Industrial Machinery Digest - January 2025

IndustrialMachineryDigest.com | January 2025

North America’s Manufacturing Resource for Industry Professionals Since 1986

Cut Costs, Not Corners: Are Finishing Operations Your Key to Labor & Cost Efficiency?

Revolutionizing Material Handling: Insights from Deloitte's 2025 Manufacturing Outlook Reference: "2025 Manufacturing Industry Outlook," Deloitte Insights Enhancing Workplace Safety Through Machine Guarding LK Metrology Innovates Eco-Friendly Solutions for CMMs with EcoAir Technology How Advanced Technology is Tackling the Shortage of Skilled Workers Can Cobots Attract More Young Talent to Welding?

Precision as a Passion: The Zoerkler Success Story Embracing the Future: How Advanced Software Solutions Are Reshaping Manufacturing Tooling and Workholding in Focus: Advancing Precision and Productivity

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Table of Contents

January 2025 8 10 14

EDITORIAL DIRECTION INDUSTRY NEWS FABRICATION Cut Costs, Not Corners: Are Finishing Operations Your Key to Labor & Cost Efficiency?

Aaron Wagner, Global Segment Director, Heavy Equipment, SherwinWilliams General Industrial

20

MATERIAL HANDLING Revolutionizing Material Handling: Insights from Deloitte's 2025 Manufacturing Outlook Reference: "2025 Manufacturing Industry Outlook," Deloitte Insights

24

SAFETY & MAINTENANCE

28

QUALITY

30

ROBOTICS

Enhancing Workplace Safety Through Machine Guarding LK Metrology Innovates Eco-Friendly Solutions for CMMs with EcoAir Technology How Advanced Technology is Tackling the Shortage of Skilled Workers Can Cobots Attract More Young Talent to Welding?

34

14

METAL WORKING

24

Precision as a Passion: The Zoerkler Success Story How an Austrian Family Business Became a High-Tech Forge for Sophisticated Gearboxes

38

SOFTWARE Embracing the Future: How Advanced Software Solutions Are Reshaping Manufacturing Insights from Deloitte's 2025 Manufacturing Industry Outlook Highlight the Role of Digital Transformation in Driving Efficiency and Innovation

42

30

TOOLING & WORKHOLDING Tooling and Workholding in Focus: Advancing Precision and Productivity 2024’s Innovations and 2025’s Transformative Trends in Precision Manufacturing Solutions

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Happy New Year and welcome to Industrial Machinery Digest’s January 2025 issue!

As we turn the page to a new year, it’s the perfect time to reflect on the incredible strides made in manufacturing throughout 2024 and to look ahead with optimism and excitement for what 2025 holds. This past year has been a testament to the resilience, adaptability, and ingenuity of our industry.

In 2024, we saw manufacturers embrace digital transformation at an unprecedented pace. Technologies like generative AI, IoT-enabled devices, and digital twins moved from buzzwords to essential tools, enabling greater efficiency, precision, and innovation. Sustainability also took center stage, with eco-friendly materials and energyefficient processes becoming integral to operations worldwide. These advancements not only addressed environmental concerns but also drove cost savings and improved productivity, proving that sustainability and profitability can go hand in hand.

As we welcome 2025, the momentum continues.

The focus on automation, customization, and smarter workholding and tooling solutions is set to redefine manufacturing processes. From advanced tooling materials that promise unparalleled durability to integrated systems that enhance connectivity and data-driven decision-making, this year promises to be a transformative one.

At Industrial Machinery Digest, our mission is to keep you informed and inspired as we navigate these exciting changes together. This issue is packed with insights, trends, and expert commentary designed to help you stay ahead in this fast-evolving landscape.

We’re also proud to feature some of the standout innovations of 2024, highlighting the products and technologies that shaped the year and set the stage for even greater achievements in 2025. From groundbreaking tooling systems to the latest advancements in workholding, these developments are proof that the future of manufacturing is bright and filled with possibility.

As we embark on this new year, I want to thank you— our readers, contributors, and partners—for your continued support and engagement. Together, we’ll explore the tools, technologies, and ideas that will define the next era of manufacturing excellence.

Here’s to a successful and innovative 2025!

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Industry News

INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industry's top companies.

WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com

Helios Gear Products Welcomes Engineer Caeden Keith Helios Gear Products proudly announces the addition of Caeden Keith as an Applications Engineer. A Mechatronics Engineering graduate from Northern Illinois University, Keith’s passion for innovation is evident through his achievements, including leading NIU’s team in NASA’s BIG Idea Challenge and mentoring a high school robotics team in the FIRST Robotics Competition.

Keith brings a wealth of hands-on experience to Helios, having held roles as a CNC operator intern and manufacturing engineering intern before joining Helios as a co-op intern. His prior work laid the foundation for his expertise in gear manufacturing and automation.

“Caeden’s commitment to excellence and innovative approach makes him an asset to our team and our customers,” said Adam Gimpert, Helios president.

In his full-time role, Keith collaborates with manufacturers to develop custom cutting tools and automation solutions. His work is key to empowering gear manufacturers to excel in a competitive global market.

Helios Gear Products Welcomes Engineer Caeden Keith

Website: www.heliosgearproducts.com

CINCINNATI, Inc. Welcomes Alan Oak as New President & CEO Cincinnati Incorporated (CI), a leader in built-to-order machine tools, has announced that Alan Oak will assume the role of President & CEO effective January 1, 2025.

After more than four years of impactful leadership, Timothy Warning will step down but remain with the company as Vice President & General Manager, ensuring a smooth transition.

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CINCINNATI, Inc. Welcomes Alan Oak as New President & CEO

Oak brings decades of executive experience, known for fostering vision and strategy while delivering both top- and bottom-line growth. His career spans notable positions, including Vice President General Manager at BF Goodrich and Chief Operating Officer at Rhinestahl

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Corporation, where he spearheaded exponential growth initiatives. A graduate of the University of Cincinnati with a B.S. in Mechanical Engineering and an MBA from Drake University, Oak embodies the leadership values CI has upheld for over a century.

“Alan’s commitment to putting people first and cultivating a culture of excellence makes him the ideal leader to drive CI’s continued success,” said Christina March, CI’s owner. She also expressed gratitude to Warning, stating, “Tim’s leadership has provided unprecedented stability and growth, including transformative ERP implementations and operational improvements.”

Rakesh Kumar, departing as Vice President & General Manager, leaves behind a legacy of increased sales, service, and marketing achievements. “Rakesh’s relentless focus on quality and service has built a strong, loyal customer base that will benefit CI for years to come,” March added.

CI’s leadership changes position the company to build on its legacy and accelerate growth.

Website: www.e-ci.com

Metalforming Manufacturers See Optimism Despite Year-End Shipping Decline Metalforming manufacturers are optimistic about the economic outlook heading into 2025, according to the December 2024 Precision Metalforming Association (PMA) Business Conditions Report. The report highlights increased confidence, with 30% of surveyed companies predicting improved activity in Q1 2025, compared to 23% in November.

Manufacturers also forecast growth in incoming orders, with 34% expecting an increase over the next three months. However, current shipping levels dipped in December, with 45% reporting decreases after November’s rebound. Despite this, workforce expansion remains steady, as 24% of companies continue to hire, reflecting cautious optimism for the industry’s future.

“Our members are hopeful about manufacturing growth, especially with potential policy shifts aimed at supporting the sector,” said David Klotz, PMA president. He emphasized the importance of reinstating R&D expensing and fostering supply chain strength to ensure U.S. manufacturing competitiveness.

The PMA report offers insights into economic trends shaping the metalforming industry.

Website: www.pma.org

Universal Robots Hosts North America’s Largest Cobot Event Universal Robots (UR) will host Collaborate North America 2025, the largest collaborative robot conference and tradeshow in the U.S., on January 28, 2025, in Novi, Michigan. Free to attend, the event promises to unite over 500 manufacturing professionals, automation specialists,

12 | IMD January 2025

Universal Robots Hosts North America’s Largest Cobot Event

and industry leaders to explore the latest advancements in collaborative robotics.

Attendees will engage with hands-on demonstrations of 30+ cobot solutions for applications such as welding, inspection, assembly, and more. “This event is designed to inspire manufacturers to leverage cobots for greater productivity and innovation,” said Jonathan Sbert, UR’s VP of Sales, Americas.

Keynotes include insights from UR’s Chief Commercial Officer Stacey Moser and thought leaders from MIT, Siemens, and A3. Ben Armstrong of MIT will explore robotics’ role in sustainable growth, while Jake Hall, “The Manufacturing Millennial,” will address bridging traditional and modern manufacturing.

Website: www.universal-robots.com

Walter USA Opens State-of-the-Art Americas Campus Walter USA has unveiled its new Americas Campus in Greer, South Walter USA Opens State-of-the-Art Americas Campus Carolina, marking a significant milestone in its commitment to innovation and growth. This advanced facility, operational from January 1, 2025, will serve as a hub for cutting-edge research, collaboration, and customer engagement across the Americas.

Equipped with state-of-the-art machinery, testing labs, and collaborative workspaces, the campus is designed to meet diverse customer needs. Dmitry Andreev, Vice President of Global Sales, highlighted the facility’s potential: “This campus represents a new chapter for Walter USA, offering unparalleled resources that drive innovation and foster growth.”

The campus will also host digital events, training sessions, and industry gatherings, furthering Walter’s mission to deliver transformative solutions. By expanding its capabilities, Walter aims to set new standards in manufacturing innovation.

Website: www.walter-tools.com

Fabrication

Spraying red liquid paint.

FABRICATION Transforming Materials Into Excellence Discover the innovative tools and technologies shaping today’s manufacturing landscape. Highlighting processes that transform raw materials into precision-crafted products, from advanced cutting and forming systems to welding and finishing techniques, the focus remains on efficiency, accuracy, and innovation driving modern fabrication.

From advancements in automation and sustainable manufacturing practices to the latest developments in material processing, gain insights into trends and solutions that enhance productivity, improve quality, and maintain competitiveness in a rapidly evolving industry. This overview showcases the equipment and expertise behind the products powering industries worldwide.

14 | IMD January 2025

Cut Costs, Not Corners: Are Finishing Operations Your Key to Labor & Cost Efficiency?

Aaron Wagner, Global Segment Director, Heavy Equipment, Sherwin-Williams General Industrial

T

he manufacturing industry continues to face labor challenges.

As experienced workers near retirement, the skills gap left in their wake is proving difficult to fill. Skilled trades are in short supply, with many companies struggling to hire and retain qualified candidates.

Demand is also down. In industries like heavy equipment, short-term improvements remain uncertain. While some indicators like falling interest rates suggest a potential rebound, the debate continues as to whether these sectors will bounce back sooner or later, making it impossible to predict.

Cyclical markets like these can pose a greater risk to small businesses and job shops than larger corporations.

To remain in business and profitable, small business owners may need to adjust operations and find creative ways to manage costs while times are slow.

This is the time to look at your current processes.

As leaders at Sherwin-Williams like to say, “focus on what you can control.”

Instead of stressing about the cyclical nature of the market, think about what you can do now to be better prepared when it comes back. » How can you reduce operational costs now while times are slower, in turn increasing profitability for the future? » Is there an opportunity to reduce complexity and labor needs so you’re better prepared when the market ramps back up?

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» Are there hidden bottlenecks or inefficiencies that you can streamline to increase capacity and profitability going forward?

There are many ways to approach this sort of ‘efficiency audit.’ For now, we’ll focus on one area: the paint line. While paint may seem like a tiny portion of your overall operation, the finishing process can significantly impact operational costs, specifically when it comes to labor and throughput.

Breaking down total applied finishing costs.

Total applied costs measure everything it takes to put the paint onto the part. This goes beyond the price of paint to factor in elements like labor, application speed, dry times, rework, waste, material and energy usage and, most importantly, throughput.

Today’s industrial coatings offer a lot of variety.

There are formulas to meet all types of challenges, from faster dry times to reduced labor and more. Identifying bottlenecks now, while times are slow, is a great way to utilize down time and advance efficiency so that you’re ready when the market circles back.

For example, we had a customer that was facing significant challenges meeting supply demands. They had a complex finishing process and limited time to train crews, which led to quality issues and rework. Once we

Measuring mil thickness.

understood their challenges, we recommended Duraspar Industrial Performance (IP) – a liquid coating known for its application efficiency.

The ready-to-spray formula and easy application of Duraspar IP improved their first pass yield and reduced defects by 50%. Faster cure times cut their baking cycle by 30% and the extended pot life reduced material consumption and waste. By making this one simple switch, this customer cut their finishing cycle time in half, from 48 hours to just 24 – proving that even small adjustments to

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the finishing line can drive substantial improvements across multiple areas of operation.

Pay attention to coatings content.

Coatings selection should be based on your shop’s specific application and performance needs. While it’s easy to go with the lowest price per gallon or pound, it’s also just as easy to overspend on attributes that you may not need. Finding the best solution requires knowing what’s out there and what questions to ask.

Spraying Orange HE Whether you use liquid or powder, the quality of your coatings has a big impact on the overall cost of your paint line. Spending a little bit more up front can lower your total applied costs by saving significant amounts of time and labor.

If you're using liquid coatings, formulas with a higher solids content can bring multiple benefits. With these formulas, painters can usually reach the appropriate film build in less passes, meaning you’ll buy less paint and spend less time applying it. Less solvents can also mean less VOCs, which can help companies meet sustainability regulations.

Pigment selection can also affect coating costs and performance – an important factor to consider if you’re exploring a new color or palette. Certain pigments cost more than others, depending on things like hiding strength, UV-resistance and organic content. Often, we recommend customers go with a shade slightly darker than their original choice, because the hiding strength can end up saving significant material, time and labor in the end.

Ensure optimal efficiency.

Ultimately, throughput depends heavily on the speed of your finishing line, so efficiency is critical. For powder coatings operations, that translates to transfer efficiency, which is substantially influenced by proper grounding.

When parts are grounded, the surface attracts negatively charged powder particles and helps them stick evenly for a smooth, quality finish, delivering a faster application and reducing the need for rework.

All powder coating booths should have a grounding wire connected to an outside copper pole reaching six feet underground for this reason. Without proper grounding, the powder will cloud the spray booth instead of being attracted to the parts. This not only wastes product and affects the quality of your film builds, but it extends

16 | IMD January 2025

application time and means filters will need to be changed prematurely. All of this leads to an uneven finish and additional rework, requiring unnecessary money, time and labor. Most importantly, proper grounding is essential for the safety of your crew.

Particle size and the specific gravity of your coating will also affect how the powder charges. If the particles are too fine or coarse, they will have trouble being charged and either fall to the floor or escape into the filter. If you’re using a powder reclamation system, particles will break down and get smaller the more they cycle through. If you’re not using a reclamation system, proper grounding is even more critical.

Measure film thickness.

For liquid and powder, film thickness – or the right amount of paint left on the surface with each coat – is a key factor to reducing waste and optimizing dry times.

There are tools to help you measure film thickness, each with its own benefits and drawbacks. Dry film thickness gauges are relatively inexpensive – around a couple hundred dollars each – and they are good, accurate tools. However, measurements with this tool can only be taken once the paint is dry, so this type of testing can slow operations.

Measuring wet film thickness is another option. This tool is similar to a ruler. It is very affordable but requires you to dig into the paint while it’s wet. To avoid ruining a part, you may need to test measurements on a scrap piece of material prior to coating your parts.

A more technologically advanced type of film gauge uses lasers to measure without impacting the surface of the paint. These top-of-the-line tools work on wet or dry/ cured coatings, however they can run between $15,00020,000 each. Many small businesses lean on their coatings

supplier to bring these tools on-site during testing to help dial in processes.

Explore new formulas and technologies.

Industrial coatings have come a long way. If you’ve been using the same formula for a few years, now might be a good time to explore alternative solutions.

New technologies can enhance both the quality and efficiency of your operations while working easily within your existing setup. These advanced formulas may have a higher price tag, but as stated before, the efficiency improvements gained can end up benefiting profitability in numerous ways.

Some new coatings formulas can eliminate an entire step in your finishing operation. For example, we have a Dust-on-Dust powder coating formula that allows the primer and topcoat to cure together in one step. This not only enhances efficiency and reduces energy usage, but it delivers better adhesion between the coats, strengthening durability and corrosion protection.

New liquid formulas can also help speed up your finishing line. One of our newest solutions called Durapeak is a rapid cure coating that performs like a traditional polyurethane. We recommended Durapeak to a customer that was struggling to meet increased demands. Their cure cycles were creating bottlenecks, and the wet paint was causing quality issues during storing and transporting.

By switching to Duraspar High Speed epoxy primer and Durapeak topcoat, the customer increased first-pass yield by 30%. They reduced their repair needs by 30% and cut the time to repair by 20 minutes per part. All of this led to a 20% increase in capacity, allowing them to keep up with demand and position themselves for growth.

Identify the best partner.

Some coatings suppliers function more like partners than salespeople, even for small businesses. Being fully entrenched in the coatings industry, these experts can help educate you on the latest technologies and give specific advice on what would work best for your operation.

Act now, while times are slow, so you can streamline processes and achieve higher profit margins before demand returns. When it does, your operations will be ready to reach new heights.

AMADA WELD TECH

AMADA WELD TECH Advances Micro Welding with Blue Diode Laser Technology AMADA WELD TECH has introduced state-of-the-art blue diode laser technology to its micro welding systems, setting a new standard in welding precision and efficiency

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for challenging materials like copper. Unlike traditional infrared lasers, blue diode lasers operate at a wavelength of approximately 450 nanometers, enabling superior energy absorption by reflective materials.

This innovation results in reduced heat input, minimized spatter, and unparalleled accuracy in micro welding applications.

With power levels ranging from 1500 to 4000 Watts for industrial applications, AMADA WELD TECH’s blue laser systems excel in joining delicate components, making them ideal for the electronics, medical device, and automotive industries.

Dr. Mark Boyle, Director of Product Engineering and Applications, remarked, "This technology significantly enhances our ability to weld challenging materials and provides a unique solution that boosts production efficiency for our clients."

Feasibility studies are conducted at the Western Technical Center in Monrovia, utilizing spot sizes between 200 to 500 microns to meet diverse application needs. This commitment to innovation reinforces AMADA WELD TECH’s leadership in advancing micro welding technology and delivering cutting-edge solutions for modern manufacturing.

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STRATASYS

ArcelorMittal Research Center Achieves Breakthroughs with Stratasys F370® 3D Printer ArcelorMittal’s research center in Maizières-lès-Metz, France, has revolutionized its prototyping and tooling processes by adopting Stratasys’ F370® 3D printer. The integration of this advanced additive manufacturing solution has enabled the steel manufacturer to achieve remarkable reductions in lead times, enhance design

18 | IMD January 2025

A 3D-printed protection cap, taking the place of an original aluminum part that wasn't fitting properly. With 3D printing the company was able to do several iterations and find the best fit possible. (Photo: Business Wire)

flexibility, and significantly lower costs—transformations previously unattainable with traditional manufacturing methods.

With the ability to create complex tooling and validate part designs overnight, the research center has slashed production costs. For example, validating parts with polymer 3D printing now costs less than 200 Euros per run, compared to nearly 2,000 Euros using aluminum prototypes. Louis Wolfer of ArcelorMittal Research highlighted the impact, stating, "3D printing allows for quicker iterations, reduced risk, and greater agility,

ensuring continuous efficiency in our operations."

The Stratasys F370® printer supports a wide range of materials, including carbon fiber and thermoplastics, making it a versatile tool for both office and factory settings. Looking ahead, ArcelorMittal plans to expand its capabilities further with the integration of the Stratasys Origin DLP printer to explore industrial-grade resin applications, continuing its leadership in additive manufacturing innovation.

For more information, visit www.stratasys.com.

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Material Handling

MATERIAL HANDLING Empowering Efficiency and Precision Material handling is at the heart of efficient industrial operations, focusing on the movement, storage, and organization of materials. This section highlights strategies and technologies that streamline these processes, from automated storage and retrieval systems to advanced conveyor solutions. Readers can explore innovations like forklifts, cranes, hoists, and magnetic lifters, which play a pivotal role in optimizing material flow across warehouses, factories, and supply chains.

In addition to hardware advancements, this area emphasizes cutting-edge solutions like warehouse management systems and parts tracking technologies, which integrate seamlessly into modern production environments to enhance operational control. Topics also cover sustainable practices, such as energy-efficient lift equipment and ergonomic tools designed to improve workplace safety while reducing strain. Whether tackling inventory management or enhancing material logistics, this section provides the insights and tools needed to excel in today’s industrial landscape.

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Revolutionizing Material Handling: Insights from Deloitte's 2025 Manufacturing Outlook Reference: "2025 Manufacturing Industry Outlook," Deloitte Insights

A

s the manufacturing landscape continues to evolve, material handling emerges as a critical component in ensuring operational efficiency and resilience.

Deloitte’s "2025 Manufacturing Industry Outlook" sheds light on the transformative potential of advanced technologies in material handling systems. From automation and robotics to digital twins and IoT integration, the future of material handling is defined by innovation.

The Evolution of Material Handling Material handling—the movement, protection, storage, and control of materials—is undergoing a digital transformation. Traditional methods are being replaced by smart systems that leverage data-driven insights for

enhanced precision and efficiency.

According to Deloitte, the integration of automation and connectivity in material handling systems is a key driver of operational excellence.

For example, autonomous mobile robots (AMRs) are becoming a staple in warehouses, navigating complex environments to transport goods efficiently. These robots are equipped with AI-powered sensors that enable real-time decision-making, reducing errors and labor costs. Similarly, conveyor systems with integrated IoT sensors monitor the flow of materials, identifying bottlenecks and optimizing throughput.

The Role of Digital Twins One of the most exciting advancements in material handling is the use of digital twins. A digital

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

twin is a virtual replica of a physical system, enabling manufacturers to simulate, analyze, and optimize operations in a risk-free environment. Deloitte highlights how digital twins are revolutionizing inventory management and warehouse operations.

For instance, digital twins allow manufacturers to visualize the movement of materials, predict equipment failures, and optimize storage layouts. This not only reduces downtime but also improves space utilization and inventory accuracy. By integrating digital twins with predictive analytics, companies can anticipate demand fluctuations and adjust material handling processes accordingly.

IoT and Connectivity The Internet of Things (IoT) plays a pivotal role in modern material handling systems. By connecting equipment, sensors, and software platforms, IoT creates a seamless flow of data that enhances visibility and control. Deloitte’s insights emphasize the importance of IoT in enabling real-time tracking and proactive maintenance.

For example, smart pallets and containers equipped with IoT sensors provide real-time updates on the location and condition of goods. This ensures that perishable items are stored under optimal conditions and that high-value assets are secure. Additionally, IoT-enabled predictive maintenance minimizes unplanned downtime by alerting operators to potential equipment failures before they occur.

Robotics and Automation Robotics and automation are at the forefront of material handling innovation. Deloitte’s report underscores the growing adoption of collaborative robots (cobots) and

automated guided vehicles (AGVs) in manufacturing and warehousing environments. These technologies not only enhance productivity but also address labor shortages.

Cobots, designed to work alongside human operators, streamline repetitive tasks such as packing and sorting.

Their ability to learn and adapt to new tasks makes them invaluable in dynamic environments. Meanwhile, AGVs transport materials with minimal human intervention, navigating pre-defined routes and avoiding obstacles with precision.

Sustainability in Material Handling Sustainability is a driving force behind advancements in material handling. Manufacturers are increasingly adopting eco-friendly solutions to reduce their environmental footprint. Deloitte highlights how energy-efficient equipment and renewable energy integration are becoming standard practices in material handling systems.

For example, solar-powered AGVs and energyefficient conveyor systems reduce operational costs while aligning with sustainability goals. Additionally, recycling and repurposing materials within the supply chain minimize waste and promote circular economy practices.

Enhancing Safety Through Technology Safety is a top priority in material handling, and technology is playing a crucial role in mitigating risks. Deloitte’s analysis points to the adoption of advanced safety features such as real-time monitoring, AI-driven risk assessments, and augmented reality (AR) training modules.

IoT-enabled safety systems monitor equipment and worker interactions, identifying potential hazards and INDUSTRIAL MACHINERY DIGEST.COM

IMD | 21

alerting operators in real-time. AR training modules provide immersive learning experiences, equipping workers with the skills needed to operate complex machinery safely. These technologies not only protect workers but also improve overall efficiency by reducing accidents and downtime.

Challenges and Opportunities While the benefits of advanced material handling systems are clear, manufacturers face challenges in implementation.

High upfront costs, integration complexities, and workforce adaptation are among the barriers highlighted in Deloitte’s report. However, these challenges present opportunities for innovation and collaboration.

By partnering with technology providers and investing in employee training, manufacturers can accelerate the adoption of advanced material handling solutions. Scalable and user-friendly systems ensure a smoother transition, while fostering a culture of continuous improvement empowers workers to embrace new technologies.

Conclusion The future of material handling is defined by innovation, connectivity, and sustainability. As highlighted in Deloitte’s "2025 Manufacturing Industry Outlook," advanced technologies such as digital twins, IoT, robotics, and automation are revolutionizing material handling processes.

By embracing these solutions, manufacturers can enhance efficiency, reduce costs, and build resilient supply chains.

In an era where agility and adaptability are paramount, investing in advanced material handling systems is not just a competitive advantage—it’s a necessity. As we look toward 2025 and beyond, the role of material handling in manufacturing will continue to evolve, driving the industry toward a more connected, sustainable, and efficient future.

Combilift Scoops ‘Company of the Year’ at the 2024 Business & Finance Awards

€500 million, the company’s export-driven strategy has solidified its status as a global leader.

“This award reflects the bold vision and relentless drive that have been at the heart of Combilift since Robert Moffett and I started in 1998,” said McVicar. “Every forklift, every innovation, and every milestone reflects our commitment to pushing boundaries and transforming material handling worldwide. This moment belongs to our employees, our dealers, and our customers who rely on us to deliver quality material handling solutions to optimize their warehouse space.”

Combilift’s legacy of innovation, sustainability, and dedication to research and development has earned it a reputation as a forward-thinking industry leader. The company’s achievements place it in the ranks of past "Company of the Year" winners, including Glen Dimplex, Kingspan, Primark, Google, and Intel.

COMBILIFT

For more information, visit www.combilift.com.

Combilift Scoops ‘Company of the Year’ at the 2024 Business & Finance Awards

OZ LIFTING

Combilift, the global leader in material handling solutions, has been honored with the prestigious "Company of the Year" award at the 2024 Business & Finance Awards, presented in association with KPMG Ireland. This accolade highlights Combilift's enduring commitment to innovation and its significant contributions to both the Irish economy and the global material handling market.

The award was presented to Combilift CEO Martin McVicar by Seamus Hand of KPMG at the 50th Business & Finance Awards ceremony in Dublin. Combilift, founded in 1998, has grown to become the largest manufacturer of multi-directional, articulated, and sideloading forklifts, as well as large-scale material handling equipment such as straddle carriers. With over 85,000 units in operation across 85 countries and annual revenue exceeding

22 | IMD January 2025

OZ Lifting Unveils New Tele-Pro Davit Crane at ProMat OZ Lifting Products LLC has debuted its enhanced Tele-Pro davit crane at ProMat, the premier material handling tradeshow held at Chicago’s McCormick Place from March 17-20. Renowned for its innovative lifting solutions, the Winona, Minnesota-based manufacturer showcased improvements that promise smoother operation, greater durability, and advanced safety features.

Available in 500 lb., 1,200 lb., and 2,500 lb. capacities, the upgraded Tele-Pro allows operators to telescope the boom in and out under load. This functionality, combined with an ergonomic handle for 360-degree load control, provides unmatched precision and ease of use in industrial

OZ Lifting Unveils New Tele-Pro Davit Crane at ProMat

settings. The crane now features a high-visibility yellow powder coat for enhanced durability and corrosion resistance, replacing the previous zinc-plated finish.

Additional advancements include dual rating decals for instant load verification, as well as top and bottom grease zerk fittings to simplify maintenance and extend the crane’s lifespan. Demonstrations at OZ Lifting’s booth (S309) also highlighted other equipment, such as wheel bases compatible with davit cranes up to 1,200 lbs. capacity and wireless adapters for electric chain hoists and builder’s hoists.

“The Tele-Pro’s redesign reflects our commitment to addressing real-world challenges faced by lifting equipment operators,” said Steve Napieralski, President of OZ Lifting. “ProMat provides us an invaluable opportunity to connect with users, understand their needs, and showcase the innovations that set us apart.”

Celebrating 20 years in business, OZ Lifting is set to move into a new state-of-the-art 40,000-square-foot facility and launch a revamped website, signaling continued growth and innovation in the lifting industry.

The installation was driven by increased sales at ASC, prompting the addition of a new building to accommodate larger production volumes. Specht Industries designed and implemented a solution tailored to the unique needs of the facility, including seismic survey compliance and a 16-inch elevation slope. The R&M Material Handling brand was specifically requested to ensure compatibility with existing equipment across ASC’s facilities.

“Our responsibilities include ensuring all equipment runs smoothly and safely. The new cranes have provided us with the additional space and capabilities needed to keep up with demand while maintaining high safety standards,” said Cory Demaio, Facilities Manager at ASC Process Systems.

The cranes are operated using Autec wireless remote systems and supported by a comprehensive structure, runway electrification conductor bars, and robust American Society of Civil Engineering (ASCE) rails. Specht Industries provided design, engineering, installation, and startup services, ensuring seamless integration.

“The addition of this new equipment has greatly enhanced productivity,” said Joe Specht, President of Specht Industries. “We are proud to collaborate with ASC Process Systems to deliver solutions that not only meet but exceed their operational requirements.”

With plans to install an additional 10-ton capacity crane, ASC Process Systems is poised for continued growth, further solidifying its position as a leader in the industrial oven and autoclave sector.

For more information, visit www.rmhoist.com.

For more information, visit www.ozliftingproducts.com.

R&M MATERIALS HANDLING, INC

Specht Industries Enhances ASC Process Systems with Custom R&M Cranes Specht Industries has successfully completed the installation of custom bridge cranes and hoists at ASC Process Systems, a leading manufacturer of autoclaves and industrial ovens based in Santa Clarita, California. The installation, which includes a combination of three 5-ton bridge cranes and a 30-ton bridge crane equipped with two 15-ton hoists, addresses the facility's growing production demands while enhancing operational efficiency.

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 23

Safety & Maintenance

SAFETY & MAINTENANCE The Cornerstones of Operational Excellence The Safety & Maintenance section is dedicated to creating safer workplaces and ensuring equipment longevity. Covering everything from cutting-edge machine guarding systems to advanced air filtration and dust collection solutions, this section provides actionable insights into workplace protection and preventative maintenance. Whether you're exploring ergonomic tools to reduce operator strain or electrical systems that enhance reliability, this section focuses on products and practices that prioritize both people and machines.

In addition to highlighting safety innovations, this section delves into essential maintenance strategies, including retrofitting, rebuilding, and remanufacturing, ensuring that machinery operates efficiently and reliably over time. Maintenance supplies, facility equipment, and accessories are explored alongside new safety technologies designed to meet evolving compliance standards.

Readers will discover how a proactive approach to safety and maintenance not only minimizes risks and downtime but also fosters a culture of care and continuous improvement within industrial settings.

24 | IMD January 2025

Enhancing Workplace Safety Through Machine Guarding

I

n today’s fast-paced industrial landscape, safety remains a critical priority for manufacturers and businesses. Machine guarding—physical barriers and safety devices designed to prevent accidental contact with moving parts— stands as a cornerstone of workplace safety. Its implementation not only ensures compliance with safety regulations but also significantly reduces workplace injuries and downtime, driving productivity and fostering a culture of safety.

The Importance of Machine Guarding Machine guarding is essential in environments where heavy machinery, high-speed equipment, and hazardous tools are used. According to the Occupational Safety and Health Administration (OSHA), machine-related injuries account for a substantial percentage of workplace accidents. Common incidents include entanglement, crushing, cutting, and even fatal injuries caused by moving parts.

Effective machine guarding mitigates these risks by providing a physical barrier between workers and hazardous components such as blades, gears, and belts. It also prevents debris and materials from being ejected during operation, protecting nearby personnel. Beyond physical safety, well-maintained guarding reduces liability and demonstrates a company’s commitment to employee welfare.

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

Types of Machine Guards There are several types of machine guards, each tailored to specific applications and equipment: » Fixed Guards: Permanent barriers that provide robust protection against moving parts. Commonly used on conveyors, gears, and cutting tools, these guards are simple, reliable, and cost-effective. » Interlocked Guards: Equipped with sensors that shut down machinery when the guard is removed or tampered with. This ensures that workers cannot access hazardous areas during operation. » Adjustable Guards: Flexible solutions designed for machines that require frequent adjustments. These guards can be repositioned to accommodate various tasks without compromising safety. » Self-Adjusting Guards: Often found on woodworking equipment, these guards adjust automatically based on the size of the material being processed, maintaining a consistent barrier.

Machine Guarding Standards and Compliance Compliance with safety standards is not optional; it’s a legal requirement. OSHA outlines specific regulations for machine guarding under standard 1910.212, which mandates that moving parts must be shielded to prevent injury. Additional guidelines from organizations such as the American National Standards Institute (ANSI) and

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the International Organization for Standardization (ISO) provide detailed specifications for guard design and implementation.

Failing to meet these standards can result in significant penalties and, more critically, endanger the lives of workers.

Regular audits, inspections, and employee training are essential to ensure compliance and maintain a safe working environment.

Innovations in Machine Guarding The evolution of technology has introduced innovative solutions in machine guarding, enhancing both functionality and usability. Modern guards now integrate advanced

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• Heavy Gauge Steel Design • Press Bed bolted on, not welded, to prevent distortion.

• Large press bed to accommodate a variety of tooling other than just punching.

• Pump, motor, valve and reservoir are all easily accessible for maintenance.

• Large rectangular tubes used at base of machine to give safe, instant portability.

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IMD | 25

materials, ergonomic designs, and automation for improved efficiency and worker convenience. » Smart Guarding Systems: Equipped with sensors and IoT capabilities, these systems monitor machinery in real time, providing alerts for potential hazards and maintenance needs. » Transparent Guards: Made from durable, shatterresistant materials like polycarbonate, these guards allow operators to visually monitor machine operations without compromising safety. » Ergonomic Designs: Guards are increasingly designed with user comfort in mind, reducing physical strain during operation and maintenance.

Benefits Beyond Safety While the primary purpose of machine guarding is to protect workers, its benefits extend far beyond safety. By minimizing accidents and downtime, guarding systems contribute to increased productivity and cost savings.

Efficiently guarded machines experience less wear and tear, reducing maintenance needs and extending equipment lifespan.

Moreover, a strong safety record enhances a company’s reputation, attracting skilled workers and fostering trust among clients and stakeholders. Investing in high-quality guarding systems is not just a regulatory necessity; it’s a strategic business decision.

Implementing Effective Machine Guarding Implementing an effective machine guarding program requires a comprehensive approach: » Hazard Assessment: Identify potential hazards associated with machinery and prioritize areas requiring immediate attention. » Guard Selection: Choose appropriate guarding

26 | IMD January 2025

solutions based on machine type, operational requirements, and worker interaction. » Training and Awareness: Educate employees on the importance of machine guarding, proper usage, and reporting procedures for damaged or missing guards. » Regular Maintenance: Inspect and maintain guards regularly to ensure they remain functional and compliant with safety standards. » Continuous Improvement: Stay updated on technological advancements and regulatory changes to enhance your guarding systems over time.

Conclusion Machine guarding is an indispensable element of workplace safety, protecting workers from harm while boosting operational efficiency. As industries continue to adopt advanced technologies, the integration of innovative guarding solutions ensures that safety standards evolve alongside progress. By prioritizing safety through effective machine guarding, businesses can create secure, productive environments where employees thrive.

ALEXANDER BATTERY TECHNOLOGIES

Alexander Battery Technologies Achieves ISO 45001 Certification, Reinforcing Commitment to Safety and Growth Alexander Battery Technologies (ABT), a global leader in battery pack manufacturing based in Peterlee, UK, has earned the prestigious ISO 45001 certification. This internationally recognized standard underscores ABT's unwavering commitment to health, safety, and operational excellence as the company continues to scale its global operations and support its ambitious growth targets.

With over 40 years of manufacturing excellence, ABT has delivered more than 15 million battery products worldwide, establishing itself as a trusted partner in industries ranging from medical devices and robotics to eVTOL (electric vertical take-off and landing) and industrial power tools.

During the COVID-19 pandemic, ABT demonstrated remarkable agility by ramping up production by nearly 300%, showcasing its ability to adapt and meet surging demand while maintaining a strong focus on safety and efficiency.

As ABT positions itself for continued growth, the company is targeting revenue milestones of £20 million by 2026 and £30 million by 2028. This trajectory is supported by substantial investments in infrastructure, an expanding team, and long-term partnerships that provide sustained revenue streams.

Mark Rutherford, Chief Executive Officer of Alexander Battery Technologies, emphasizes the significance of this achievement:

“ISO 45001 is a pivotal milestone for ABT. It not only highlights our dedication to creating a safe and supportive workplace but also strengthens our ability to meet the evolving demands of our customers.

Safety and quality are integral to our mission, and this certification reinforces our capacity to scale and innovate for future opportunities.”

Investment in Safety and Training Drives Excellence ABT’s dedication to safety extends beyond certification. The company has made targeted investments in advanced training, including an intensive IEC 61508 Functional Safety course for engineers. This initiative equips its team with the expertise to integrate safety principles into every aspect of product design and manufacturing, aligning seamlessly with the ISO 45001 framework. These efforts ensure that ABT remains a reliable partner in high-stakes industries requiring stringent safety and performance standards.

Looking ahead, ABT plans to achieve additional international certifications, including ISO 14001 (environmental management) and ISO 27001 (information security management), by 2025. These initiatives reflect the company’s forward-thinking approach and its commitment to maintaining a competitive edge in the global market.

“We’re expanding our workforce and pursuing higher standards to solidify our reputation as a partner of choice for OEMs worldwide,” adds Rutherford. “ISO 45001 not only showcases our dedication to safety but also sets a benchmark for other manufacturers, both nationally and internationally.”

Alexander Battery Technologies continues to lead the charge in safe, innovative manufacturing, positioning itself as a key player in the global battery market.

For more information, visit: www.alexandertechnologies.com.

FORM YOUR OWN INSERTS WITH STANDARD SHOP EQUIPMENT.

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• Increased material thickness • Long tool life • Chipless process • Innovative technology suitable for steel, stainless steel, copper, brass, and aluminum

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IMD | 27

Quality

QUALITY Ensuring Precision and Performance Quality control and assurance are the backbone of manufacturing, ensuring every product meets rigorous standards for precision, performance, and reliability. This section delves into the tools and technologies that enable manufacturers to uphold the highest quality standards. From advanced coordinate measuring machines (CMM) to vision systems and laser inspection equipment, the spotlight is on innovations that enhance accuracy and efficiency in measurement and inspection.

Nondestructive testing (NDT) equipment and positional measuring machines are also featured, allowing manufacturers to evaluate products without damage. Tools such as form measurement gauges, cutting tool inspection systems, and tool condition monitoring devices refine production processes and reduce errors. Whether through shrink-fit technologies or video inspection systems, this section highlights the importance of advanced solutions in maintaining precision, ensuring compliance, and driving continuous improvement in industrial operations.

28 | IMD January 2025

LK Metrology Innovates Eco-Friendly Solutions for CMMs with EcoAir Technology

B

ritish co-ordinate measuring machine (CMM) manufacturer LK Metrology has unveiled an innovative EcoAir system designed to enhance the energy efficiency of its CMMs while reducing their environmental impact. This cutting-edge technology, developed at the company’s Castle Donington facility in Derbyshire, UK, can be integrated into new machines or retrofitted to existing ones equipped with the LK NMC300 controller. The EcoAir system is compatible with various CMM brands, ensuring broad accessibility for manufacturers.

EcoAir operates by automatically shutting off compressed air to the CMM’s air bearings during periods of inactivity, reducing air consumption by up to 95%. This automatic feature, adjustable to trigger shutdowns after as little as one minute, significantly lowers energy costs while maintaining

the machine’s readiness for operation.

Upon resumption of activity in manual or CNC mode, the system seamlessly restores the compressed air supply, ensuring uninterrupted workflow.

This advancement aligns with LK Metrology’s long-standing commitment to sustainability. Over the years, the company has integrated other eco-friendly features, such as a thinner air bearing film to reduce air usage while maintaining

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

three-and-a-half times the stiffness of standard bearings, enhancing measurement accuracy. Additionally, advanced motor control and power management systems ensure that CMM drive motors deactivate during idle periods, further improving energy efficiency.

By focusing on lightweight materials like ceramic for critical machine components, LK Metrology minimizes energy demands during operation, contributing to a more sustainable manufacturing process.

With EcoAir, LK Metrology empowers manufacturers to meet regulatory energy efficiency standards, support corporate social responsibility goals, and enjoy financial benefits through reduced operational costs.

HEMCO’s Acid Storage Cabinet Combines Safety and Durability

For more information, visit www.lkmetrology.com

HEMCO

HEMCO’s Acid Storage Cabinet Combines Safety and Durability HEMCO introduces its Acid Storage Cabinet, designed for the safe storage of corrosive chemicals. Available in widths ranging from 12 to 48 inches, the cabinet stands 35 inches high and 22 inches deep, offering flexibility to accommodate various laboratory needs. The cabinet features a one-piece molded fiberglass liner with coved corners, ensuring easy cleaning and chemical resistance.

The cabinet’s interior includes a containment lip to manage spills, while the air-inlet-vented doors are lined and sealed to prevent exposure to corrosive vapors. No metal components are exposed, ensuring longevity in harsh environments. The removable shelf provides additional storage for smaller containers, enhancing usability.

For more information, call 816-796-2900 or visit www.HEMCOcorp.com/labfurn.html

MAHR INC

Mahr Enhances Precimar® SM 60 Line with New SM 60-V Model Mahr Inc., a leader in dimensional metrology solutions, has expanded its Precimar® SM 60 product line with the new SM 60-V model, designed to deliver exceptional flexibility

Mahr Enhances Precimar® SM 60 Line with New SM 60-V Model

and accuracy for measuring precision parts in production environments. The SM 60-V integrates Mahr’s standard contact inserts, offering adaptability for tasks such as measuring recesses, external gears, and thread diameters.

With a robust 5 N measuring force, a 25 mm sensitive contact, and a fixed reference jaw adjustable up to 35 mm, the SM 60-V achieves a total measurement capacity of 60 mm. The model is tailored for demanding production settings, featuring a durable design, fast setup capabilities, and compatibility with various Mahr readouts, including the MarCator digital indicators and Millimess® comparators.

Operators can select from interchangeable inserts made of hardened steel or carbide, catering to diverse measurement needs. The SM 60-V also includes an adjustable support table for precise part placement and a user-friendly lever for retracting the sensitive contact.

“The Precimar SM 60-V is a testament to Mahr’s dedication to addressing the evolving requirements of modern manufacturers,” said Nick Russo, Product Manager at Mahr. “Its combination of precision, durability, and adaptability provides manufacturers with the tools to enhance measurement accuracy and productivity.”

To learn more, visit www.mahr.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 29

robotics CWC-D cobot welding system, two-station solution with cobot on longitudinal axis and 2 turn/tilt positioners.

ROBOTICS Driving Automation and Innovation Robotics and automation are transforming modern manufacturing, redefining efficiency, precision, and versatility across industrial processes. From welding robots and robotic tooling to autonomous technology and cobots (collaborative robots), innovations are seamlessly integrating robotics into diverse manufacturing workflows.

Key advancements include automated cells and press transfer robotics, enabling streamlined operations and reduced cycle times.

Solutions like material handling systems and end effectors highlight the adaptability of robotics in tasks ranging from machining to assembly.

With a focus on enhancing safety and productivity, the integration of RFID and enclosure systems, along with comprehensive training, empowers manufacturers to harness the full potential of robotics in an increasingly automated world.

30 | IMD January 2025

How Advanced Technology is Tackling the Shortage of Skilled Workers Can Cobots Attract More Young Talent to Welding?

W

elding remains a cornerstone of the metalworking industry, requiring a unique combination of skill, precision, and knowledge.

Despite the high earning potential, the number of young people entering the profession continues to decline, as welding is often seen as physically demanding, hazardous, and unappealing. Collaborative robots (cobots) are poised to revolutionize this perception, making welding safer, more attractive, and more accessible to a new generation of workers.

Cobots not only address the labor shortage but also bring profitability to smaller operations, even for low-volume production.

Modern cobot systems vary widely, ranging from mobile individual workstations to fully enclosed, multistation setups. These systems often include advanced technologies such as robot tracks, turn/tilt positioners,

automatic extraction systems, and safety doors. High-tech welding machines and software for offline programming are increasingly becoming standard, transforming welding into a high-tech profession that merges manual expertise with cutting-edge automation.

The Major Advantages of Cobot Welding Systems Cobots have distinct advantages over traditional methods. Unlike even the most skilled welders, cobots produce consistent, high-quality welds around the clock. Fronius, a leader in welding technology, offers advanced cobot systems such as the TPS 400i CMT and the iWave 400i AC/DC CMT. These systems are capable of welding a variety of metals, including steel, aluminum, copper, and titanium.

Fronius’ proprietary features, like Low Spatter Control (LSC) and Pulse Multi Control (PMC), ensure precision and

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

quality, while Cold Metal Transfer (CMT) minimizes heat input, making it ideal for thin sheet welding.

Ease of Use: Cobots are designed with user-friendly programming interfaces, allowing even those with minimal training to create welding programs quickly. By guiding the welding torch to the starting point, setting contour points, and using drag-and-drop tools, operators can program welding paths intuitively.

Christian Neuhofer, Product Manager at Fronius, highlights this simplicity: “Compared to industrial robots, cobot teaching requires minimal training, enabling welding specialists to achieve proficiency within hours.”

Integrating Mobile Flexibility: The CWC-Mobile Fronius’ CWC-mobile cobot welding system offers a unique blend of mobility, advanced welding technology, and cost-effectiveness.

Its retractable transport rollers make it easy to move the system to large components, such as excavator buckets, streamlining operations for workshops of all sizes. The system is equipped with high-tech welding features, mobile fume extraction, and robust safety measures, ensuring compliance with European Machinery Directive standards. Images of the CWC-mobile in action highlight its versatility and suitability for both largescale and intricate welding projects.

CWC-S cobot welding system, one-station solution with turn/tilt positioner and tailstock.

Enhanced Productivity with CWC-S and CWC-D Systems Fronius also offers fully enclosed cobot welding systems designed for singlestation (CWC-S) and dual-station (CWC-D) operations. These systems are equipped with advanced features like turn/tilt positioners, enabling the circumferential welding of cylindrical components. The CWC-D system can accommodate components up to three meters in length and up to two tons in weight, making it ideal for small-series production.

The flexibility of these systems is further enhanced by Coordinated Motion software, which synchronizes the welding torch and positioner for

CWC-mobile welding an excavator bucket, Fronius product rendering.

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 31

CWC-mobile cobot welding system with extraction and movable housing for welding big and small components alike.

Equipped with retractable transport rollers, the system can be transported to the component.

seamless operation. Operators can easily switch between cobot and robot modes, achieving speeds of up to 2 meters per second for more complex applications. Fronius’ images of the CWC-S and CWC-D systems illustrate their capability to handle a variety of component sizes and requirements, showcasing their adaptability in diverse industrial settings.

select and store optimal welding parameters for various tasks. With NFC-enabled data transfer, users can quickly upload parameters to cobot systems, enabling immediate deployment. Younger workers, accustomed to smartphone technology, find this integration particularly appealing, making welding a more accessible and engaging career choice.

Digital Integration and the WeldConnect App

Boosting Efficiency with Offline Programming

Fronius combines advanced hardware with intuitive digital tools like the WeldConnect app. This app serves as a parameter manager, helping welding specialists

To minimize downtime and maximize productivity, Fronius offers Pathfinder offline programming software. This tool allows operators to create and refine welding programs

32 | IMD January 2025

Fronius CWC-D cobot welding system, design for a one-station solution.

Fronius CWC-D cobot welding system, design for a two-station solution.

independently of the cobot system, ensuring uninterrupted production. The ability to copy, mirror, and simulate welding processes accelerates the setup of complex geometries, enhancing productivity by up to 80%.

For more information, contact:

Safety at the Forefront Safety is paramount in Fronius’ cobot systems. Features such as power and torque limiting, advanced fume extraction, and ergonomic PPE ensure a secure working environment. Water-cooled torches, which cool down within seconds, minimize the risk of burns. Intensive safety testing, conducted with external inspectors, confirms that Fronius systems meet the highest safety standards, providing operators with confidence in their work environment.

The Path to Automation Fronius provides end-to-end support for customers transitioning to automation. From selecting the right cobot or robot system to providing commissioning and after-sales service, the company ensures a seamless integration of automation into existing operations. Neuhofer emphasizes Fronius’ role as a partner in innovation: “We help our customers achieve high efficiency and safety in their welding processes by offering tailored solutions and expert support.”

Conclusion Cobot welding systems are redefining the welding profession, making it cleaner, safer, and more appealing to a new generation. Fronius’ innovative solutions, such as the CWC-mobile, CWC-S, and CWC-D systems, empower manufacturers to enhance productivity while addressing the skilled labor shortage. By combining advanced welding technology with intuitive digital tools, Fronius is shaping the future of welding, proving that automation and human expertise can coexist to drive industry progress.

FRONIUS USA LLC, Ms. Rhonda Zatezalo 6797 Fronius Drive, 46368 Portage, IN Phone: +1 219 734 5701 E-Mail: zatezalo.rhonda@fronius.com

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FILTRATION… The range of filter

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FLUID AND MOTION CONTROL…

DIRECTIONAL CONTROL VALVES D02/D03/D05/D07/D08: Argo-Hytos DC and dual frequency AC coils can be rotated to locate connectors to your need. DIN, Deutsch Flying Leads and Wire Box Connection are available as standard Manual Override. Full line of Sandwich Controls.

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THREE SERIES: GP1-P, maximum pressures from 2300-4350 flows 1.0 gpm; GP1-T, maximum pressures from 1700-4200, flows 1.0 to 17.0 gpm; GP1-Q, maximum pressures from 2900-4500, flows 7.1 to 42.8 gpm.

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IMD | 33

Metalworking

METALWORKING Precision and Craftsmanship in Manufacturing Metalworking encompasses the tools, technologies, and processes that drive precision manufacturing.

This area highlights advancements in machining, grinding, lathing, and cutting systems, along with innovations like EDM (Electronic Discharge Machining). It captures the synergy between precision equipment and skilled craftsmanship, essential for producing high-quality components across diverse industries.

Focusing on the integration of controls, machining tools, and accessories, metalworking emphasizes the efficiency and accuracy demanded by modern manufacturing. From contract manufacturing to heat treating and gear machinery, it reflects the essential techniques and equipment shaping today’s industrial landscape. Whether utilizing traditional methods or cutting-edge innovations, metalworking celebrates the pursuit of excellence in every detail.

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Precision as a Passion: The Zoerkler Success Story How an Austrian Family Business Became a High-Tech Forge for Sophisticated Gearboxes

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n the realm of high-precision drive systems, Zoerkler Gears GmbH & Co KG stands as a beacon of innovation, quality, and technical excellence. From its modest beginnings as a mechanical engineers’ workshop nearly 120 years ago, the company has grown into a global leader, serving the automotive and aviation industries with cutting-edge transmission technologies. Managing Director Bernhard Wagner shares insights into Zoerkler’s journey, its state-of-the-art technologies, and the company’s vision for the future.

A Legacy of Precision and Growth Zoerkler’s story began as a small family-run workshop, producing spare parts for local machinery. Over the decades, the company specialized in gear cutting, initially focusing on construction machinery. The turning point came in 2008 with the move to a modern 8,000-squaremeter production facility in Burgenland. This allowed Zoerkler to

Bernhard Wagner, Managing Director of Zoerkler

expand its operations significantly, transforming into a manufacturer of high-performance drive systems for demanding industries.

Today, Zoerkler employs 100 skilled workers, including eight apprentices and a team of 15 highly qualified design engineers. The company’s workforce embodies its commitment to nurturing talent and fostering innovation. Wagner notes, "Our team is like a well-coordinated special forces unit. Every member is highly skilled, but the true strength comes from their ability to work together seamlessly."

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Modern production hall with the VL 6 vertical pick-up turning machine from EMAG at Zoerkler.

Core Competencies in Precision Drive Systems Zoerkler specializes in the design, manufacturing, and testing of drive systems that meet the most stringent requirements. These systems power high-performance vehicles in the automotive sector and are integral to helicopters and airplanes in the aviation industry.

The company also serves the railway and agricultural machinery markets, but its core focus remains on delivering precision gearboxes for the most challenging applications.

Wagner explains, “Our drive systems are custombuilt to meet exacting specifications. From the initial layout to the final assembly and testing, every step is handled in-house. This integrated approach ensures that our products meet the highest standards of quality and reliability.”

Zoerkler’s in-house test center is a cornerstone of its operations. Here, advanced facilities allow for comprehensive testing, including certification of helicopter gearboxes under extreme conditions. This ensures that every product is optimized for its intended application, whether in high-performance automobiles or aviation systems.

The Role of Advanced Manufacturing Technologies Zoerkler’s commitment to excellence is evident in its investment in state-of-the-art manufacturing equipment.

The company’s decision to adopt the VL 6 vertical pick-up turning machine from EMAG exemplifies this dedication.

This advanced machine enables the automated production

A selection of different precision parts manufactured by Zoerkler. The components vary in size and shape, from small gears to complex transmission parts.

of heavier components with unparalleled accuracy and reliability, even in small production runs.

“The VL 6 allows us to achieve exceptional dimensional accuracy while maintaining flexibility for frequent workpiece changes,” says Wagner. “Its integrated hard turning and milling functions reduce cycle times and ensure precision in every component.”

Automation is another key feature of the VL 6, enabling Zoerkler to operate the machine autonomously during second and third shifts. This significantly enhances productivity without compromising quality. The integration of the VL 6 into Zoerkler’s workflow complements an impressive array of technologies, including turning, milling, grinding, and gear cutting.

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Specialized Expertise in Complex Gear Technologies Zoerkler’s capabilities extend to producing intricate gear components, including internal gears, gear rims, and bevel gears for helicopters. The company is particularly renowned for its ability to manufacture bevel gears with angles other than 90 degrees—a highly specialized skill in the aviation industry.

This expertise is supported by Zoerkler’s focus on noise, vibration, and harshness (NVH) optimization, a critical consideration for both automotive and aviation clients.

With advanced test stands and precise measurement tools, the company ensures that its gearboxes meet stringent performance and comfort standards.

Quality Assurance and Documentation In industries like aviation, where safety and reliability are paramount, Zoerkler’s comprehensive quality assurance processes set it apart.

Every component undergoes rigorous testing, with all data meticulously documented for complete traceability.

From raw materials to finished products, Zoerkler maintains a batchspecific history, ensuring that clients have full confidence in the integrity of their gearboxes.

“Our quality assurance system is integrated into every stage of production,” Wagner explains.

“This approach not only meets regulatory requirements but also reflects our commitment to delivering excellence.”

Shaping the Future of Mobility Zoerkler is not resting on its laurels.

The company is actively investing in research and development to address emerging trends in electrification, autonomous systems, and sustainable materials. With a focus on innovation, Zoerkler aims to play a leading role in the development of next-generation drive systems for supercars, jets, and helicopters.

“Our goal is to combine cutting-edge technology with

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Close-up of a high-precision gears

NITREX

Nitrex Expands Aerospace Manufacturing Capacity with New Vacuum Furnace

Automation conveyor of the EMAG VL 6 with several workpieces in a row for automated machining. The belt transports the workpieces to the pick-up station, enabling a continuous and efficient production flow.

sustainable practices,” Wagner says.

“We see this as both a responsibility and an opportunity to lead in an increasingly eco-conscious market.”

A Commitment to Excellence From its origins as a family-run workshop to its position as a global leader, Zoerkler Gears GmbH & Co KG exemplifies the transformative power of precision manufacturing.

With a relentless focus on quality, innovation, and customer satisfaction, the company is well-positioned to meet the challenges of a rapidly evolving industry.

In a major move to support increased production demands, Nitrex Vacuum has secured an order for a seventh vacuum furnace from a leading North American aerospace manufacturer.

Known for their reliability and precision, Nitrex’s vacuum furnaces have been a cornerstone in producing high-performance aircraft engine components since the 1990s.

The new furnace, part of Nitrex’s renowned VVF series, is engineered to meet the rigorous standards of aerospace manufacturing. With a spacious 60” x 60” chamber and a load capacity of up to 3,000 lbs., this vertical precision furnace is designed for the heat treatment of critical engine components. Featuring a bottom-loading configuration, it enhances both performance and efficiency to keep up with demanding production schedules.

Mark Hemsath, Nitrex NTS Division President, emphasized the trust built over three decades:

Key features of the SG3 Grinder include a rapid material removal system with minimal vibration, a top grinding table for versatile applications, and multiple adjustable features to enhance user comfort and efficiency. Fabricators will appreciate the tool-free belt change system, which enables quick transitions to match specific finishing needs. The durable contact wheel extends belt life, while the belt tracking adjustment saves time during operation.

Specifications at a Glance: » Grinding Belt: 3" x 79" » Motor: 4.1 HP, available in 220/440v configurations » Belt Speed: 98 FPS » Weight: 176 lbs.

State-of-the-art Nitrex VVF series vacuum furnace, built by G-M Enterprises, engineered to meet the rigorous demands of aerospace manufacturing with unparalleled precision and reliability.

“The SG3 grinder is engineered for efficiency, precision, and operator ease,” said a representative from Scotchman Industries. “Its versatile design and advanced dust collection system make it ideal for professionals seeking reliable, high-quality performance.”

For metal fabricators, the SG3 represents a game-changer, with features like an emergency stop, adjustable eye shields, and a flexible contact wheel that adapts to varied applications. With a three-year warranty and Scotchman’s reputation for durability, the SG3 offers long-term value for heavy-duty grinding tasks.

“The customer’s decision to expand with Nitrex reflects G-M Enterprises’ proven track record in furnace reliability. Our commitment to quality has anchored this partnership.”

Jay Jefsen, Regional Sales Manager, echoed the sentiment, highlighting the robust technical support that Nitrex offers. “We are proud to contribute to their ongoing success and look forward to meeting their production goals with this latest addition,” he said.

With commissioning slated for April 2025, this advanced furnace will play a pivotal role in maintaining high standards of performance, efficiency, and reliability for one of aerospace’s most demanding sectors.

For more information about Nitrex and its advanced vacuum furnace solutions, visit www.nitrex.com or email info@nitrex.com.

For more details on the SG3 and other metalworking solutions, visit www.scotchman.com, email info@scotchman.com, or call 1-605-859-2542.

SCOTCHMAN

Scotchman Unveils SG3 Grinder with Advanced Dust Collection Scotchman Industries has introduced the SG3 Industrial Belt Grinder, a robust addition to its lineup of high-performance metalworking solutions. Designed with a powerful 4.1 HP motor, the SG3 delivers exceptional speed and precision, making it a standout choice for deburring and sanding in fabrication and production environments. Its integrated dust collection system ensures a cleaner, safer workspace while maintaining quiet and efficient operation.

Are you looking to spotlight your company’s innovations and expertise in the world of metalworking? Industrial Machinery Digest’s Metalworking feature is the premier destination for showcasing the latest advancements, tools, and technologies that shape precision manufacturing. With a dedicated audience of industry professionals, our Metalworking section is the perfect platform to gain visibility and connect with decision-makers. Send your press releases to editor@indmacdig.com and let us help your company stand out in the metalworking industry.

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Software

SOFTWARE The Digital Backbone of Modern Manufacturing In an era where innovation drives productivity, the Software section explores the cutting-edge tools empowering manufacturers to streamline operations, enhance precision, and optimize performance.

From CAD/CAM/CAE design platforms to CNC simulation and process verification, this category reveals how digital solutions are revolutionizing the way products are conceptualized, created, and delivered.

Covering a broad spectrum of applications—such as ERP systems, factory floor software, and industrial IT—this section emphasizes the importance of connectivity and real-time data in achieving operational excellence. Topics like quality control, job tracking, and program optimization showcase how software bridges the gap between vision and execution, enabling manufacturers to stay competitive in a fast-evolving industry.

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Embracing the Future: How Advanced Software Solutions Are Reshaping Manufacturing Insights from Deloitte's 2025 Manufacturing Industry Outlook Highlight the Role of Digital Transformation in Driving Efficiency and Innovation

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n the face of global challenges, manufacturers are rapidly evolving to adopt cutting-edge technologies, particularly in software solutions, to remain competitive and resilient. Deloitte’s "2025 Manufacturing Industry Outlook" highlights the pivotal role of generative AI, supply chain tools, and workforce management systems in reshaping the industry.

This article delves into how software is transforming manufacturing processes, improving efficiency, and enabling companies to navigate the complexities of a dynamic global landscape.

The Push for Digital Integration The manufacturing industry is entering an era where digital integration is no longer optional but essential.

According to Deloitte, companies are prioritizing the deployment of generative AI to streamline processes, predict market demands, and optimize operations. Generative AI, with its ability to analyze large datasets and generate actionable insights, is revolutionizing product design, predictive maintenance, and real-time decision-making.

For instance, advanced simulation software powered by AI allows manufacturers to test multiple

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design iterations virtually, significantly reducing prototyping costs and time to market. AI-driven analytics can also identify potential production bottlenecks and recommend real-time adjustments, enhancing overall efficiency.

Supply Chain Resilience Through Software The COVID-19 pandemic and geopolitical tensions have underscored vulnerabilities in global supply chains. Deloitte’s insights reveal a growing reliance on supply chain planning tools to address these challenges. Modern supply chain software provides manufacturers with end-to-end visibility, enabling better risk management and agility in response to disruptions.

Predictive analytics embedded in supply chain solutions can forecast demand fluctuations and identify alternative sourcing options.

Additionally, advanced logistics platforms optimize route planning and inventory management, reducing costs and ensuring timely deliveries.

By leveraging cloud-based supply chain software, manufacturers can collaborate more effectively with suppliers and partners, fostering a more resilient ecosystem.

Workforce Management in the Digital Age As the manufacturing workforce evolves, companies are turning to sophisticated workforce management software to enhance productivity and employee satisfaction. Deloitte emphasizes the importance of integrating digital tools that streamline scheduling, training, and performance tracking.

For example, software platforms equipped with machine learning algorithms can predict staffing needs based on production schedules, minimizing downtime and overstaffing. Employee training modules integrated with augmented reality (AR) provide immersive learning experiences, enabling workers to upskill quickly and efficiently.

Project manager utilizing advanced software solutions to update tasks and milestones through an interactive Gantt chart interface. This dynamic virtual screen showcases the power of modern project management systems in streamlining workflows, enhancing efficiency, and ensuring real-time progress tracking—key elements of digital transformation in manufacturing and business operations.

Quality Assurance Through Advanced Software Quality assurance (QA) remains a cornerstone of manufacturing excellence, and software solutions are playing a transformative role in this area. Deloitte’s report highlights the integration of AI-powered quality control systems that detect defects in real-time, reducing waste and ensuring compliance with stringent standards.

Manufacturing execution systems (MES) equipped with QA modules allow for automated tracking and documentation of production processes. These systems not only ensure product consistency but also provide traceability, which is critical in industries like aerospace and pharmaceuticals.

Sustainability and Software Sustainability is becoming a key focus for manufacturers, driven by regulatory requirements and consumer demand.

Advanced software tools are enabling companies to track and reduce their environmental impact. Deloitte’s analysis points to the use of energy

management software that monitors and optimizes energy consumption across production lines.

Furthermore, lifecycle assessment tools help manufacturers design products with sustainability in mind, considering factors such as recyclability and material efficiency. By leveraging these tools, companies can align with global sustainability goals while reducing operational costs.

Cybersecurity in Manufacturing As digital transformation accelerates, the importance of robust cybersecurity measures cannot be overstated.

Deloitte identifies cybersecurity as a critical area where manufacturers must invest in advanced software to protect sensitive data and infrastructure from cyber threats.

Cybersecurity platforms designed for industrial environments provide real-time monitoring and threat detection. These tools not only safeguard intellectual property but also ensure compliance with industryspecific regulations. As manufacturers integrate more IoT devices and INDUSTRIAL MACHINERY DIGEST.COM

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cloud-based solutions, cybersecurity software will be pivotal in maintaining operational integrity.

Challenges and Opportunities While the adoption of advanced software offers numerous benefits, manufacturers face challenges such as integration complexities, high implementation costs, and workforce adaptation. Deloitte’s "2025 Manufacturing Industry Outlook" suggests that companies can overcome these hurdles by prioritizing scalable and user-friendly solutions, investing in employee training, and fostering a culture of innovation.

Moreover, collaboration with technology providers and industry peers can accelerate the adoption of best practices and shared learnings. By taking a proactive approach, manufacturers can unlock the full potential of software-driven transformation.

Conclusion The manufacturing industry is at a pivotal juncture where advanced software solutions are driving unparalleled efficiency, resilience, and innovation. From generative AI to workforce management tools, the integration of cutting-edge technologies is redefining how manufacturers operate in a competitive global market.

Deloitte’s insights underscore the importance of embracing digital transformation to navigate the complexities of modern manufacturing. By investing in software solutions, companies can not only enhance their operational capabilities but also position themselves as leaders in a rapidly evolving industry. As we approach 2025, the role of software in manufacturing will undoubtedly continue to expand, shaping the future of the industry for years to come.

Reference: "2025 Manufacturing Industry Outlook," Deloitte Insights

NORELEM

Digitalization of the Industry - Moving to a Digital Customer Journey Almir Jakupovic, Sales Director at norelem, highlights how the company is leading the way in providing a streamlined, fully digital customer experience.

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As industries increasingly embrace digitalization, partners and suppliers must be prepared to support this transformation.

To remain competitive, suppliers often need to anticipate market trends and act as early adopters. For norelem, this meant becoming fully "digital-ready" before our customers even made the leap. In the fast-paced world of engineering and manufacturing, customers cannot afford to wait for their suppliers to catch up. By being ahead of the curve, norelem ensures its readiness to meet evolving customer needs while actively encouraging and supporting them in their own digital journeys.

The Digital Advantage At the core of norelem's offering are standardized components that simplify product development.

Digitalization amplifies these benefits, making it easier for engineers and designers to engage with and integrate norelem's products into their workflows.

This starts with providing free, accessible 3D models of our products online. Almost all designers use CAD software daily, as it integrates seamlessly into their planning and manufacturing processes. Instead of designing a component from scratch, engineers can save time by downloading pre-designed norelem parts in 2D and 3D formats, complete with 360° rotation views and comprehensive technical data. This not only improves productivity but also enhances accuracy.

Partnering with CADENAS, norelem offers a comprehensive CAD library that includes all relevant geometric and technical specifications of its components.

Seamless Integration For digitalization to succeed, it must be seamless. norelem's proprietary PART2CAD plug-in allows designers to integrate CAD data directly into their CAD systems, eliminating the need for manual importing or buffering. The plug-in supports leading software platforms, including Catia, Creo, Inventor, NX, SolidEdge, and SolidWorks.

Moreover, norelem provides CAD models in all major 2D and 3D formats, compatible with software like AutoCAD and SolidWorks. The company also supports widely-used CAD data interchange formats, such as SAT, STEP, IGES, and DFX. Additionally, all norelem products are ERP-compatible, ensuring smooth data transfer to resource management systems. CAD models are enhanced with features like ECLASS classification, customs tariff numbers, RoHS compliance, and EAN numbers for effortless integration into customer processes.

Key Benefits of Digitalization Digital tools like online 3D models, CAD files, and a robust CAD platform empower engineers and designers to access real-time, accurate product data. This streamlines workflows, improves decision-making, and minimizes errors.

Beyond data accessibility, norelem enhances the customer experience with advanced tools like a product selection assistant integrated into its online store. Engineers can specify material, dimensions, and feature requirements, and the system suggests the ideal components for their project.

To further support customers, norelem ACADEMY provides an extensive knowledge database, featuring application examples, best-practice videos, and detailed technical data on components. This ensures users fully understand the capabilities of each part, facilitating proper usage and unlocking the potential of norelem's products.

Digital twins further extend the benefits of digitalization by enabling designers to experiment and test virtual prototypes without the cost or time required for physical models. This fosters creativity while accelerating product development.

Finally, norelem streamlines the purchasing process with a one-click ordering system. With over 100,000 standardized products available and 98% of them in stock, customers have access to a wide range of solutions, backed by reliable and efficient delivery.

Transforming Industry Interactions The rise of Industry 4.0 demands comprehensive digitalization. Without digital data and processes, manufacturers cannot unlock the full benefits of automation and AI. To remain competitive and meet evolving customer needs, companies must adopt the technologies shaping the factories of the future. norelem is at the forefront of this transformation, redefining customer interactions with innovative digital

tools, enhanced online services, and real-time support. By doing so, norelem creates a more efficient, transparent, and accessible experience for industry professionals, driving productivity and innovation in engineering and manufacturing.

ABOUT NORELEM For over 65 years, norelem has been a trusted manufacturer and supplier of high-quality components for the mechanical engineering industry. Offering more than 100,000 standardized parts, norelem supports the fast-paced demands of its customers with reliable delivery and extensive technical expertise.

The norelem online shop offers convenient 24/7 access to its product portfolio, along with a robust CAD library that saves engineers significant time by providing pre-designed, accurate parts.

Going beyond its role as a manufacturer, norelem ACADEMY is dedicated to shaping the future of engineering. With online resources, technical articles, webinars, and hands-on training opportunities like the ShowTruck, norelem empowers both students and professionals with the knowledge and tools needed to succeed in a rapidly evolving industry.

To discover how norelem can enhance your digital product development journey, visit norelemusa.com.

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Tooling & Workholding

TOOLING AND WORKHOLDING Precision in Action Tooling and Workholding is the cornerstone of precision manufacturing, ensuring that materials are securely held and processes are executed with unparalleled accuracy.

This section highlights the latest innovations in clamps, chucks, collets, and magnetic workholding, alongside advancements in rotary tables, toolholders, and modular fixturing systems. Together, these solutions enable manufacturers to achieve repeatability, reduce setup times, and enhance overall productivity.

From versatile milling and turning tools to specialized threading and gear-cutting instruments, this category delves into the diverse range of equipment designed to meet the unique demands of every operation. Whether exploring robotic end-effectors for automation or custom fixtures for intricate designs, Tooling and Workholding underscores the critical role these components play in driving efficiency and precision across the manufacturing spectrum.

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Tooling and Workholding in Focus: Advancing Precision and Productivity 2024’s Innovations and 2025’s Transformative Trends in Precision Manufacturing Solutions

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s we reflect on advancements in tooling and workholding throughout 2024 and anticipate the developments on the horizon for 2025, it's evident that this sector remains pivotal in driving precision manufacturing forward. The integration of automation, digitalization, and sustainable practices has redefined industry standards, enabling manufacturers to achieve unparalleled accuracy and efficiency.

2024: A Year of Innovation and Integration The tooling and workholding industry in 2024 embraced transformative changes, with an emphasis on technological integration and sustainability. Automation and digital connectivity emerged as critical elements, empowering manufacturers to streamline operations and achieve greater precision.

Key highlights from 2024 » Automation and Robotics: Companies increasingly relied on robotic systems and automated processes to reduce labor-intensive tasks and enhance efficiency. Flexible workholding systems designed for robotic integration gained popularity, enabling seamless production transitions. » Sustainability in Focus: Eco-friendly materials and energy-efficient processes became central to tooling and workholding, addressing environmental concerns while maintaining performance standards. » Enhanced Modular Systems: Modular fixturing systems saw significant adoption due to their adaptability and cost-effectiveness, providing manufacturers with customizable solutions to meet diverse production needs.

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"The move toward modular and eco-friendly solutions in 2024 marked a turning point for the industry, paving the way for smarter, more sustainable manufacturing," said Sarah Mitchell, a senior industry analyst.

Anticipating 2025: The Next Wave of Transformation The momentum of 2024 is set to accelerate in 2025 as manufacturers continue to adopt cutting-edge solutions. Several trends and advancements are poised to shape the landscape: » Digital Twins for Workholding Optimization: The adoption of digital twins will allow manufacturers to simulate and refine workholding setups virtually. This innovation is expected to reduce errors, shorten setup times, and maximize efficiency. » Advanced Tooling Materials: Emerging materials such as reinforced composites and ceramics promise enhanced durability and precision, catering to industries with demanding requirements, such as aerospace and medical devices. » Smarter Automation: Workholding devices equipped with IoT-enabled sensors will provide real-time feedback, enabling predictive maintenance and process optimization. » Customization for Complexity: As manufacturing processes grow more intricate, the demand for

custom tooling and workholding solutions tailored to specific applications is expected to rise.

"Customization is no longer a luxury; it’s a necessity in today’s fast-evolving manufacturing landscape," said Thomas Reed, a tooling specialist.

Industry Challenges and Opportunities While innovation is at the forefront, challenges such as integration complexities, high costs, and the need for skilled labor remain. However, opportunities abound for manufacturers willing to invest in training, research, and strategic partnerships.

"Overcoming challenges in tooling and workholding requires a collaborative approach," emphasized Emily Carter, an engineering consultant. "Manufacturers must align with technology providers to ensure seamless implementation and long-term success."

Looking Forward The advancements in tooling and workholding not only reflect the industry’s adaptability but also its commitment to driving precision and efficiency. By embracing automation, sustainability, and digitalization, manufacturers are better equipped to navigate a competitive global market.

As we move into 2025, the focus on innovation will continue to redefine manufacturing processes. Whether

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through smarter workholding systems, advanced tooling materials, or comprehensive digital integration, the industry is set to achieve new milestones in precision and productivity.

"The future of tooling and workholding is about bridging tradition with technology, ensuring that every solution delivers unparalleled accuracy and efficiency," concluded Mark Douglas, CEO of Precision Tools Inc.

Sources This article incorporates insights from key industry reports and events, including the "2025 Manufacturing Industry Outlook" by Deloitte, market analyses by IMARC Group and DataIntelo, and expert interviews conducted at IMTS 2024.

Additional references include statements from industry leaders and tooling specialists. For more information, visit www.industryinsights.com.

E-Z LOK

E-Z LOK Offers Comprehensive Installation Tools for Threaded Inserts

E-Z LOK, a prominent manufacturer and distributor of threaded inserts for metal, plastic, and wood, delivers an impressive range of specialized installation tools tailored to meet diverse application needs. Whether you are working with E-Z LOK™ Solid Wall Inserts, Knife Thread, Coil, or Hex Drive applications, E-Z LOK has the right tools to enhance your project’s efficiency and precision.

Solid Wall Insert Tools: The E-Z LOK™ installation tools for Solid Wall inserts stand out for their ability to avoid engagement with internal threads, preventing crossthreading or stripping during installation. These tools integrate seamlessly with standard power drills and drill presses, making them invaluable for industrial projects, automotive repairs, and more. Their versatility extends to applications in both metalworking and woodworking, ensuring they meet the demands of modern manufacturing.

Knife Thread Insert Tools: Engineered for accuracy, these tools simplify the installation of Knife Thread inserts while minimizing effort and preventing damage. The optional power drive wood insert tools further enhance efficiency and consistency, making them ideal for high-volume projects where precision is key.

Coil Insert Tools: Designed for repairing or fortifying tapped holes in soft metals, the E-Z Coil™ tools offer cost-effective solutions for installing premium inserts. The

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mandrel-style tools and manual tang break options ensure secure and durable installations, no matter the project size.

Hex Drive Tools: Tailored for softwood applications, Hex Drive tools ensure snug and precise installations with every use. Constructed from high-grade materials, these tools are engineered for durability, dependability, and repeat performance, even under demanding conditions.

E-Z LOK’s tools are compatible with every insert size the company offers, ensuring no project is too large or too small.

Customers can explore the entire range with detailed CAD files available for download in over 100 file formats at www. ezlok.com/cad-downloads. Free samples are also available upon request, empowering customers to experience E-Z LOK’s superior quality firsthand.

FIXTUREWORKS®

Fixtureworks® Enhances Workholding Capabilities with New Flexible Locators and Expanded One-Touch Snap Clamps Fixtureworks®, a leader in innovative fixturing accessories and machine tool components, continues to set the standard in precision manufacturing with the introduction of advanced Flex Locators and an expanded range of One-Touch Snap Clamps. These groundbreaking solutions cater to the ever-evolving demands of quickchange applications and light-duty industrial processes, empowering manufacturers to achieve unparalleled efficiency and precision.

Flex Locators: Redefining Quick-Change Applications Fixtureworks’ Flex Locators provide an all-in-one solution for locating and clamping, streamlining fixture setups for both small and large applications. Designed to offer exceptional repeatability and precision, these locators are indispensable for industries requiring reliable, high-accuracy workholding.

Product Variants: » Knob Style (CP723): Available in 32 mm and 40 mm diameters with M3 threads, ensuring straightforward and reliable operation. » Adjustable Handle Style (CP722): Offered in tapered and straight versions for versatile applications. » Cam Handle Style (CP731) & Hex-Head Style (CP730): Featuring diameters from 39 mm to 56 mm and threads from M4 to M5, these options deliver enhanced precision.

When paired with CP727 or CP735 receptacles, Flex Locators achieve exceptional tolerances: » ±0.01 mm horizontally and ±0.02 mm vertically for knob and adjustable handle styles. » ±0.008 mm horizontally and ±0.01 mm vertically for cam handle and hex-head styles.

These locators are ideal for mounting on fixture bases and plates, enabling seamless transitions and reducing setup times. Flex Locators integrate seamlessly into Fixtureworks’ extensive portfolio, which includes shaft locking clamps, pneumatic fasteners, and mechanical linear actuators.

Each clamp is equipped with a non-slip ergonomic handle for user comfort and smooth operation. The spring-powered design eliminates risks of over-tightening, protecting workpieces from damage while ensuring consistent results. These clamps excel in inspection, assembly, and other light-duty processes, offering a durable and cost-effective alternative to traditional toggle clamps.

Empowering Manufacturers with Precision Tools Fixtureworks’ Flex Locators and expanded One-Touch Snap Clamps are a testament to the company’s commitment to innovation and excellence in workholding solutions.

These products deliver unmatched reliability, accuracy, and adaptability, enabling manufacturers to meet the dynamic demands of modern industrial applications.

For more information on these products and the complete range of Fixtureworks’ tooling solutions, visit www.fixtureworks.com.

INNOVATIONS OF 2024

Notable Tooling and Workholding Innovations of 2024 As the manufacturing landscape evolves, 2024 has been a banner year for innovation in tooling and workholding.

From advanced materials to IoT-enabled devices, these cutting-edge solutions are helping manufacturers tackle complex challenges while boosting efficiency and precision.

Below is a spotlight on some of the standout products introduced this year and their remarkable features.

Fixtureworks’ Flex Clamping Locators

Expanded One-Touch Snap Clamps: Consistent and Reliable Clamping Fixtureworks has bolstered its lineup of One-Touch Snap Clamps, introducing an expanded range tailored for light-duty industrial applications. Designed to provide uniform clamping force without the need for tools, these spring-powered clamps ensure repeatable and error-free setups.

Innovative Designs: » Push/Pull Clamps (QLSNS): Heights range from 133 mm to 157 mm, delivering clamping forces of 50-140N (37-103 lbs.). » Toggle Clamps (QLSND): Offering heights from 140 mm to 158 mm, with clamping forces of 20-60N (15-44 lbs.). » Miniature Toggle Clamps (QLSNDM): Compact and precise, these clamps range from 39 mm to 53 mm in height and provide clamping forces of 10-30N (7-22 lbs.).

Fixtureworks revolutionized quick-change applications with their Flex Clamping Locators, offering seamless clamping and positioning in a single operation.

Key Features: » Four styles: knob, adjustable handle, cam handle, and hex head. » Repeatability of up to +/- 0.008 mm for horizontal plates. » Versatile receptacles designed for both small and large fixtures. » Compatible with various machining environments, from general mechanical to die and mold making.

Why It Matters: These locators eliminate tool requirements for adjustments, streamlining workflows and enabling precise, repeatable results in multi-machine setups.

Walter’s Extended Xtra-tec® XT M5130 Milling Cutters Walter expanded its highly successful Xtra-tec® XT M5130 shoulder milling cutter line with new inch sizes, enhancing versatility and application breadth.

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Key Features: » New body sizes supporting 09, 12, and 16 mm inserts for broader material compatibility. » Improved stability through optimized insert angles and enhanced tool geometry. » Suitable for face milling, ramping, pocket milling, and circular interpolation. » Coverage of ISO P, M, K, N, S, and H material groups.

Why It Matters: These milling cutters boost productivity while maintaining exceptional reliability, making them a go-to solution for manufacturers in aerospace, energy, and general machining.

Fixtureworks’ One Touch Manual Snap Clamps Known for their versatility, Fixtureworks added new push/pull and toggle-style snap clamps for light-duty clamping applications.

Key Features: » Spring-loaded mechanisms for uniform clamping force, preventing over- or under-tightening. » Ergonomic, non-slip handles for safe and comfortable operation. » Miniature versions for small or intricate assembly tasks. » Durability ensured through premium materials and robust construction.

Why It Matters: By simplifying clamping processes and improving accuracy, these clamps cater to inspection, assembly, and other light-duty applications requiring fast setups.

Sandvik Coromant’s Lightweight Modular Toolholders Sandvik Coromant debuted a new range of modular toolholders crafted from lightweight composites, offering exceptional performance without the bulk.

Key Features: » Reduced weight for easier handling and compatibility with robotic automation. » Superior vibration-dampening properties, ensuring higher accuracy during machining. » Modular design for quick assembly and customization. » Optimized for high-speed and high-precision operations.

Why It Matters: By improving handling and reducing operator fatigue, these toolholders contribute to safer work environments while enabling ultra-precise machining.

Big Kaiser’s Smart Tool Measuring Systems Big Kaiser released a state-of-the-art tool measuring system that integrates seamlessly with Industry 4.0 platforms.

Key Features: » IoT-enabled sensors for real-time tool monitoring

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and data logging. » Automated calibration processes for faster, error-free setup. » Compatibility with a wide range of toolholder types. » Intuitive user interface for streamlined operation.

Why It Matters: This system eliminates guesswork in tool measurement, enabling consistent results and minimizing downtime in high-demand production lines.

Jergens’ Modular Fixturing Kits Jergens introduced a new line of modular fixturing kits designed for maximum adaptability and quick setups.

Key Features: » Interchangeable components for endless configuration possibilities. » High-strength materials for durability and reliability under load. » Scaled options for small, medium, and large workpieces. » Compatibility with robotic end-effectors for automated applications.

Why It Matters: These kits offer manufacturers unparalleled flexibility, reducing the time and cost associated with designing and fabricating custom fixtures.

The Takeaway The innovations of 2024 have set a new benchmark for tooling and workholding, emphasizing adaptability, precision, and sustainability. As manufacturers prepare for 2025, these groundbreaking products showcase the ingenuity driving the industry forward.

Whether through smarter clamping systems, advanced milling tools, or integrated IoT solutions, the products highlighted here are shaping the future of precision manufacturing. Keep an eye on these technologies as they continue to transform operations across industries.

Are you ready to highlight your company’s cutting-edge solutions in tooling and workholding?

The Tooling and Workholding feature in Industrial Machinery Digest is your premier opportunity to showcase the latest advancements in clamps, chucks, modular systems, and precision solutions that drive the manufacturing industry forward. With a targeted audience of industry professionals and decisionmakers, our platform offers unparalleled visibility for your innovations. Send your press releases to editor@indmacdig.com and let us help your company shine as a leader in tooling and workholding.

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Advertiser Index Actek Manufacturing and Engineering Inc. — www.actekmfg.com ...............................................................8 Advent Tool & Manufacturing Inc. — www.adventtoolusa.com .................................................................... 15 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ................................................... 3, IBC Betenbender Manufacturing, Inc — www.betenbender.com ..........................................................................9 Clamprite — www.clamprite.com.........................................................................................................................43

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Cosen Saws, USA — www.cosensaws.com ....................................................................................................... 17 Denver Breaker & Supply — www.denverbreaker.com ...................................................................................47 Dynabrade, Inc. — www.dynabrade.com ..........................................................................................................BC ENM Co — www.enmco.com .............................................................................................................................. 49 Essex Structural Steel Co. — www.essexstructuralsteel.com .........................................................................47 Formdrill USA Inc. — www.formdrill-usa.com ..................................................................................................27 H&K Equipment, Inc. — www.hkequipment.com ............................................................................................ 48 HMI div of Betenbender Manufacturing — www.betenbender.com ............................................................25 HYDMECH — www.hydmech.com ........................................................................................................................5 HyPneuMat Inc. — www.hypneumat.com ......................................................................................................... 11 IMDauctions.com — www.imdauctions.com ............................................................................................. 47, 49 KHK Gears — www.khkgears.us ............................................................................................................................ 13 Lenzkes Clamping Tools, Inc. — www.lenzkesusa.com ................................................................................ IFC L&L Special Furnace Co., Inc. — www.llfurnace.com ..................................................................................... 49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ............................................33 MarkinBox — www.MarkinBox.com .......................................................................................................................6 MB Metal Technologies — www.mbmetaltech.com ..........................................................................................6 Morgan Manufacturing, Inc. — www.morganmfg.com .................................................................................. 49 Pro-Line — www.1proline.com ............................................................................................................................ 49 Royal Products — www.mistcollectors.com ..................................................................................................... 49 Schweiss Doors — www.schweissdoors.com .................................................................................................. 49 Sprinter Marking, Inc. — www.sprintermarking.com .......................................................................................25 Standard Direct — www.standard-direct.us ...................................................................................................... 48 Stor-Loc — www.storloc.com ................................................................................................................................ 7 Wellsaw Inc — www.wellsaw.com .........................................................................................................................6 WF Wells — www.wfwells.com ...............................................................................................................................6

50 | IMD January 2025

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