change and adapting to new WES for welding fumes – Where to from here?

As your business navigates towards a changed welding safety and compliance landscape, you’ll require a proactive approach and reliable partnership. By prioritising health protection for workers and ensuring compliance with new regulations while utilising sustainable extraction solutions, businesses can successfully meet new safety requirements whilst simultaneously creating more efficient workplaces.

With Nederman’s expertise, welding industry professionals can confidently navigate these changes and continue to uphold the highest standards of safety and excellence in their workplaces. nederman.com

MASTERTIG ACDC FAR FROM THE ORDINARY Perfect for manufacturing work, the MasterTig ACDC welding machine sets new standards for weld quality, usability and power efficiency. Made in Finland, feature-rich, robust and with a modular design, it can be tailored to your exact needs.

Call (02) 8785 2000 or visit www.kemppi.com

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CUTTING TOOLS

Controlling mechanical loads in milling operations Tool paths and cutter positioning on mechanical loads in milling.

A milling operation exposes multiple cutting edges to rapidly changing intermittent loads. Success in milling requires millingspecific choices and considerations.

Whenever a milling cutter is employed, its cutting edges consistently enter and exit the workpiece material. The loads on the milling teeth vary from zero before entry to peak values during the cut and then return to zero at exit. The goal is to manage the intermittent loads of the milling process, thus maximising tool life, productivity, and process reliability. Essential factors for successful applications include cutter positioning, entry and exit strategies, and the control of chip thickness.

Approaching the workpiece The loads on the milling tool are primarily determined by how the cutter and its cutting edges engage with the workpiece. In conventional or “up” milling, the cutter rotates against the direction of the workpiece feed. In climb or “down” milling, the cutter moves in the same direction as the feed. As a result, in conventional milling, the cutting edge enters the workpiece at minimum chip thickness and exits at maximum chip thickness. Conversely, the cutting edge in climb milling enters the work at maximum chip thickness and exits as the chip thickness decreases to zero. In both scenarios, the operation produces a tapered chip. In most cases, tool manufacturers recommend climb milling because it minimises the rubbing and friction that occur at the shallow-thickness entry of conventional milling. In climb milling, entering the work material at full thickness also facilitates heat transfer into the chip, safeguarding both the workpiece and the tool. Chips flow behind the cutter, reducing the risk of recutting them.

In a few cases, however, conventional milling may be preferred.

Face milling with the climb method generates downward force that can cause backlash movement on older manual machines.

Traditional milling, in which the cutter pulls up on the workpiece, may be a better choice with less stable machines, particularly in heavier cuts. Conventional milling also can be effective when milling rough-surfaced or thin-walled materials, and the gradual entry into the workpiece material can protect brittle super hard cutting tool materials from impact damage. On the other hand, the excessive friction and heat that can occur in the shallow entry zone of conventional milling may have detrimental effects on a tool. Uneven force on the tool edge can cause edge chipping and increase tensile stresses. Surface finish may suffer because chips drop in front of the cutter and may be recut.

The full thickness entry of the cutting tool in climb milling subjects the tool to heavy mechanical loads. For most cutting tool materials that is not a major problem. Modern tool materials like cemented carbides and ceramics are powder-based products that have good compressive strength. When discussing cutter positioning and tool entry strategies, machinists should note that positioning the cutter to one side or the other of the workpiece centreline is always preferred. Central positioning mixes the forces of conventional and climb milling, which can result in unstable machining and vibration.

Exit strategies How the cutting edge exits the workpiece is equally important as to how it enters. There is a clear relation between the positioning of the cutter at exit and cutting tool edge life. Cutting edges will chip or break if the exit is too sudden or uneven. On the other hand, attention to the tool's exit can result in as much as a 10-fold increase in tool life. The critical value is the exit angle, defined as the angle between the milling cutter radius line and the exit point of the cutting edge. The exit angle can be negative (above the cutter radius line) or positive (below the radius line). Tool edge failure is

more apparent with exit angles between approximately minus 30 degrees and plus 30 degrees (see Figure 3 image). The width of the workpiece area encompassed by those angles is roughly half the diameter of the milling cutter.

Another way to improve the intermittent nature of the loads on the edges of a milling cutter is to maximise the number of cutting edges engaged with the workpiece at any one time. Applying smaller diameter, close-pitch cutters and larger radial depth of cuts puts more teeth in contact with the workpiece and more evenly distributes cutting forces.

Chip thickness The thickness of the chips produced in milling strongly influences cutting forces, cutting temperature, tool life, chip formation, and evacuation. If the chips are too thick, heavy loads are generated that can chip or break the cutting edges. When chips are too thin, cutting takes place on a smaller portion of the cutting edge, and increased friction creates heat that results in rapid wear.

Chip thickness is measured perpendicular to the effective cutting edge. As discussed earlier, the chips generated in milling continually change in thickness as the cutting edge passes across the workpiece. For programming purposes, tool suppliers utilise the concept of “average chip thickness.” The average thickness is the numerical average of the chip’s thickest and thinnest dimensions. Average chip thickness recommendations for specific tool geometries are such as that when applied and maintained will produce maximum tool life and productivity.

Machinists utilise these principles and methods in basic milling applications to control the intermittent stresses on milling tools.

However, as part requirements become more complex — even at the level of simply milling into corners — manually changing feed rates to maintain recommended average chip thicknesses is essentially impossible. For those cases and beyond, including very complex 5-axis milling, makers of CAM software and advanced CNC equipment have developed techniques such as trochoidal milling and corner peeling as well as constant tool engagement tool path programs such as Dynamic Milling, Volumill, or Adaptive Clearing.

Conclusion Milling machines and milling tooling have evolved to an unbelievable extent, but in many cases their users are not taking full advantage of that technical progress. Recognising the unique interaction of workpiece and tool that takes place in milling and working to moderate the intermittent stresses involved in the process enables manufacturers to achieve the rarely attainable triple goal of maximum productivity, quality and tool life. secotools.com

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Tracks to the future Precision machining for tomorrow’s rail. The world's railway network spans over 1.3 million kilometres. Harish Maniyoor, turning manager at Sandvik Coromant, explores the routes.

Urban and high-speed rail infrastructures have rapidly scaled up over the past decade, establishing a foundation for convenient, low-emission transport. As one of the most efficient modes of transport for freight and passengers, ongoing investment in rail is a high priority for creating a more sustainable, resilient future. But what might this look like from an engineering perspective?

According to the International Energy Agency, rail is among the most energy-efficient modes of transport. Although it represents just 2% of total transport energy demand, it accounts for 8% of world passenger and 7% of global freight transport. Thus, it’s easy to see why world leaders are taking rail investment seriously.

Railway advancements In Europe, significant investments are being made to double highspeed rail traffic and increase rail freight volumes by 50% by 2030, as part of the European Union's sustainable mobility strategy.

Elsewhere, the Biden Administration announced nearly $30bn in investments for rail projects, demonstrating a commitment to enhancing rail infrastructure and service.

Perhaps most significantly, the railway sector in India has undergone many developments in recent years, driven by government initiatives such as dedicated freight corridors (DFCs), high-speed rail projects, and the modernisation of railway infrastructure.

However, to continue driving progress, rail infrastructure will need to undergo substantial upgrades and expansions to meet rising demand, ensure safety, and accommodate technological advancements. This includes modernising aging rail networks, increasing capacity through electrification, implementing advanced signaling systems, and integrating digital technologies for more efficient operations.

Meeting tough demands Railway components such as axles, wheels, tracks, suspension tubes, and other structural parts require high-quality machining tools capable of exceptional accuracy, durability, and efficiency.

These components must withstand heavy loads, intense wear, and harsh environmental conditions, making precision machining critical to ensuring the reliability and safety of rail systems. Highquality machining tools must also offer tight tolerances, consistent performance, and the ability to work with a wide range of materials.

Take rail wheels, for instance, which are subject to extreme stresses and wear from continuous contact with rails, often under heavy loads and at high speeds. Several machining challenges present themselves here. First, very tight tolerances must be maintained.

Even a slight deviation from the specified dimensions could lead to issues like uneven wear, vibrations, or noise during train operation, compromising passenger comfort and safety.

Another major challenge is working with materials that can withstand the intense mechanical stresses and harsh environmental conditions trains are exposed to. Train wheels are typically made from high-strength steel or steel alloys with excellent fatigue resistance and wear properties. However, due to their hardness and toughness, these materials are often difficult to machine. As a result, thermal management during machining is also a key consideration.

Machining high-strength steel generates significant heat, which can cause thermal deformation in the workpiece, affecting dimensional accuracy.

It’s important to recognise that components for different rail types come with their own specific requirements. Freight trains, for instance, are heavy, leading to significant wear on the wheels, and

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brake marks from cargo cars often appear on the outer diameter of the wheels. In contrast, metro wheels are considerably smaller and may feature rubber layers between the outer diameter of the wheel and the hub to minimise noise. Furthermore, those operating on high-speed rail networks have stringent demands for precise wheel dimensions, as these are directly related to passenger comfort. To ensure that the wheels are balanced, the tolerances on the outer diameters are tight, and wheels are frequently re-tuned.

On track with precision machining

Several machining strategies, when combined with robust machine tools, can enhance the production of durable rail components.

Heavy turning is an outstanding method for machining rail components due to its capability to manage large components and high-strength materials, along with its efficiency and precision in working with complex shapes and heavy-duty parts.

When performing heavy turning on rail components, tool life can be significantly improved by focusing on a few key factors. First, choose a cutting tool with a strong, wear-resistant grade that suits the material's hardness and ensures stability throughout the cut.

Minimise cutting forces by using the appropriate feed rate and depth of cut to balance tool pressure, and always ensure proper coolant application to control heat and prevent thermal deformation. Finally, make sure the tool setup and machine stability are optimised to handle high forces and maintain accuracy in turning.

Sandvik Coromant recommends the T-Max P product range for external turning, which offers enhanced cutting stability, better chip control, and extended tool life, allowing for precise and efficient machining of tough rail components like wheels and axles.

Optimised for external turning—from roughing to finishing—TMax® P efficiently handles medium to large components made of steel, stainless steel, cast iron, heat-resistant alloys, and hardened steel. With high precision over and under coolant and the Coromant Capto® quick tool change interface, high stability and a reduced tool inventory can be easily achieved in rail machining.

Additionally, Sandvik Coromant offers expert recommendations on the most suitable turning grades for your rail application, ensuring a complete machining solution tailored to the workpiece's specific requirements.

The future of rail infrastructure hinges on precision machining and innovative technologies to meet increasing demands for safety and efficiency. By focusing on effective machining strategies and tailored recommendations, we can ensure that the rail industry not only meets today's challenges but also paves the way for a sustainable and efficient transportation network for the future. sandvik.coromant.com

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Machining aluminium Is machining aluminium really that easy? What are the main issues when machining aluminium, and how can cutting tools mitigate them?

Aluminium possesses unique qualities and can transform from white to silver. It is incorrodible like gold, as tenacious as iron, as fusible as copper, and as light as glass. It is easily workable and found widely in nature, as it is based on alumina, which forms the basis of most rocks. Aluminium is three times lighter than iron; in short, it has been created expressly to furnish projectile material! This characteristic of aluminium, described by Jules Verne, the French novelist, poet, and playwright, many years ago, explains why aluminium and its alloys have become essential engineering materials. Its lightweight nature, good formability and machinability, and high corrosion resistance have made aluminium extremely popular in the aerospace, automotive, and packaging industries as well as in resin mold manufacturing, homeware, and other fields. The use of pure aluminium is limited. In most industrial applications, aluminium is used as alloys with various alloying elements, typically copper, magnesium, silicon, zinc, and others. Therefore, when discussing aluminium machining, it usually refers to cutting aluminium alloys.

Aluminium is considered a material with good machinability. There is a strong belief that machining aluminium does not cause any particular problems. “Take a sharp cutting tool and machine aluminium as fast as you can” - this tenet is very common in the manufacturing environment. Indeed, aluminium is one of the most machinable engineering materials. Hence, the main task when machining aluminium, as manufacturers perceive, is to ensure maximum productivity based on the capabilities of the machine tools. This is correct; however, your cutting tool should not only allow for this but also facilitate reasonable tool life and not break shortly thereafter. So, what are the main problems in machining aluminium, and what are the requirements for a cutting tool to solve these problems?

Although aluminium has good machinability, cutting aluminium presents challenges. Here are some of them: •

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Difference in machinability Machining aluminium depends on several factors, one of which is its chemical composition. For example, the silicon percentage is an important aspect that affects tool life.

Another factor is the fabrication method: generally, there are two main groups of aluminium alloys – cast and wrought, with the latter representing the majority of alloys. These groups can be further divided into heat-treatable and non-heat-treatable alloys. Additionally, there has been an increase in the usage of sintered aluminium alloys in the industry. All of these factors influence machinability, which can vary within relatively broad limits. Some alloys exhibit machinability that is approximately half that of commercially pure aluminium.

Chip evacuation When cutting, aluminium generates long, curly chips that can wrap around the cutting tool and machined workpiece. This may cause problems with chip evacuation and worsen the surface finish.

Built-up edge Aluminium tends to form built-up edge (BUE) on the cutting tool, which negatively affects surface finish and machining accuracy. High thermal conductivity of aluminium contributes to the BUE development.

Surface quality The sticking of aluminium to the cutting tool results in galling that diminishes the quality of the machined surface.

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Machining stability Low stiffness of aluminium can be a source of vibration, reducing machining results.

Seemingly simple aluminium machining relates to several issues requiring appropriate solutions. The cutting tool has no small, probably even critical, part to achieve success in this process. The development of cutting tools for machining aluminium includes several directions.

Cutting material Advanced carbide grades, including coated ones and extra-hard polycrystalline diamond (PCD), increase performance significantly.

Cutting geometry The optimised cutting geometry, which is achieved through appropriate rake and clearance angles, sharp cutting edges, the topology of chip-forming surfaces, and the shape of chip spaces, is a significant factor in improving cutting action. It ensures free chip flow and reduces the BUE phenomenon.

Tool design Machining aluminium involves high cutting speeds, meaning rotating cutting tools operate at substantial rotational velocities and can experience considerable centrifugal loads. This places additional requirements on the tool's dynamic behaviour and dynamic balance, especially in the case of indexable tool designs and modular tool solutions. Effective cooling is an important factor for improving chip evacuation, eliminating galling, and diminishing BUE formation. Pinpointing coolant supply directly to the cutting zone via the tool body is a helpful way to enhance cooling and lubricity in cutting operations.

ISCAR prominently features cutting tools for machining aluminium in its product range. These tools hold a significant place among the turning, milling, hole-making, and threading solutions offered by the company. In recent years, ISCAR has introduced various new designs that have enriched these products. The newcomers exemplify the development trends in tools for machining aluminium.

Diamond-like carbon (DLC) coating offers an advantageous combination of high hardness and excellent wear resistance.

Additionally, the low friction ratio of DLC against aluminium considerably helps reduce adhesion and built-up edge (BUE) Fig 1

CUTTING TOOLS Fig 2

Fig 4

In indexable milling, ISCAR expands its HELIALU family with inserts made from a hard submicron grade to maintain the insert's cutting-edge sharpness. The new high-accuracy inserts feature aggressively positive cutting geometry and a polished rake face, intended for milling aluminium and aluminium-lithium alloys at very high feed rates (Fig. 3).

New products have also been added to MULTI-MASTER, the popular family of versatile assembled tools with exchangeable cutting heads. These products include solid carbide three-flute 90° milling heads with chatter-resistant geometry and four-flute barrel-shaped heads primarily targeted for 5-axis milling of complex surfaces.

Fig 3

Additive manufacturing (AM) opens new horizons for tool development. New exchangeable heads carrying indexable inserts with MULTI-MASTER and FLEXFIT threaded adaptations (Fig. 4) provide a high-pressure coolant (HPC) supply option through internal channels and outlets produced using 3D printing technologies.

These channels are optimised for coolant flow using computational fluid dynamics. The threaded adaptations allow for customisation based on the modularity principle of the MULTI-MASTER and FLEXFIT families, which offer a wide variety of replaceable adapters, extensions, and reducers. The heads, which are also suitable for machining with minimum quantity lubrication (MQL), significantly expand the application range for milling aluminium alloys, including abrasive ones with high silicon content.

AM enables the creation of ingenious tool configurations to meet the requirements of specific machining applications. A good example is a special boring tool with polycrystalline diamond (PCD) tipped inserts that harmoniously combines inventive design, the results of design optimisation through structural analysis using the finite element method (FEM), and 3D printing capabilities (Fig. 5).

formation during cutting. These properties make DLC ideal for machining non-ferrous metals, particularly aluminium containing up to 12% silicon. ISCAR's two nanocomposite DLC-coated carbide grades—IC1520 for turning and grooving inserts (Fig. 1), and IC1508 for solid end mills and parting inserts—expand the customer's options for improving efficiency.

So, is aluminium really that easy to machine? Probably, but only if you have truly effective tools at your disposal. iscar.com Fig 5

ISCAR's indexable standard-range products have been enhanced with new inserts featuring cutting geometries designed for machining aluminium. These include high-precision double-ended grooving inserts and double-sided ISO-type rhombic and trigon turning inserts. They all have polished rake faces with specially shaped chip breakers to eliminate built-up edge formation and ensure a smooth and light cut. In the solid carbide tool families, ISCAR has added new endmills with a variable flute design to improve vibration-dampening abilities.

Quick-change tooling is one of the main trends in the metalworking industry. Specifically for customers involved in the machining of aluminium wheels, ISCAR has developed a new range of quickchange modular tools for various external and internal turning operations, including profiling and undercutting, facing, and boring (Fig. 2). The system utilises a dovetail connection and full-face contact between the cutting head with an indexable insert and the body, providing extremely high clamping forces to ensure stability and resistance to tough machining conditions.

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WA & NT

STATE SPOTLIGHT

Goldwind renewing power Gold Fields awards wind turbine contract as part of St Ives Renewable Energy project.

Gold Fields has awarded a contract to Goldwind to design, manufacture and construct seven wind turbines for its St Ives gold mine, located 80km south of Kalgoorlie in Western Australia.

The turbines will form a 42MW wind farm as part of Gold Fields’ landmark $296m St Ives Renewable Energy project, which will become one of Western Australia’s largest renewable energy initiatives at an existing mine site.

It’s not the number of turbines that’s news, but their gargantuan size. Together, these elements make the project one of the largest to be commissioned at an existing mine site in WA. Mobile batching plants will be deployed to the site in Kambalda to mix the 900m3 volume of concrete and allow for continuous pours at each of the seven turbine bases.

The entire renewable system is projected to provide power for 73% of the St Ives site and reduce the mine’s carbon emissions by approximately 50% by 2030.

Gold Fields Principal Specialist and Project Director Simon Schmid said the St Ives project was part of Gold Fields’ expanding decarbonisation initiatives at its ten sites and projects across Australia, South Africa, Ghana, Canada and South America.

"We have already made significant progress at our Australian operations, using renewable energy and BESS to generate and store 16MW at Gruyere, 20MW at Granny Smith and 35MW at Agnew.

“We are excited to see the project’s contribution to our broader global decarbonisation strategy, which contains a target of 30% net emission reduction by 2030, reinforcing our long-term and growing commitment to sustainability,” explained Schmid. Turbine manufacturing is already underway, with the components expected to arrive in Western Australia in September 2025, before being transported to the site and construction beginning the following month.

Once commissioned, the project will transform St Ives to be predominantly (73%) powered by clean, green energy, as part of Gold Fields’ growing commitment to ESG and decarbonisation initiatives.

Switching on St Ives will help accelerate total renewable electricity consumption across Gold Fields’ global business to 25%, almost double that of 2022.

Goldwind’s General Manager of Sales and Marketing, William Ives, said the company was building on its delivery of turbines to Gold Fields in WA. “Goldwind is pleased to deliver the wind farm component of the St

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Ives Mine project, the second renewable energy microgrid project in partnership with Gold Fields,” he said.

As part of the St Ives renewables program, Gold Fields has partnered with leading creative consultancy, FORM Building a State of Creativity, to collaborate with local school students and an emerging Indigeous artist in creating a series of artworks that will be showcased on the turbines.

“This program fosters collaboration, creativity and connection and celebrates community by encouraging young artists to share their interpretations of wind as an energy source and what it means to their communities,” Schmid said.

“Their artwork will be showcased across many different applications, including on the turbine cells themselves, which are 130m high once constructed.”

Solar The project also includes a 35MW solar farm, which is currently under construction in partnership with Pacific Energy and should be completed in the first half of 2026. Pacific Energy has received the first batch of solar support frames, the steel frames supporting the individual panels. Those frames will support 66,000

solar panels, stretched across a 2.5sqkm footprint. Some of those components include the solar inverter enclosures and platforms, which Pacific Energy designs and manufactures locally.

The company’s metal fabricators and tradespeople team will construct and assemble the inverter enclosures and Australian steel platforms in its Perth-based workshops. In-house electricians then connect the inverter technology, which undergoes onsite factory acceptance tests to ensure the highest quality and performance standards.

Energy consumption at St Ives is not expected to increase or decrease dramatically. However, transitioning to a greater renewable energy mix will positively impact production costs by reducing reliance on traditionally more expensive grid energy. Ultimately, this project is anticipated to lower power costs to a third of what was previously projected at St Ives without renewables.

Goldfields’ 2030 target of reducing Scope 1 and 2 emissions by a net 30% against its 2016 baseline remains. Gold Fields has also committed to Net Zero by 2050. goldfields.com goldwindaustralia.com

WA & NT

STATE SPOTLIGHT

WPF Overcoming workforce and efficiency challenges at WPF (Formerly Wilson’s Pipe Fabrication).

WPF, a company based in Western Australia with operations nationally, is a leader in multi-discipline engineering services for the Australian energy sector. Renowned for handling diverse materials, from carbon steel to exotic alloys like duplex and copper-nickel, WPF serves some of the most demanding energy producers in the world. Their commitment to quality, with stringent internal acceptance criteria, often exceeding code requirements, sets them apart. WPF facilitates material segregation and process integrity while delivering exceptional results by fabricating across multiple workshops in Western Australia and the Northern Territory.

Operational challenges The tight labor market in Australia presented a significant challenge for WPF. Skilled coded welders capable of adapting to various conditions and fit-ups were scarce, making it difficult to maintain production efficiency and quality. Furthermore, the high cost and disruption caused by weld repairs, estimated to be similar to North America’s average of $1,000 per weld, added pressure to maintain repair rates below 1%. WPF’s reliance on traditional welding methods also introduced inefficiencies. While their manual processes were effective, scaling production without compromising quality or safety proved challenging. The need for a solution that could increase productivity while preserving their reputation for exceptional quality became a priority.

The solution: Novarc’s Spool Welding Robot (SWR™) After evaluating semi-automated options, WPF turned to Novarc’s Spool Welding Robot (SWR™). Unlike other solutions, the SWR stood out as a purpose-built robotic system for pipe welding. Its ability to automate root, fill, and cap passes, combined with advanced seam tracking and rotator communication, offered a comprehensive solution tailored to WPF’s needs. Implementing Novarc’s SWR™ The decision to invest in the SWR™ was driven by its compact design, high-quality welds, and ability to alleviate reliance on highly skilled welders. WPF’s setup included four positioners, enabling a productionline approach where multiple team members could work simultaneously. This configuration optimized material handling and welding processes, enhancing efficiency.

The learning curve for WPF’s operators was well-supported by Novarc’s team.

The SWR™ also proved instrumental in extending the careers of older welders by reducing the physical strain and enabling them to continue contributing to highquality work.

Productivity gains Geometry dependent, WPF reported a 4060% reduction in weld time across initial projects, significantly accelerating project timelines and enabling the company to confidently take on larger, more complex jobs.

Quality assurance With the SWR™’s automated passes and advanced seam tracking, WPF achieved repair rates consistently below 1%. This precision reduced costly rework and optimized quality assurance efforts.

During initial stages, when completing qualifications, WPF exceeded industry standards by identifying, then testing welds at their weakest points, fine tuning the employed methodology and parameters, and enabling consistent mechanical properties to be achieved. This exceeded ASME requirements and has set a new benchmark for quality in the industry.

Strategic benefits The introduction of the SWR™ has strengthened WPF’s position as a market

leader in welding automation in Australia.

The robot’s performance has allowed the company to bid more competitively while maintaining margins.

A partnership built on trust Throughout the process, Novarc’s team provided exceptional support, from commissioning to troubleshooting, ensuring WPF maximized the SWR’s potential. Mitch Wilson, General Manager at WPF, shared, “The support from Novarc has been absolutely fantastic. The relationship we have with their team is solid from the top down.”

The future of pipe fabrication WPF’s investment in Novarc’s Spool Welding Robot highlights how adopting advanced technology can overcome labor shortages, improve productivity, and uphold the highest quality standards.

By combining innovative robotics with thoughtful operational strategies, WPF is setting new standards for efficiency and innovation in pipe fabrication.

As Mitch Wilson remarked, “The SWR™ has positioned us to be market leaders here in Western Australia, and even Australia.

We’re excited to get the most out of our unit in 2025.” novarctech.com

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Hobson Engineering Prevent zinc whiskers with hot dip galvanised products.

Zinc whiskers can pose significant problems if not addressed. Despite their innocuous name, they can cause considerable disruption in data centres. While monitoring temperature and having an effective layout can mitigate risks, it’s crucial to remain vigilant about this concealed threat.

Zinc whiskers are tiny filaments that form on steel surfaces electroplated with zinc.

Zinc protects against corrosion, but the molecular stress from the electroplating process causes it to expand and crystallise to relieve the pressure. They start at only a few microns in length but can grow to several millimetres. It’s important to note that various surfaces develop whiskers at different rates and densities. Zinc whisker growth is unpredictable, but it is believed to be influenced by the conditions during the electroplating process itself. The tiny shards can lead to catastrophic consequences for data centres. They can remain undisturbed for years on floor tiles and other structural supports. While they are more prevalent in older data centres that used electroplated zinc, they can form on this material anywhere, regardless of environmental conditions.

Hazards Unchecked zinc whiskers can lead to everything from a short circuit to a complete system reset, resulting in downtime, repairs, and data loss. Even a gentle air current can be sufficient for them to detach from the surface. Given their microscopic size, they can easily evade filters and settle in sensitive hardware.

Zinc is a highly conductive metal created through electroplating, producing whiskers that function both as tiny wires and lowcapacity fuses. When in contact with microcircuits, these whiskers can either connect currents or cause malfunctions by introducing their own charge. They also possess a DC fusing current, which is the amount of current required to melt the fuse.

This is measured in milliamps (mA) and ranges from 10mA to 30mA. Currents from short circuits can potentially vaporise the whisker, erasing all evidence and making it harder to identify the culprit.

However, if the issue isn't addressed, the electrical failures will only escalate.

Warning signs The clearest sign of zinc whiskers is the equipment's behaviour. If a particular piece of equipment continues to malfunction while the rest function perfectly, it’s likely an individual problem. However, if the equipment behaves erratically, zinc crystals may be the cause. Pay close attention to

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any changes in equipment performance following maintenance work or after a significant disturbance in the data centre, as this could indicate that many zinc filaments were dislodged.

Identification Collect several samples from various spots in the room, particularly from areas that haven’t been disturbed or moved for a considerable time. Carry out the assessment away from equipment sensitive to the zinc filaments, and be cautious not to snap off any whiskers inadvertently.

It may be useful to direct a light or laser onto the surface and tilt the material for a better examination. Use a magnifying glass to look for a dull, slightly shiny silver or dust-like texture. Select a sample likely to exhibit zinc whisker growth. Trim a small section and use double-sided conductive tape or a similar material to secure it under the microscope. Tilt it vertically and direct light down onto the surface to look for any filaments emerging from the metal.

Removal Cleaning or coating strategies unfortunately won’t resolve the issue. Cleaning is only a temporary fix since it doesn’t prevent future growth, and there’s no assurance it was done thoroughly. Additionally, the cleaning process can cause the whiskers to break loose, meaning they will ultimately end up back in the equipment. Coating merely applies a short-term solution to the problem, as the whiskers will continue to grow underneath. This can even cause the coating to chip, further contaminating the air.

The only way to resolve the issue is to address the root cause. Replace all zincelectroplated materials with alternatives to minimise risk. Consider collaborating with an installation company and ensure that any zinc whiskers that break off during the replacement process cannot access the equipment. While working, wear highefficiency particulate air (HEPA) masks to avoid inhaling pollutants. Use a HEPA vacuum to clean up any remaining particles and install HEPA filters throughout the data centre to prevent even the smallest particles from entering.

The data centre should be able to keep running throughout the process, and the time and resources spent replacing the zinc elements is more than worth it.

Prevention Avoid using zinc electroplated materials, as that’s where the trouble begins. Find another method to protect susceptible steel and aluminium in data centres from corrosion, as rust brings problems. Hot dip galvanising is one of the best solutions, as it provides a corrosion-resistant layer of zinc by submerging the steel in molten zinc instead of electroplating, eliminating the risk of whiskers. Powder coatings are a less effective but cheaper alternative that suits applications requiring only light protection against rust.

Hobson’s hot-dip galvanised range is perfect for applications needing a high level of corrosion resistance. No evidence of zinc whiskers has ever been found on these products, making them suitable for sensitive applications. hobson.com.au

FORMING & FABRICATION

CNG supplier Tauranga-based Oasis Engineering – the world's New Zealand energy and fuel transfer specialist.

Oasis products include Hydrogen quick couplers, cylinder valves, ball valves and trailer load/unload manifolds.

Tauranga-based Oasis Engineering continues to expand its international market as a specialist manufacturer delivering world-leading solutions to those pushing the boundaries of energy and fluid transfer to benefit humanity and the environment.

The company initially began as the maintenance division of a soft drink brand but was separated during a restructuring during the 1980s. The new company quickly established a strong reputation as a machine shop that reliably produced high-tolerance precision machined parts in difficult-to-work materials such as stainless steel and titanium. This led to work manufacturing valves and couplings that were required for the new and emerging Compressed Natural Gas (CNG) fuel market for a major CNG supply company and this quickly expanded to every major CNG supplier and to every significant CNG market in more than 40 countries.

Today, Oasis Engineering is part of the ELAFLEX Group of Companies of Hamburg and is manufacturing precision CNG, LPG and Hydrogen reticulation products for the world market, with approximately 80% of production going to the USA, 10% to other world markets and 10% to the local New Zealand market. The company is well placed to meet the demands of emerging markets, including Hydrogen and Methane for heavy transport vehicles and renewable Natural Gas, with sales doubling within the last two years. Oasis also produces specially designed high-quality fluid couplings for the milk industry trailers.

This state-of-the-art manufacturer is fully accredited to ISO 9001:2015 with product

testing facilities, including a Hydrostatic test rig rated to 4000 BAR and an Environmental Test Chamber rated between -800C and +1850C. A new addition will be a Hydrogen product test laboratory which is scheduled to be commissioned by the end of the year.

Meeting the demands for the highest precision and ultimate efficiency from day one, the company invested early on in an Okuma CNC machine and today this hightech machine shop has fourteen Okuma CNC Machines including Multi-tasking CNC Machines, 5-axis Machining Centres, CNC Lathes, Bar Feeders and Robotics.

“Okuma has always been at the centre of our precision manufacturing machine shop, providing unparalleled reliability, easy programming, time-saving multi functions and the highest quality output, coupled with the high level of service backup directly from the manufacturer,” said Managing Director Kevin Flint.

Keeping abreast with future products and meeting the demands of special applications and solutions for clients, is a team of ten engineers in the internal design office covering industrial design, hydraulics, environmental and future product development. Some of the latest

Kaizen methodology plays an important part in increasing productivity in the manufacturing plant and teaching people to perform experiments on their work using scientific methods to identify waste processes. Kaizen is an ongoing daily process in all areas of the business that produces measurable outcomes.

The team of skilled engineers at Oasis Engineering has many years of experience working with different materials, including stainless steel, titanium, brass, aluminium, and engineering plastics.

Oasis Engineering has provided precision contract manufacturing services to external clients worldwide since its inception.

Overall, the company employs some 50 personnel and has at least two apprentices under training at any time, with one or more taken on each year. This is leading to a high retention rate of skilled labour.

“Following the long-term relationship that recently retired Okuma General Manager Fred de Jong has built up with this outstanding company, it will be a pleasure for me to continue with this close relationship to ensure that the right machines always meet their requirements and market needs,” said newly appointed Okuma New Zealand Manager Karl Medley.

“The newly appointed Okuma Service Engineer will also play an important role in further strengthening our services in this area,” he said. oasisengineering.co.nz okuma.nz

SUSTAINABILITY. IT’S UP TO US.

At KAESER, our approach - Research, Rethink, Reuse and Repair - ensures that we minimise resource consumption from the ground up. Every step, from product development to production and maintenance, is designed with environmental responsibility in mind.

Let us help you achieve your sustainability goals. au.kaeser.com

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FORMING & FABRICATION

Rösler shot blasting system Highly automated shot blast machine for engine blocks replaces two spinner hanger blast machines.

With an innovative shot blast machine, one of the largest foundries in Turkey has expanded its capacity for de-sanding and cleaning engine blocks. The high degree of automation of the workpiece handling and the shot blast process was a significant factor in the decision to purchase the RMBS 1-6-400-30 shot blast system from Rösler. Compared to spinner hanger machines, the RMBS system offers not only drastically shorter cycle times but also requires less personnel. In addition, by replacing the two existing blast machines, the new system helped provide valuable additional manufacturing space.

Among other products, the renowned Turkish foundry supplies grey and nodular cast iron engine blocks used in commercial vehicles and ships. The raw castings have maximum dimensions of 900 x 330 x 140 mm and weigh up to 237 kg. To date, both the customer and many other foundries have used spinner hanger blast machines for de-sanding and cleaning the workpieces. In this particular case, the customer operated two machines— one for de-sanding and another for general cleaning. However, due to steadily increasing production volumes, the shot blasting operation has become a growing bottleneck. Consequently, the company decided to purchase an additional, or alternative, shot blast system. The customer project team consulted with four different equipment manufacturers, one of which was Rösler Oberflächentechnik GmbH. Loading and unloading of the engine blocks into and from the blast chamber is handled fully automatically by a robot.

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A shot blast machine, specially designed for engine blocks Rösler presented a unique, highly innovative, and efficient concept unlike other equipment suppliers—the RMBS

1-6-400-30 engine block blast machine.

Adapted to customer requirements, this blast system enables fully automatic simultaneous blast-cleaning of one large or several smaller engine blocks within short cycle times. The machine is equipped with a specially engineered gripper manipulator to achieve this. Once a robot has precisely positioned an engine block

The engine block blast machine RMBS allows the fully automatic de-sanding and cleaning of one large or several smaller engine blocks in very short cycle times.

FORMING & FABRICATION

NYLON POLYAMIDE PA6, PA6.6, 66

Ideal for diverse industrial and commercial applications demanding non-metallic fasteners, our Nylon range offers exceptional durability, chemical resistance, and nonconductive properties After a robot has precisely positioned an engine block in the blast chamber, the gripper picks up and firmly holds this engine block. Once the blast chamber door is closed, the gripper precisely rotates the work piece through the blast media stream.

in the blast chamber, the gripper picks up and securely holds the engine block.

After the blast chamber door has been closed, the blast program, customised for specific workpieces, commences. The gripper accurately rotates the workpiece through the blast media stream. The rotation can be slowed or interrupted for a predefined duration to enhance the exposure of specific surface areas of the engine block to the blast media. These are mounted onto a special workpiece fixture for the simultaneous processing of several smaller engine blocks. The entire fixture is then picked up by the gripper and rotated through the blast media stream.

The Rösler solution increases operational efficiency and drastically reduces personnel costs With the old spinner hanger blast solution, the workpieces had to be manually loaded onto a special ‘hanger’ before being blasted. The new system achieves the required blast results by moving the engine blocks through the blast stream.

The resulting savings in cycle time mean that the de-sanding and surface cleaning operations can now be combined into a single process. This substantially increased the overall shot blasting capacity, making the two spinner hanger blast machines previously used unnecessary. Furthermore, the risk of some regions of the workpieces being shielded from the blast stream by other workpieces has been eliminated.

Special wear-resistant foundry version minimises costs maintenance The six blast turbines, type Gamma 400G8 HD, quickly achieve the desired shot blast results, with each turbine boasting an installed drive power of 30 kW. These turbines are specially designed for shot blasting in foundries and come equipped with eight throwing blades arranged in a typical “Y-design,” as opposed to the standard Gamma turbines with six blades.

Another significant feature of the HD turbine version is its housing, which is lined with extremely wear-resistant tool steel. This unique design allows the throwing blades to attain up to three times longer uptime compared to their standard counterparts.

This reduces maintenance efforts and ensures significantly higher productivity and cost efficiency. The innovative throwing blade design produces up to 20% higher blast intensity while also reducing energy consumption. This provides a highly effective shot blast operation. Additionally, both sides of the throwing blades in the Gamma turbines can be utilised, resulting in considerable cost savings for spare parts. Blade changes are made easier through a quick-change system that does not require removing the turbine from its housing. rosler.com

Protects surfaces and provides excellent insulation in electrical and electronic applications

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Lightweight and resistant to vibrations and abrasions

Quality Fasteners Since 1935

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Driving CNC Efficiency How Dimac and Marand are shaping the future of manufacturing.

For over 30 years, Dimac has supported manufacturers across Australia and New Zealand with expert workholding solutions that enhance the performance of CNC machines. As a trusted performance partner, Dimac works closely with clients to streamline processes, improve productivity and strengthen operator safety.

With tailored solutions that deliver precision, repeatability and efficiency, Dimac helps clients achieve consistent performance while reducing operational costs and driving long-term value.

One such client is Marand Precision Engineering — a leader in precision manufacturing that understands the value of continuous improvement. Looking to implement a more efficient workholding strategy, Marand engaged Dimac’s Sales Manager (Victoria and Tasmania), Adrian Crisan, to explore the best fit solution.

Challenges in modern CNC manufacturing For over five decades, Marand has been at the forefront of precision engineering, supplying high-quality solutions to industries including defence, aerospace, rail, mining and energy.

As the demand for higher efficiency and standardised manufacturing processes grew, Marand needed a solution to: •

Reduce machine downtime caused by lengthy and inconsistent workholding setups.

• Ensure part accessibility to optimise cycle times across various CNC machines.

• Create a universal workholding approach to streamline operations and improve accuracy.

With a strong focus on precision and efficiency, Marand required a high-performance workholding system that would enhance productivity without compromising quality.

Engineering a smarter workholding strategy Adrian worked closely with Marand’s Machining Supervisor, Marco Rando and Manufacturing Manager, Walter Bracciale, to assess their machining requirements and identify a tailored solution.

Understanding Marand’s need for faster setups and greater machining flexibility, Dimac introduced a combination of high precision workholding solutions including: •

Lang Workholding Systems – Standardising clamping across both 3-axis and 5-axis CNC machines for greater consistency and efficiency.

• OK-Vice & Mitee Bite – Enabling high density machining, increasing part capacity per cycle and eliminating unnecessary setups.

• Reven Mist Extractors – Enhancing air quality by reducing coolant emissions, creating a safer, cleaner working environment.

“Dimac has a comprehensive product range for milling and turning machines," said Marco Rando, Machining Supervisor at Marand.

"Adrian and the team have an excellent understanding of machining concepts, whether it be a one-off part or a small-to-medium batch run.” With these solutions in place, Marand experienced significant improvements in workflow, operator efficiency and overall machine utilisation.

Achieving precision, productivity and cost efficiency Since implementing Dimac’s solutions, Marand has achieved measurable gains in its CNC operations: •

Setup Time Reduced – Zero-point clamping eliminated the need for repetitive clocking in of vices and chucks, significantly cutting idle time.

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•

Fewer Errors, Better Finishes – With 90% of parts machined in a single setup, repositioning errors were eliminated, resulting in flawless surface finishes.

• Cost Efficiency & Material Savings – Workholding requirements were cut to just 5mm, reducing waste and maximising material usage.

• A Safer & More Ergonomic Workplace – Operators experienced less fatigue, thanks to a streamlined and intuitive workholding process.

“Our throughput has increased on key machines due to machining process optimisation," said Walter Bracciale, Manufacturing Manager at Marand. “The requirement for fixturing is no longer necessary, which has significantly improved our efficiency.”

Why choosing the right workholding partner matters While advancements in technology and automation continue to shape manufacturing, precision, consistency and efficiency remain the foundation of success. The right workholding strategy plays a crucial role in achieving these goals.

For Marand, working with Dimac wasn’t just about sourcing the right products — it was about building a long-term partnership focused on continuous improvement. “Even after implementing a solution, Adrian follows up with strategies for ongoing optimisation,” added Marco Rando. “He understands our needs and the importance of refining processes for long-term success.”

With Dimac’s workholding expertise, Marand has strengthened its competitive edge, achieving higher precision, greater efficiency and long-term cost savings. “Dimac has been a game changer — not just for 5-axis machines but also for 3-axis and turning applications,” said Walter Bracciale. “Their solutions ensure a safer, cleaner workshop with enhanced productivity.”

Workholding for the future The collaboration between Dimac and Marand is a testament to the power of strategic workholding in modern manufacturing. By investing in high-performance solutions, Marand has successfully optimised productivity while maintaining the highest standards of precision and quality. As Australian manufacturers continue to push the boundaries of CNC technology, choosing the right workholding partner will be key to achieving new levels of efficiency and profitability.

Maximise your CNC performance with precision-engineered solutions that improve accuracy, efficiency, and profitability— backed by Dimac’s expertise. dimac.com.au

FORMING & FABRICATION

CE certification The hidden risks of non-certified machinery in Australian manufacturing.

In the fast-paced and cost-driven world of manufacturing, businesses often face tough decisions when investing in new machinery. While price is a major factor, cutting costs by opting for non-certified machines can have serious consequences—ranging from safety hazards to costly downtime, regulatory challenges, and limited resale opportunities. Globally, machinery safety regulations have become more stringent, particularly in regions like Europe, where CE certification is the benchmark for compliance. While Australia does not mandate CE certification, the risks of operating non-certified equipment are becoming increasingly evident.

CE certification, or CE marking, is a European safety and compliance standard ensuring machinery meets rigorous health, safety, and environmental protection requirements. The CE mark signifies that the manufacturer has verified the machine’s compliance with European safety directives, often involving independent assessments and rigorous testing. For manufacturers, CE certification assures that equipment meets a globally recognised standard, minimising the chances of operational failures, safety incidents, and compliance issues. While Australian standards such as AS/NZS 4024 focuses on machinery safety, CE certification continues to be a well-regarded mark of quality and reliability, providing businesses with a safeguard against unforeseen risks.

Australian manufacturers importing non-certified machinery often do so to cut costs, but these machines can introduce significant risks: •

Workplace safety concerns – Machines without stringent safety testing may lack essential protections, increasing the likelihood of accidents, injuries, and workplace liabilities.

•

Operational downtime – Unverified equipment can fail more frequently, leading to unplanned maintenance, production slowdowns, and costly repairs.

• Regulatory & compliance challenges – Although not legally required in Australia, safety authorities and insurers may impose restrictions on non-compliant equipment.

• Limited resale & export opportunities – Machinery that doesn’t meet international standards may be difficult to sell or operate in highly regulated markets like the EU. • Insurance & legal risks – Some insurers may refuse coverage for non-certified equipment, leaving manufacturers exposed to financial liabilities in the event of an accident.

• Long-Term Support & Maintenance Issues – Non-certified machines may lack local technical support and spare parts, leading to extended downtime and expensive workarounds.

As Australian manufacturers continue to navigate a rapidly evolving industry landscape, ensuring that their machinery complies with global standards will be a key factor in maintaining a competitive advantage. Whether through CE certification or adherence to AS/ NZS 4024, prioritising certified equipment is an investment in both safety and sustainability.

Investing in the right equipment is crucial for your business’s growth and safety. With Headland Technology, you gain a trusted partner dedicated to delivering machines that meet the highest international standards. Let’s build a safer, smarter future together! headland.au

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Technidrive Drive systems for harsh environments. Technidrive takes an Eiffel.

During the construction of the Eiffel Tower, engineer Gustave Eiffel noticed the tower could be used as a giant thermometer.

Due to the structure expanding and contracting with temperature changes, its height can vary by up to 15cm. This engineering quirk demonstrates the impact of temperature extremes on industrial structures.

However, temperature is just one of many engineering considerations in today's complex industry settings. Here, James Chester, director at Technidrive, explains how the right systems integrator can help to navigate these complexities.

Environmental conditions can wreak havoc on the longevity of motors and gear units. From extreme temperatures and corrosive substances to dust, moisturelace, and vibration, the environment can put a significant strain on equipment. Consequently, engineering suitable drive trains can be extremely challenging. Additionally, many end users are unaware of these specific requirements when commissioning a system.

Among the most common challenges is the fluctuation of temperatures. Whether extremely hot or cold, this variation can lead to thermal stress, affecting the lubrication and performance of motors and gear units. Continuous operation at either end of the temperature spectrum can also cause damage — whether that’s the extreme heat experienced in an oil refinery or the operation of a motor in a consistently sub-zero environment, such as that of a cold storage facility.

Moisture and humidity also have an impact. Ideally, an integrator would have prior experience of drive systems that operate in a similar environment, or the technical knowledge to advise on the correct materials selection. Does the system need to be resistant to corrosion and rust? If so, the integrator may specify using corrosionresistant coatings or specialised alloys in the construction of motor casings, drive enclosures and gearbox housings.

Ensuring that cable entry points, shaft openings and other potential entry points are properly sealed is also crucial. This is an area that is often missed when end users integrate systems themselves. Calling on a professional with knowledge can ensure cable entry points, shaft openings and other potential entry points are not exposed to moisture — minimising maintenance and repair headaches in the long run. In fact, systems integrators like Technidrive can guide equipment selection based on ingress protection (IP) ratings, ensuring that the chosen components meet or exceed the required level of protection against containments. For example, an IP65rated motor can withstand water jets and dust ingress, making it suitable for harsh conditions in industries like pharmaceutical and food production.

Testing and performance Systems for harsh environments should also be tested against the conditions they will face in the field. As well as the aforementioned environmental conditions, a system will be exposed to vibration, shock loads and wear and tear throughout its operational lifespan.

With each project Technidrive completes, we use our experience to ensure the system is built to last. Even with the best preventative measures, drive systems will require maintenance throughout

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their lifespan. A systems integrator can support this in several ways. As standard, Technidrive’s engineers provide a comprehensive suggested maintenance schedule. For users that want more reassurance, there are also options to incorporate remote monitoring technology within the system.

Using a combination of sensors and data capture technology, these tools provide operators with real-time data on environmental conditions and equipment performance.

In an extremely hot environment, like an industrial bakery, this could measure the temperature. The system will then generate alerts and notifications when predefined thresholds are crossed.

Let's say a motor surpasses the safe temperature limit, the bakery’s maintenance team will be informed immediately, allowing engineers to make adjustments or repairs to avoid downtime or stoppages.

This technology minimises the likelihood of expensive unplanned downtime and can also yield major safety benefits. This is particularly important since many harsh environments are also hazardous — think bakeries, oil and gas facilities, pharma and mining. Choosing a systems integrator that understands the challenges and regulations of harsh and hazardous environments is crucial.

The height variation of Gustave Eiffel’s tower seems pretty minor in comparison to the engineering challenges faced in industry.

Integrating a drive train package is incredibly complex and leaning on the expertise of an experienced systems integrator is even more important in extreme environments. technidrive.co.uk

FORMING & FABRICATION

The Flexible Smart Job Shop Salvagnini’s Flexible Smart Job Shop (FSJ) integrating three different stand-alone systems which work together to handle converging production jobs.

FSJ is an evolved, connected, and fully integrated flexible production system that enables the automatic production of various parts without requiring operator intervention or machine downtime for retooling. The systems that comprise the FSJ can function independently or collaboratively, adapting to diverse production needs, ranging from the creation of small batches to the production of complex kits. The integration of intermediate storage and upstream and downstream workstations ensures an exceptional level of flexibility, making it ideal for optimising production flows and supporting just-in-time production, thereby reducing idle times and waste.

The FSJ consists of the new L3.G4 fibre laser, in a fully automated configuration; the P-Robot, combining a P2-2120.G4 panel bender and a 6-axis robot; and the B3 press brake.

High-performance and versatile fibre laser. L3.G4 boasts automated configuration, neural-network-based artificial vision, and advanced material handling. The system introduces a high-accessibility gantry architecture, combining rigidity, precision, and a 15% increase in performance on medium-to-thin thicknesses. The ACUT option enables cost-effective cutting with compressed air, while NVS and SVS artificial vision systems enhance beam centering accuracy and the efficient reuse of sheet metal leftovers.

P-Robot. 100% flexible production strategy. P-Robot is the Salvagnini application that combines a P22120.G4 panel bender with a 6-axis robot to maximise flexibility in kit, batch, or single-part production. Integrated with the innovative RVS (Robot Vision System), P-Robot autonomously identifies and positions parts, and loads them without operator intervention and centring.

P-Robot’s flexible operating modes—robot-to-robot (R2R), robot-to-human (R2H), and human-to-robot (H2R)—adapt to production needs seamlessly without retooling. Thanks to adaptive technologies, the P2.G4’s universal bending tools and automatic ABA blankholder allow continuous production without downtime, ensuring zero-waste output. The panel bending program, created with STREAMBEND, works seamlessly on both P-Robot and standard panel benders without modification.

Technical innovations such as Direct Drive motors and KERS energy recovery ensure fast, efficient, and environmentally friendly operation without sacrificing productivity. Adaptive technologies like MAC3.0, S-Crowning, TFC2.0, and AMS laser angle measurement enhance accuracy, compensate for material variations, and assure consistent bending results. The intuitive STREAMFORMER software, ideal for offline programming, further increases overall system efficiency and productivity. salvagninigroup.com

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Price’s Fabrication TXM Lean Solutions streamlines Price’s Fabrication + Steel shed and tank supplier.

Price’s Fabrication + Steel is a family-owned business based in Williams, Western Australia. They specialise in custom-designed agricultural sheds and water tanks, serving the Southern Wheatbelt and Lower Southwest regions. Their shed offerings include machinery, workshop, hay, commercial, drive-through, and fertiliser sheds. Price’s Fabrication + Steel is a strong, well-managed, and successful WA business with a positive outlook.

The challenge Price’s Fabrication + Steel encountered several growth-related challenges and sought external support to help resolve bottlenecks, uncover new opportunities, and enhance overall productivity. An initial visit to the Williams site revealed several areas ready for improvement.

Price’s was dealing with a 12-month backlog of orders at the time.

Compounding the issue, large volumes of materials occupied valuable space on-site due to long restock times—some items required up to six months to replenish. As a result, the company held six months' worth of inventory at any given time to manage supply chain delays.

One of their most persistent issues was design inaccuracy.

Transitioning design plans from paper to digital was underway to improve precision, but inefficiencies remained. Additionally, the fabrication schedule was managed through a complex, manual process with limited visual management tools, making it difficult for operators to track progress or gain clear visibility into workflows.

TXM Senior Consultant Jeremy Wylie was brought on board to lead the initiative. He began by guiding a cross-functional team in mapping current-state processes and identifying existing bottlenecks.

The solutions “Price's Fabrication has a lot going for it,” said Wylie. “There are some real opportunities here to streamline processes, cut waste, and make things run smoothly across the facility.” A comprehensive action plan was developed and structured into three key components. “The RACI method has proven valuable to ensure everyone knows what they are doing. As we employ more staff, this has become a game changer as people are not waiting for the go-ahead from Jon, nor are two people doing the same thing. Also, Jon and I are kept informed of what is happening,” said Managing Director Tracey Price.

A robust and scalable visual management system was introduced to enhance visibility of work in progress. TXM designed and implemented visual management boards, offering a simple and effective way to display key information for all staff. Additionally, a kanban system was introduced to streamline the management of consumables and stock replenishment.

“Visual management has brought the tools out of toolboxes, the information out of the computer, and helped minimise waste. It has also empowered our people by removing their frustrations and allowing them to be proud of their workplace,” said Tracey Price.

One of the most impactful improvements targeted a major bottleneck: design inaccuracies. Previously, outdated paper drawings often led to errors and rework due to unrecorded design changes. To address this, a contractor is now responsible for completing the initial design at the quoting stage, helping to catch and prevent errors early in the process.

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The results The team at Price’s fabrication has gone above and beyond to change their processes and develop a new way of working. In the process, they have found a new revenue stream. The results from the TXM engagement have enabled them to take on new and emerging work in defence as well as: • • • •

Reducing Lead Times from 12 months to six months; Increasing tank installations from 120 to 240 a year; Increased gross profit by 45%; Created an alternative revenue stream – Laser cutting automation.

TXM Lean Solutions is one of Australia’s leading Lean and Operational Excellence Consultancies, delivering achievable, sustained results.

Our experienced consultants have the expertise and resources to make your business vision a reality. txm.com

FORMING & FABRICATION

Advanced Steel Fabrications Advanced Steel Fabrications elevates productivity with AORE CNC laser technology.

In the current competitive manufacturing landscape, the principles of efficiency and precision are paramount. Advanced Steel Fabrications, a leading steel processing and fabrication company in Australia, has recently made a significant investment in cutting-edge CNC laser technology to enhance its production capabilities. By integrating both AORE 2D Sheet and 3D Tube CNC Laser Cutting Machines, the company has effectively improved the speed, quality, and versatility of its operations.

Meeting industry demands with AORE CNC lasers Advanced Steel Fabrications has built a solid reputation for delivering high-quality steel components for sectors such as construction, mining, and infrastructure. As the demand for more complex and precision-engineered components grew, the company sought a solution to streamline production without compromising accuracy.

After evaluating various options, Advanced Steel Fabrications selected AORE’s 2D and 3D CNC laser cutting solutions. The combination of these machines has enabled them to increase cutting speeds, minimise manual processing, and achieve superior edge quality, ultimately enhancing the efficiency of their production workflow.

Transforming production with 2D & 3D cutting capabilities The AORE 2D Sheet CNC Laser Cutting Machine has afforded Advanced Steel Fabrications the ability to cut flat sheet materials with remarkable precision. Utilising high-speed fibre laser technology, it has significantly reduced cycle times and minimised material waste. Furthermore, the machine's automated functionalities have diminished the dependency on manual labour, thereby enabling the company to fulfil stringent production deadlines with greater efficiency. The AORE 3D Tube CNC Laser Cutting Machine has been a game-changer for processing tubular and structural steel

sections. This machine allows for precise notching, hole cutting, and complex profile cutting in a single setup, eliminating the need for secondary operations. As a result, Advanced Steel Fabrications has improved component accuracy and consistency, ensuring better fitment and weld-ready parts straight off the machine.

Boosting productivity and quality standards Since implementing AORE CNC laser cutting machines, Advanced Steel Fabrications has experienced up to a 40% reduction in processing time and a significant decrease in material handling requirements. The advanced automation and intelligent software have optimised nesting and cutting paths, maximising material utilisation and reducing waste.

Moreover, the high-quality cuts produced by the AORE machines have enhanced the company’s finishing processes, reducing the need for post-processing work such as grinding and deburring. This has not only improved turnaround times but also enhanced overall product quality, meeting the stringent demands of their customers.

Advanced Steel Fabrications’ investment in AORE CNC laser technology underscores the importance of adopting innovative solutions to remain competitive in the manufacturing industry. By leveraging the latest advancements in laser cutting, they have positioned themselves as a forward-thinking company ready to tackle the challenges of modern steel fabrication.

At Industrial Machinery Sales & Service (IMS), we take great pride in supporting Australian manufacturers by offering world-class CNC solutions such as AORE. As the industry continues to evolve, we are steadfast in our commitment to providing cutting-edge machinery that enhances efficiency, ensures quality, and fosters long-term success. industrialmachinery.net.au advancedsteel.com.au

1936AMTJUNJUL25

AMTIL gratefully acknowledges the support of its Corporate Partners.

AMTIL’s corporate partners offer a selection of products and services that will benefit our members in their business. For any enquiries about our Corporate Partnerships, and how they can benefit you, contact AMTIL on 03 9800 3666.

Our Partners. Our Members. Your Benefits. amtil.com.au

Scan to learn more about AMTIL Corporate Partners.

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FORUM GOVERNANCE

Governance in manufacturing How governance has become a strategic edge for manufacturing businesses. Ruthra Sundararajah is Senior Manager, Audit & Assurance, and Jeffrey Luckins is a Partner, Audit & Assurance at William Buck.

In manufacturing today, strong governance is the foundation of resilience, competitiveness and growth. Businesses which treat governance as a strategic weapon, not just a compliance exercise, will be the ones that survive disruption, protect value and lead the next era of Australian industry.

perspectives, sharpen oversight and encourage rigorous decisionmaking. Financial institutions also assess governance quality when reviewing credit applications, particularly in sectors that are exposed to cost volatility or offshore supply chain dependencies.

In 2023, the Australian Securities and Investments Commission (ASIC) reported 41% of SME failures were linked to poor financial control. Manufacturing businesses made up 13% of all insolvencies — evidence that better financial governance is required.

Manufacturers with formal risk registers, escalation policies and contingency plans have navigated workforce disruptions, supply chain bottlenecks and shifting customer demands far more effectively since the COVID-19 pandemic.

The failures of Australian manufacturing businesses Qenos (2023), Tritium (2023), and Highline Caravans (2024) illustrate that operational strength alone is insufficient. High labour costs, volatile and increasing energy costs, under-capitalisation, the need for investment in new plants, excessive debt, and weak financial controls crippled these businesses.

Research by the Australian Institute of Company Directors (AICD) in 2023 found that businesses with structured governance frameworks were 25% more likely to survive over the long term. Similarly, a 2023 Australian Industry Group survey found that manufacturers with formal governance arrangements achieved higher productivity and faster recovery after economic disruptions.

Today, with new tariffs and rising protectionism reshaping global trade, Australian manufacturers face new pressures and opportunities. Businesses with resilient governance structures, clear escalation protocols, transparent financial reporting, diversified supply chains and proactive risk management are adapting faster and more successfully.

Manufacturers working with the Advanced Manufacturing Growth Centre (AMGC) demonstrated stronger performance during supply chain crises, using governance frameworks to diversify markets, drive innovation and secure new investments. Formal governance structures provided the foundation for these businesses to expand into new export markets, negotiate more favourable financing terms, and strengthen customer loyalty.

Governance must be flexible enough to adjust as business conditions evolve. Frameworks that anticipate change and enable responsive decision-making are a critical advantage.

Good governance is about implementing and monitoring practical systems: •

Internal control systems that minimise the potential for errors or fraud; • Accountability structures that support sound decisions; • Board oversight that challenges assumptions; and • Risk management analysis and decision making that addresses challenges beyond immediate threats.

For smaller manufacturers, the discipline of governance is equally essential. Even a modestly sized board can drive accountability, improve lender confidence and strengthen supplier and customer relationships. Appointing independent non-executive directors or external advisors can provide valuable complementary

AMT JUN/JUL 2025

Governance practices directly strengthens operational resilience

Some practical steps manufacturers can implement immediately to enhance resilience and address opportunities are scenario planning, stress-testing financial assumptions, maintaining liquidity buffers and involving the board and management in risk discussions.

Good governance is essential for Australian manufacturers to successfully navigate solvency and grow operations. In an industry exposed to supply chain disruptions, rising costs and geopolitical tensions, good governance can be the difference between resilience and collapse.

For more information, please contact Jeffrey Luckins, Partner, Audit & Assurance at Jeffrey.Luckins@williambuck.com or Ruthra Sundararajah, Senior Manager, Audit & Assurance at Ruthra.

Sundararajah@williambuck.com. williambuck.com

97

FORUM FINANCE

Smart cash flow strategies Mastering working capital management can help unlock financial resilience and fuel business growth.

Elizabeth Huxley, General Manager Trade and Working Capital CommBank takes up the story.

Businesses that understand and efficiently manage their cash flow can keep working capital costs down and have the confidence to take advantage of opportunities and meet unexpected challenges.

This requires a two-pronged approach. Firstly, there is optimising the amount of cash coming into and going out of the business, and secondly, drawing on a loan facility to make up any shortfall.

The collaboration between finance, operations and the supply chain teams in a business is critical, all those areas together determine what cash flow needs there are for the business.

Balancing inventory levels with precision Striking the right balance in inventory management is a constant challenge. Finance and operations teams must work closely to determine not just how much stock they want to hold, but how much they actually need—without tying up too much capital or risking shortages.

Ultimately, businesses aim to balance their inventory, avoiding both excess and shortages, while minimising the time their cash is tied up. But achieving this requires precise forecasting, strong collaboration, and the agility to adjust as market conditions shift.

Robust sales forecasts can also help a business manage the fine line between holding too much inventory and holding enough to meet customer needs. The cash flow gap is the time between outgoing payments and incoming receipts. Understanding this gap helps identify the best funding approach.

Tools and tips to help manage cash flow The Business Cash Flow tool, accessed by eligible consumers in the CommBank app, offers a monthly summary of incoming and outgoing cash flow. The tool provides a cash flow summary at a glance and allows comparisons with the previous 12 months and a real-time transaction history.

There is also Daily IQ, a free business insights tool for eligible CommBank business customers. Business leaders can compare trends and changes in their cash flow balance to help them identify risks and opportunities for their cash to work harder.

Building confidence to grow and adapt Importantly, it’s quick and efficient for businesses to manage their use of the facility. Rather than requiring businesses to provide monthly reconciliations and details of invoices, Stream Working Capital links into the business’ own accounting software and automatically receives the receivables data.

The bank also has another loan product, called the Working Capital Facility, which unlocks cash tied up in receivables, like Stream, but also in inventory. These financial solutions give businesses the confidence to make strategic decisions, navigate unexpected challenges, and seize growth opportunities that might otherwise have been out of reach due to liquidity constraints.

Things you should know: This article is intended to provide general information of an educational nature only. It does not have regard to the financial situation or needs of any reader and must not be relied upon as financial advice. You should consider seeking independent advice before making any decision based on this information. The information in this article and any opinions, conclusions or recommendations are reasonably held or made, based on the information available at the time of its publication but no representation or warranty, either expressed or implied, is made or provided as to the accuracy, reliability or completeness of any statement made in this article.

Credit provided by the Commonwealth Bank of Australia ABN 48 123 123 124 AFSL and Australian credit licence 234945. Applications for finance are subject to the Bank’s eligibility and suitability criteria and normal credit approval processes. Full terms and conditions, interest rate, establishment fee and line fee are included in the Loan Offer, you should consider these before making any decisions about these products. Bank fees and charges may apply.

The target market for this product can be found within the product’s Target Market Determination, available at commbank.com.au/tmd commbank.com.au

Closing cash flow gaps Business’s also draws on a working capital facility from CommBank.

The facility lends against the debtors’ ledger.

Once a business has put in place good stock and inventory management, accurate cash flow forecasting and an efficient debt collection process, they can fill the remaining cash flow gap with a loan facility.

To unlock cash caught up in receivables, Stream Working Capital is a CommBank solution that can help manage fluctuations in business cash flow. Rather than securing a loan against a property, such as the business owner’s home, it uses the business’ outstanding invoices for security.

We use invoices as collateral, essentially saying, ‘We recognise that you will receive this payment in 90 days, so we can advance the funds to you immediately.’ For businesses, it means they can support their cash flow needs right when they need it.

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AMTIL INSIDE

CEO dinners AMTIL brings together industry leaders to discuss the business of manufacturing.

AMTIL recently hosted a small collection of CEOs, MDs and C-suite Managers at events in Victoria and New South Wales, designed to raise and discuss manufacturing issues to improve our industry.

The format was appreciated; the food and drink were excellent, and those present said they found the evening to be, “most insightful. The range of subjects raised was expansive.” Topics ranged from skills,

training, power, and tax. For good reason, STEM education is a priority for schools and technical colleges. Developing the next generation's expertise is crucial for the future of Australian manufacturing.

One guest provided us with particular food for thought. “We should work even closer together to put on STEM events at schools and organise onsite manufacturing events with industry that stimulate the

younger generation so they can see what manufacturing is all about,” they said.

The feedback received showed that these kinds of gatherings were incredibly valuable and appreciated. Future CEO dinners, roundtables, and other events are planned for the year ahead. Watch AMT issues, the AMTIL website, and your inbox for more details. amtil.com.au

MSA Driving machine safety forward in industry Machine Safety Australia (MSA) is committed to leading the way in practical, high-impact safety solutions & training for the manufacturing industry. They are partnering with AMTIL to deliver machine safety risk assessment workshops to its members and the broader industry, led by

AMT JUN/JUL 2025

one of their TÜV-certified safety training engineers. This initiative provides AMTIL members and the broader industry with practical training to enhance machine safety in the workplace, while promoting the broader adoption of effective safety practices and technical excellence. Every

risk assessment & training workshop delivered reinforces MSA’s mission — helping the Australian manufacturing industry operate safer, smarter, and more efficiently. MSA’s vision is to revolutionise machine safety machinesafetyaus.com.au

AMTIL HEADING INSIDE

New Members RCR Mining Technologies is an Original Equipment Manufacturer that designs and delivers award-winning materials-handling solutions for mining applications, including Apron Feeders, Belt Feeders, Conveyors, and stackers. Headquartered in Western Australia, their innovative product range is manufactured locally at cutting-edge facilities in Bunbury and Welshpool. With a rich legacy dating back to 1975, RCR has built a reputation for its industrial equipment and installations' efficiency, durability, and value and for continually pursuing new ways to improve manufacturing efficiencies.

AML3D is an Australian-based leader in advanced manufacturing, specialising in Wire Additive Manufacturing (WAM®) technology.

Leveraging its proprietary ARCEMY® systems and software, AML3D enables the sovereign manufacturing of large-scale, high-strength metal components with superior efficiency and reduced lead times compared to traditional methods. Serving industries such as aerospace, marine, defence, energy and oil and gas, AML3D’s innovative approach supports sustainable manufacturing through material efficiency and waste reduction.

Headquartered in Adelaide, with a growing global footprint, AML3D transforms how metal parts are produced. Its cutting-edge solutions enable manufacturers to stay competitive in a rapidly evolving industry focused on performance, sustainability, and technological advancement.

Demand Management Systems (DMS) – Smarter supply chains for the automotive aftermarket. With AI-driven planning solutions, DMS assists automotive aftermarket businesses in optimising inventory, enhancing demand forecasting, and bolstering supply chain resilience.

Trusted by industry leaders, DMS empowers distributors and manufacturers to reduce stockouts, minimise excess inventory, and respond swiftly to market shifts. By leveraging advanced analytics and automation, DMS ensures seamless supply chain operations, improved service levels, and increased profitability. Whether facing demand volatility or streamlining S&OP, DMS delivers tangible results for the automotive aftermarket.

RCR MINING TECHNOLOGIES

AML3D LIMITED

DMS PTY LTD

1 Temple Road PICTON EAST, WA 6229

Unit 4, 136 Mooringe Avenue NORTH PLYMPTON, SA 5037

1 Maitland Place NORWEST, NSW 2153

rcrmt.com.au

aml3d.com

demandmgmt.com

NCTOOLS specialises in CAM and manufacturing software, offering cuttingedge solutions for sheet metal, CNC machining, and manufacturing. Our portfolio includes ENCY CAM, designed for robotic programming, CAMWorks for seamless integration with SOLIDWORKS users, and MaxxCAM, an advanced laser cutting and turret punching solution, featuring powerful nesting capabilities. Additionally, Smart Cut Quote streamlines cost estimation for laser cutting and metal fabrication businesses.

With automation, nesting, and precision manufacturing expertise, NCTools delivers reliable software solutions to enhance productivity and efficiency across CNC machining, sheet metal processing, and robotic manufacturing applications.

Weldclass is a proudly Australian-owned and operated national welding equipment brand.

Designed for Australian welders and metal fabricators, Weldclass products are distributed through a network of over 1,000 dealers across Australia and the South Pacific. Since 1979, our mission has been to make life easier and safer for welders.

Nitty-Gritty SRL are specialist in stainless steel surface treatment, providing electro-polishing solutions for cleaning and passivation of stainless steel. Nitty-Gritty SRL are manufacturers and global market leaders in electropolishing technology, offering many benefits with their full inverter systems which are designed to save you time and money.

NCTOOLS

WELDCLASS

COMPLETE WELDING HIRE AND SALES

Suite 12, 31 South Corporate Avenue ROWVILLE, VIC 3175

70 Newton Drive BEERWAH, QLD 4519

20 Tarnard Drive BRAESIDE, VIC 3195

nctools.com.au

weldclass.com.au

nitty-gritty.it

We offer extensive range of electro-polishing machines as well as passivation testing kits and testing kits for confirming the grade of stainless steel. Our focus on innovation and sustainability makes us a great addition to your business.

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INDUSTRY CALENDAR Readers are advised to check with all event organisers for the latest information. For the latest international travel advice, please visit smartraveller.gov.au. For more events, please visit amtil.com.au/events

INTERNATIONAL METALFORUM POZNAN POLAND, Poznan 3-6 June 2025

CMTS CA CANADA, Toronto 29 Sept – 2 Oct 2025

MACH 2026 UK, Birmingham 20-24 April 2026

itm-europe.pl/en/about-event/metalforum

cmts.ca

machexhibition.com

MANUFACTURING EXPO 2025 THAILAND, Bangkok 18-21 June 2025

MANUFACTURING WORLD 2025 OSAKA JAPAN, Osaka 1-3 October 2025

INTERMOLD ASIA JAPAN, Osaka 20-22 May 2026

manufacturing-expo.com

manufacturing-world.jp/osaka/

intermold.jp

AUTOMATICON 2025 POLAND, Warsaw 24-27 June 2025

WESTEC 2025 USA, Anaheim, CA 7-9 October 2025

INTERPLAS UK, Birmingham 2-4 June 2026

automaticon.pl/en

westeconline.com

interplasuk.com

METALFORM CHINA 17-20 June 2025 CHINA, Shanghai

ADVANCED DESIGN & MANUFACTURING EXPO CANADA, Toronto 21-23 October 2025

ALL ABOUT AUTOMATION GERMANY, Messe Straubing 10-11 June 2026

china-metalform.com

LASER WORLD OF PHOTONICS FINLAND 24-27 June 2025 world-of-photonics.com/en/trade-fair/

ALUMINIUM CHINA 2025 CHINA, Shanghai 9-11 July 2025 aluminiumchina.com

MANUFACTURING WORLD TOKYO JAPN, Makuhari 9-11 July 2025 manufacturing-world.jp/tokyo/

AI MANUFACTURING & SCADA TECHNOLOGY (AIMST) 2025 USA, Pittsburgh 25-27 August 2025 aimanufacturingconference.com/

SCHWEISSEN & SCHNEIDEN ESSEN GERMANY, Rhine-Westphalia 15-19 September 2025 schweissen-schneiden.com

METEC THAILAND, Bangkok 17 September 2025 metec-southeastasia.com

EMO HANNOVER GERMANY, Hannover 22-26 September 2025

admtoronto.com

FORMNEXT GERMANY, Frankfurt 18-21 November 2025

35.BI-MU 2026 ITALY, Milan 13-16 October 2026 bimu.it

formnext.mesago.com

EUROBLECH

2026

GERMANY, Hanover 20-23 October 2026

EUROGUSS GERMANY, Nuremberg 13-15 January 2026 euroguss.de

SIMODEC 2026 FRANCE, La Roche-Sur-Foron 2-6 March 2026 en.salon-simodec.com

KONEPAJA FINLAND, Tampere 17-19 March 2026 konepajamessut.fi

INTERTOOL AUSTRIA, Vienna 1 April 2026 intertool.at

MANUFACTURING WORLD NAGOYA NAGOYA, PortMesse 8-10 April 2026 manufacturing-world.jp/nagoya/

emo-hannover.com

REAP THE BENEFITS OF AMTIL MEMBERSHIP Contact us to learn more. amtil.com.au AMT JUN/JUL 2025

allaboutautomation.de

euroblech.com

JIMTOF JAPAN, Tokyo 26-31 October 2026 jimtof.org

2027 METEC GERMANY GERMANY, Dusseldorf 21-25 June 2027 metec-tradefair.com

NEWCAST GERMANY, Dusseldorf 21-25 June 2027 newcast.de

INDUSTRY CALENDAR HEADING LOCAL FOODTECH QLD GOLD COAST CONVENTION & EXHIBITION CENTRE 19-20 JUNE 2025 Sharing opportunities, pushing boundaries and feeding innovation - FoodTech Qld is all about growing our agricultural and food manufacturing communities. foodtechqld.com.au

CEMAT AUSTRALIA SYDNEY OLYMPIC PARK 22-24 JULY 2025 Intralogistics, Robotics and Automation, Warehousing, Supply Chain Management and Materials Handling.

WORKPLACE HEALTH & SAFETY SHOW 2025 SYDNEY THE DOME, SYDNEY SHOWGROUND 22-23 OCTOBER 2025 Elevate your safety standards at Workplace Health & Safety Show – showcasing technology, products and services to keep your workforce and work environment safe.

Packed full of exhibits, live demos, seminars, workshops, networking - and attended by thousands of health and safety professionals - this all-encompassing event provides the knowledge, tools, resources and connections you need to achieve world-class safety. whsshow.com.au

cemat.com.au

REGEN EXPO SYDNEY, ICC 23-24 JULY 2025 Australians are looking towards the waste and recycling industry to drive positive change. As the premier business event for the waste, recycling and resource recovery sector, the Australasian Waste and Recycling Expo is where the best come together to join forces for a world of solutions towards a cleaner, more sustainable future.

2026

regenexpo.com.au

AIMEX 2025 ADELAIDE SHOWGROUND 23-25 SEPTEMBER 2025 Following a strong bid from the South Australian Government, AIMEX will now call South Australia home for the next ten years.

Asia-Pacific’s International Mining Exhibition (AIMEX) is the key event on the mining calendar. It is an internationally renowned platform showcasing the latest mining technology, equipment and services. AIMEX offers unparalleled opportunities to connect with Australia’s largest mining suppliers and professional community in an environment that stimulates innovation and collaboration.

Advertiser Index 33DSystems

63

Applied Machinery

9

Biesse

91

Biesse

93

Dimac

35

EPOL

55

Hare & Forbes

2,3

HenryBros

39

HiTech Metrology

69

Hobson Eng.

89

IMTS

11

Industrial Machinery

OBC

Kaeser Compressors

87

Kemppi Australia

77

AUSTRALIAN MANUFACTURING WEEK (AMW) 2026 BRISBANE CONVENTION & EXHIBITION CENTRE 12-14 MAY 2026 For the first time in Brisbane, AMW is bringing the premier event showcasing the latest innovations, technologies, and equipment in the advanced manufacturing sector. Explore new opportunities, and meet and network with industry leaders and technology experts, all at the doorstep of a very busy Australian state.

Koenig Machinery

75

australianmanufacturingweek.com.au

AMW2026

FOODPRO MELBOURNE CONVENTION & EXHIBITION CENTRE 26-29 JULY 2026 Eight zones, each dedicated to the various steps in the food manufacturing process: Ingredients, Food Science & Technology, Processing Equipment, Plant Equipment, Packaging and more.

KUKA

43

Ladder Solutions

103

MTIQualos

73

Objective3D

79

Objective3D

81

OKUMA

7

RJS Tech

13

SECO

15

Thermasafe

51

VirtualStaff 365

71 46,47

AMW2025 Stats

4,5

AMTIL Corporate Partners

95

AMTIL Membership

98

foodproexh.com

aimex.com.au

YOUR INDUSTRY. YOUR MAGAZINE. Australian

FACTURING • STATE SPOTLIGHT: WESTE RN AUSTRALIA

A NEW FRON TIER …

TORY

& NORTHERN TERRI

Pavla Thomas: 0431 753 381

• ADDITIVE MANU

Call me now for a no-obligation chat about how AMTIL can help.

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AMW2025 REVIEW

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Reach out to 31,500 targeted readers and 63% decision-makers.

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MEDICAL INDUSTRY 4.0 ENERGY & SUSTAINABILITY STATE SPOTLIGHT: VICTORIA COMPRESSORS & AIR TECHNOLOGY SAFETY CUTTING TOOLS FORMING & FABRICATION MATERIALS HANDLING WASTE & RECYCLING

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HISTORY

Big wheels & little wheels – the story of UK-born Australian Sir Laurence John Hartnett (1898 – 1986) Australia’s “Father of the Holden” and much more

PART 66

INTERRUPTED HOLIDAY

Back at my hotel in New York, the day I finally parted from GM, I felt lonely, tired, and desperately anxious about being home in Australia with my family.

I

found a telegram waiting for me from Jim Mooney, now president of Willys Overland in Toledo, Ohio. It said: “Will be phoning you. We'd be pleased to see you here.” At about 5pm, Jim’s call came through. “The news got through pretty quickly, Larry,” he said. “I hear you’ve thrown it in with GM. Well, we’re having a lot of fun here in Toledo. You’d better come over and look us up.”

I had a return ticket to Australia, which included a trip across the US. I arranged to break my journey at Toledo. Jim's call gave me a very warm feeling. It was wonderful to know that the president under whom I’d served at GM was the first to say, virtually, “There's a job here if you want it.”

Art Weiand, a former general sales manager of GM's Overseas Operations, met me at Toledo. He and several others had quit GM to join Mooney's operation at Willys. Mooney insisted on taking me immediately for a tour of the factory. I noticed that his machine shops were reasonably old and rather down at heel, and we started talking about the best ways of improving his plant. In the new press shop they were building, Jim, knowing of my love of presses, explained in detail the layout taking shape and invited my comments.

Suddenly, Jim said, “Larry, you’re the kind of guy we want around here. You’ve come up the hard way in Vauxhall and that set-up in Australia, and we’ve got a lot to do here in a hurry.”

The following day, in Jim's office, I met several of my old GM friends, who are now with Jim, and immediately could sense the difference in the atmosphere here compared to New York. This was like old times. For a moment, I was tempted, but I knew I couldn't change my mind. I didn't want to leave Australia for anyone or anything.

“All right, Larry,” Jim said, “if that's how you feel, I understand. After all, you know, we Yanks love home, too. But what about looking after Willys in Australia for us? Do you want to make our cars down there?”

“Sure,” I said. “I’d love to.”

“Well, we’ll help you. If you only want to sell cars but not make them, that’ll be OK by us too. You’ll have exclusive rights to Willys in Australia. Art Weland here will give you all the papers sewing it up.”

Art Weland and I then drew up documents granting me the Australian franchise for Willys Overland. This gave me a good feeling and helped to take my mind off the GM trouble.

It was also a potential gold mine because the Willys Jeep had won millions of friends during the war. Mooney told me his plans to produce a rugged, simple utility range of vehicles. I don't entirely agree with his views because, in my opinion, the public will always turn its head to a good-looking car, as it will to a good­looking woman. I've seen them run away from the logic in motor cars and go for the flash. What was needed, I felt, was a car with the ruggedness Jim mentioned but with attractive lines. However, Jim had a good earthy programme, and I thought we could mutually benefit each other when he got going.

We parted after another day or so, and I continued my trip west to Los Angeles for the plane journey home.

Mooney overcame most of his problems at Willys, made a lot of money, and then retired. No one who has ever known him would begrudge him a cent of his wealth or success. Mooney was a great leader of men, a courageous pioneer, thinking and planning away ahead of most leaders and, above all, a straight-down-the-centre human being.

Back in Melbourne, after my trip across the Pacific on one of the first post-war civil flights by Pan-Am, I called the senior men of GM-H together and announced that I had resigned and that Harold Bettle was taking over immediately as managing director. One of the first outside calls I took was from Sir

John Jensen, asking me to see him as soon as possible. “Whatever has happened?”

Jensen asked when I walked into his office.

“Well, I suppose they’ve had enough of me, and I’ve had enough of them,” I said. “The Australian and American aspects of this car project haven’t jibed very well, I'm afraid.”

I briefly told him about the problems, real or imagined, that GM saw coming because of my association with the Labor Administration during the war, the arguments I had had with GM about Australian shareholding, and the need to maintain an Australian character with the new car.

“From a personal point of view,” I continued, “I am flat exhausted after six years without a break. I have three children going through school, and we like living in Australia.”

Jensen was very upset by my news. “I feel somewhat morally responsible for all this,” he said. “What are you going to do? You're not thinking of getting out of the motor business?”

“I don't know. There are many things I can do in fact, I might enjoy something different for a change. You know, I'm a professional hobbyist. I love doing things. I can get steamed up about almost anything. There’s no reason why I shouldn’t forget all about cars, but I won’t do anything until after I’ve taken my wife and children for a trip overseas for a break.” I had promised them that all through the war.

To be continued…

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT JUN/JUL 2025

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