No matter how many “ings” your process has, Productivity PLCs can handle them all while providing substantial cost savings. Whether you’d prefer a single controller for complete end-to-end control or a segmented control system with multiple controllers, the scalable Productivity PLC family has what you need for less.
This family offers three series of PLCs each with different I/O capacities but all using the same FREE advanced programming software, so you can easily scale your control hardware up or down depending on the application.
NEW! More discrete and relay I/O expansion modules have been added to the Productivity PLC family for even more affordable control options.
For the Productivity1000 PLC series:
• A 4-channel, high current relay output module with up to 7A/point and four Form C contacts, perfect for applications with higher current loads
For the Productivity2000 PLC series:
• A 6-channel, high current (7A/point) relay output module with both Form A and Form C contacts
• A 16-point low voltage discrete input module and 16-point low voltage discrete output module, ideal for devices that utilize transistor-transistorlogic (TTL) and voltage levels ranging from 3.3 to 5 VDC
Expert Enclosure Printing
Application Dependent Turnkey
Solutions
• Maximum print layout 300mm*420mm
• Multi-colour printing
• well-suited for small series or samples
• Colour gradients are possible Digital
Pad
• Maximum print layout diameter of 60mm
• Single colour
• Well-suited for printing of logos or test symbols
• The selection of the appropriate colour is important for the durability
Screen
• Maximum print layout 330 * 230 mm
• Multiple-colour
• Durability with thick colour application
• Not suitable for colour gradients and photorealistic subjects
Laser Marking
• Environmentally-friendly
• Clean cut edges and precise details
• Short processing times
• Permanent enclosure labelling and identi cation
• Short processing, reaction and delivery times
Hot Embossing
• Normally monochromatic (depending on the lm)
• Variable print layout based on the respective embossing tool
• Smear-proof
• Scratch-proof
• Can be implemented with a variety of surfaces and effects from high-gloss to metallic
SNAP SIGNAL
Snap Signal is an easily deployable, complete portfolio of IIoT hardware and software that delivers your actionable machine data forming an overlay network without disrupting existing infrastructure. Whether you’re monitoring key equipment in one area or your entire facility, Snap Signal distributes data quickly and seamlessly—empowering real-time decisions and maximizing uptime across your factory.
Help wanted: AI-enabled manufacturer seeking intelligent people and robots
Technology is no substitute for talent, but when you lose skilled labor and neglect to nurture a pipeline, technology solutions can help bridge the gap. Most industry reports published within the past few years indicate that manufacturers worldwide are prioritizing upskilling and reskilling their current workforce, recruiting and retaining top talent, and augmenting labor with automation. There is also an effort to bring skilled retirees back to work and transfer knowledge and experience to train technology solutions and employees.
Eaton’s recent research report, The Impact of the Labor Shortage on Machine Builders, stated that 79% of respondents are feeling the impacts of skills and workforce gaps on their operations, especially in product development and production. Such product development teams are emphasizing recruitment for highly skilled technical people, whereas production teams are prioritizing automation solutions.
Rockwell Automation’s 2025 State of Smart Manufacturing Report revealed similar trends and stated that 41% of surveyed manufacturers are using artificial intelligence (AI), machine learning (ML), and automation to address skills and labor gaps. Additionally, 47% of respondents agreed that using AI is extremely important within their organizations,
and pretty much everybody thinks AI will have the most significant impact on workforce concerns.
Now last year, Deloitte and The Manufacturing Institute predicted that manufacturers will need 3.8 million new employees by 2033. However, about half of those positions may go unfilled as applicant pools dwindle, further widening the workforce gap at every level, from entry to highly skilled. But that data was captured before international trade and tariff agreements went haywire. According to the National Association of Manufacturers' Q2 2025 update, manufacturers are now more concerned about trade uncertainties, raw materials, and economic conditions than they are about workforce retention.
With all the various data out there attempting to capture what is really going on in manufacturing today, a few things are crystal clear: (1) AI and automation are not a threat to manufacturing jobs but a necessity to make any future jobs available; (2) we need more people, not fewer, and we need them to be smarter; and (3) companies that prioritize intelligence in their workforce and technologies will survive and surpass those that do not. DW
Rachael Pasini
rpasini@wtwhmedia.com
linkedin.com/in/rachaelpasini
SOURCES:
• The impact of the labor shortage on machine builders, Eaton: wtwh.me/machinebuilders
• 10th Annual State of Smart Manufacturing, Rockwell Automation: wtwh.me/smartmanufacturing
• Taking charge: Manufacturers support growth with active workforce strategies, Deloitte and The Manufacturing Institute: wtwh.me/takingcharge
• Manufacturers’ outlook survey Q2 2025, National Association of Manufacturers: wtwh.me/nam2025Q2
Italian machine builders lead the way in machine and process innovation.
Machines Italia’s Fall 2025 issue will focus on how technology-focused innovations makes Italian machinery a standout in the market; how Italian machine builders are overcoming industry challenges through new/innovative/creative design applications and design solutions on their machinery and lines; how Italian innovation in machinery can help drive down organizations’ operating costs; and how Italian OEMs are working in a collaborative way with end users to bring new innovations and new transformative processes to industries. This issue will seek to place special emphasis on what makes Italian machinery uniquely superior in the market and how Italian machinery and solutions are being used in new, innovative ways to solve old industry challenges.
For more details and to read the digital edition, visit machinesitalia.org
Italian machine builders are bringing innovative and transformative solutions to their industries.
Linear-motion component features are key to long-term reliability in demanding environments and applications.
Hygienic hardware for high-performance food equipment
Food and beverage manufacturers face precision, hygiene, and reliability challenges with equipment. See how the right shaft collars and rigid couplings are helping them meet demands.
These
EDITORIAL
VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com
Digital Production Specialist Elise Ondak eondak@wtwhmedia.com
WEB DEVELOPMENT
Web Development Manager B. David Miyares dmiyares@wtwhmedia.com
Precise electromechanical actuation on the seabed
Nothing beats the power of hydraulics, but hydraulic fluid leaks and spills pose safety and environmental hazards in marine applications. Modern electromechanical technologies provide alternative options that can mitigate such concerns without compromising power.
To address this problem, the Subsea division at Wittenstein Motion Control (WMC) developed a new SSEAC actuator jointly with Bosch Rexroth and presented it for the first time at this year’s Offshore Technology Conference (OTC).
The SSEAC is a new electromechanical subsea actuator for actuating choke and other valves in subsea applications. Rated for a service life of at least 25 years, this actuator controls the continuous flow of gases and liquids at a depth of up to 4,000 m. As an alternative to hydraulic systems traditionally chosen for this purpose, the SSEAC has two redundant 24-V motors that drive the actuator’s
planetary gearbox and enable precise rotary adjustment of the valves. The subsea actuator is designed for use in offshore oil and gas extraction, systems for injecting CO2 into the seabed, or the production, transport, and storage of hydrogen at sea.
WMC asserts that replacing hydraulics with electromechanical actuation permanently reduces costs, improves safety, and provides a more environmentally friendly solution by eliminating hydraulic leaks and pipelines along the seabed.
Similarly compact as hydraulic modules, the SSEAC can provide torques of up to 2,700 Nm for adjusting the valve flaps to achieve precise flow control via the rotary movements. Since these torques consume less than 96 W of power, existing sensor lines can be used to adjust the valves. Additionally, the actuator has a mechanical Class 4 ROV interface and
electrical SiiS L2 interface and offers standard connectivity options for both mechanical components and power and data transmission.
The SSEAC also integrates various sensors for monitoring the subsea actuator’s condition. Absolute positions, torques, and other operating data, which engineers can use for remote online checks of the actuator condition, are continuously recorded. Engineers can track flow control precision at any time in this way and optimize the deep-sea drive module’s availability over its entire service life.
Subsea systems of this kind are no longer operated solely for the purpose of extracting oil and gas. In the context of industrial and environmental decarbonization, applications for subsea storage of carbon dioxide or for producing hydrogen at sea are other promising and sustainable fields of use. DW
Wittenstein
wittenstein.de
Design For Industry
More load capacity for cleanrooms
Precision, contamination control, and operational efficiency demands drive laboratory automation advancements. In response, Hiwin upgraded its Single-Axis Robot KC B-Type Series for use in cleanroom environments, including pharmaceutical laboratories, biotechnology facilities, and semiconductor manufacturing sites.
The fully enclosed design protects against particle generation and environmental contamination. The system is compatible with Class 10 cleanroom standards and features high repeatability of ±0.01 mm, making it suitable for many precision applications. Automated laboratory tasks such as sample handling, microplate manipulation, and high-throughput screening operations, where microscopic variations can compromise results, require this level of precision.
The KC-B Type’s enhanced load capacity, increased by 10 to 30% compared to previous models, expands the robot’s utility, enabling the handling of heavier equipment, larger sample containers, and multicomponent assemblies. The design also allows assembly in any configuration without removing the outer cover, which can reduce integration time and minimize disruption to ongoing operations. Additionally, the one-point lubrication ensures synchronized lubrication of the guideway and screw while eliminating the need for component removal during routine maintenance. Hiwin generally recommends lubrication every three months or 100 km, yet higher working frequencies or loads may require shorter maintenance cycles. DW
POWER TRANSMISSION RETAINING DEVICES & maintenance & assembly tools
WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.
Visit our website–whittet-higgins.com–to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.
Digitally integrated hybrid energy systems provide flexiblity
The International Energy Agency projects that global electricity demand will grow at approximately 4% annually through 2027, resulting in increased load demand and dynamic changes in energy markets. Battery storage sites face operational complexities, including siloed data, higher maintenance costs, and requirements for flexible operation to manage demand effectively.
As energy producers develop hybrid projects that combine multiple renewable energy types, including solar, wind, and battery storage, their responsiveness requires rapid switching between operating modes, necessitating battery energy management systems that integrate with site SCADA systems.
Emerson has released battery energy storage system (BESS) solutions that include energy and asset management
software for its Ovation Green renewable energy portfolio. The solution combines power plant controllers, energy management strategies, and SCADA software to connect devices and systems across manufacturers, aggregating battery storage data to optimize usage and extend its life.
Ovation Green BESS solutions include a battery algorithm suite that streamlines battery control through customizable function blocks. These function blocks distribute proportioned setpoints to individual components, such as inverters and battery management systems. The resulting control strategy automatically optimizes grid interactions and charge and discharge cycles for demand management.
Emerson’s collaboration with Zitara Technologies integrates advanced
battery management software with the Ovation Automation Platform. This integration provides operators with visibility into battery state of charge and health conditions, improving energy power and availability forecasting and predictive safety.
The system provides increased visibility and granular control of batteries, enabling owners and operators to optimize usage and extend battery life. The more standardized approach to battery energy management also enables faster deployment across multiple sites, reduces site visits, and ensures consistent operations by eliminating the need to train operators on multiple OEM battery management interfaces. DW
Emerson • www.emerson.com
MATERIALS
Aerospace composites get a second chance
Aerospace manufacturers increasingly use composite materials instead of traditional metals to reduce aircraft weight and improve its strength. Composites also allow manufacturers to create more complex and aerodynamically efficient shapes with fewer fasteners required. However, composites are more difficult to reuse and recycle, prompting the need for new end-of-life planning.
Toray Advanced Composites, Daher, and Tarmac Aerosave recently launched a joint End-of-Life Aerospace Recycling Program for commercial aircraft production. Working with Airbus, this collaborative initiative will focus on advancing recycling technology practices in aerospace manufacturing by recovering and reusing end-oflife secondary structural components made from continuous fiber-reinforced thermoplastic composites.
repurpose them for other aeronautical applications.
This collaborative initiative unites expertise from the aerospace and materials sectors. Airbus provides support for the advanced material reuse framework, while Tarmac Aerosave will ensure components are dismantled without damage, preserving material integrity. Daher is leading the reshaping and the quality validation (performed as serial production conditions) of repurposed parts, while Toray, as a materials supplier, is monitoring the material quality for the second-life application.
At the core of this initiative is the endof-life recycling of the A380 pylon cover, specifically the Toray Cetex TC1100 (carbon/PPS) thermoplastic composite structure. As thermoplastic parts become more prevalent in aircraft, this pilot case sets the foundation for new methodologies in recycling, repurposing, and reprocessing composite materials. The A380 alone contains over 10,000 flying parts made from continuous fiberreinforced thermoplastic composites, making it an ideal platform for testing and validating recycled material recovery practices. DW
The project aims to extend the useful life of composite materials and help the industry achieve its net-zero goals by developing remanufacturing processes and creating a closed-loop recycling system. The initiative aims to reuse secondary structural thermoplastic parts from end-of-life Airbus A380 aircraft and Toray Advanced Composites www.toraytac.com
Interpower® Accessory Power Strips (APS) are perfect for multiple IEC 60320 jumper cords for smooth integration. Country-specific cords can be terminated with an IEC 60320 connector such as a C13 or C19 to mate with a C14 or C19 outlet in the APS. Now you can plug IEC 60320 jumper cord sets into the APS to power multiple devices— the jumper cord sets contain IEC 60320 plug connectors on one end and IEC 60320 connectors on the other.
Toll-Free Phone: (800) 662-2290
E-mail: info@interpower.com
Business Hours: 7 a.m.–5 p.m. CST Order Online! www.interpower.com ® ®
• BY MIKE THOMAS
6 reasons MBD is tricky— and the ways forward
Model-based definition has many benefits, but ditching 2D drawings has even more challenges. Here’s what needs to happen for MBD to succeed.
Model-based definition (MBD) is all about annotating and detailing your designs directly in 3D. All the manufacturing details that would normally be found on the 2D drawing— geometric dimensioning and tolerancing (GD&T), material specifications, surface finishes, bills of materials, assembly and manufacturing instructions, and other notes—are instead tied to the 3D model, which becomes a single source of truth. No drawings required.
MBD has a proven track record of improving communication and reducing errors. Understanding a 3D model comes naturally to most—if you can pan, zoom and rotate, every detail is right where you’d expect. 2D drawings provide the same info, but reading (not to mention creating) drawings is a learned skill that takes time and practice.
For these reasons, many manufacturing-focused CAD systems
Adding MBD dimensions in Autodesk Inventor. Mike Thomas, engineering.com
have started to implement MBD and 3D annotation features. MBD sure seems excellent. So what’s the problem?
Problem 1: Resistance to change
The first MBD obstacle is a classic: resistance to change. Established workflows and ingrained habits mean fighting change. Veteran staff prefer 2D drawings. Why? You can get everything you need immediately. No panning, zooming,
rotating or changing views. Everything is out in front of you. And you can still print a drawing when needed. It is something tangible.
Now this issue alone is no reason to shun new processes or tools. It can be overcome by selling the vision.
But what if the benefits are not that easy to see? Many stakeholders, like shop supervisors, don’t fully understand the benefits nor see the value of using MBD to replace 2D drawings. This can happen for any technology where the benefits are not equally apparent to all impacted. With insufficient backing, MBD adoption is challenging.
The solution is selling the vision and clearly communicating the “why.” Moving to MBD means improved quality by making less mistakes. Selling the vision starts with the supervisors but carries onto the shop floor. Ask for feedback, especially from the veterans, so they have input and feel ownership of the new process.
Problem 2: Non-existent standardization
Creating 2D drawings is an art, and the people who do it are good at it. Long-established standards for creating 2D drawings, complemented
by industry best practices, means 2D drawings are consistent. The shop floor knows what to expect.
To implement MBD and ensure the same level of consistency and quality, establishing standards for annotating the 3D model is crucial—but challenging.
The key standards organizations (like ASME and ISO) have standards for MBD and detailing in 3D, but they’re not nearly as extensive as the 2D equivalents.
As MBD standards evolve and mature, CAD vendors need to update their tools accordingly. When detailing 2D drawings there are many workflows that lead to consistency. For example, when placing a dimension, it snaps a set distance away from the object and also a set distance away from other dimensions. This is exactly the sort of feature that CAD vendors need to implement for MBD.
Problem 3: MBD is a time investment
No matter what country, Interpower cords plug directly into the mains power while the other end, bearing an IEC 60320 connector, can plug into an Accessory Power Strip (APS) inlet. The APS contains IEC 60320 outlets allowing IEC 60320 jumper cords to connect to multiple devices. Popular APS choices are 4-12 Sheet F outlets or a Sheet F and Sheet J combination. No reconfiguration is needed as the cords plug directly into the wall and equipment straight out of the box.
Any process switch requires training. Engineers, designers and Toll-Free Phone: (800) 662-2290
E-mail: info@interpower.com
Business Hours: 7 a.m.–5 p.m. CST Order Online! www.interpower.com
Example of MBD in Autodesk Inventor. Mike Thomas, engineering.com
Design Notes
drafters must learn how and when to use MBD. At first, engineers will be less efficient at producing MBD than in creating 2D drawings. It’s a timeconsuming and frustrating changeover. Changing to MBD forces other changes as well. For example, if you’ve built processes for distributing information to the shop using 2D drawings, switching to 3D viewing means deploying new software and training for the end users.
There is no easy fix for this problem. Implementing a new process like MBD is going to be an investment in time and money.
A pilot is a good place to start. Complete a project running MBD alongside the 2D drawings. Then run another project just using MBD. You’ll learn a lot about best practices and can use the experience to develop a training plan. Then train, train, and do more training—but do it efficiently. Develop a plan. Follow the plan. And do not be afraid to adapt the plan when all does not go to plan. Training builds trust and confidence, and both lower resistance to change. And don’t forget to take feedback along the way. People like to feel involved in change and in the decision-making process.
Problem 4: Software limitations
When rolling out something new, you want it to look as much like the old as possible. However, not all detailing and annotations can be easily replicated with 3D annotations. Some get close, but require workarounds. The workarounds are inefficient and do not always look like their traditional 2D equivalent.
Step one in tackling this problem is to pressure CAD vendors to improve the product. Between beta testing programs, community forums, resellers, and technical support, there are many avenues to express concerns and provide feedback. You might be
Switching between MBD views in Autodesk Inventor. Mike Thomas, engineering.com
a single voice, but you’re likely not the only one with a given problem.
Next is to look for help on how to deal with limitations. Look to the community and involve your CAD reseller, many of whom have on-staff expertise. You’ll have to incorporate those limitations into your best practices.
Problem 5: Supplier compatibility
Ensuring smooth and reliable data exchange between your company and suppliers can be challenging. Not all suppliers can handle 3D models or interpret MBD data.
For example, some vendors need 2D drawings. You could use MBD for the components you build and assemble, and continue to create 2D drawings for subcontracted operations. It’s not ideal, but it would only affect engineering. Your production team would get the benefits of MBD, and vendors would continue receiving data with which they can work.
Problem 6: What about the old drawings?
Many companies have a significant investment in 2D, with thousands of drawings engineering-approved and ready for shop consumption. If you switch to 3D, what do you do with
the existing 2D? Do you maintain two systems? Or do you start a massive investment in switching all existing drawings to MBD?
The solution is to leave the existing drawings and detail everything new using MBD. During a revision, an effort-vs-reward analysis would help decide if you should update the existing 2D drawing or if the change is extensive enough to justify moving the design to MBD.
For selected equipment you could consider offloading the conversion to a third party—someone experienced in MBD who could convert the 2D drawings more efficiently (i.e., cheaper).
Is MBD right for you?
It’s important to assess your organization’s needs carefully before making a process change. MBD implementation is no different.
A 2D legacy and vendor requirements make it challenging for many companies to justify the costs of transitioning to MBD. The effort must at least equal the reward; right now, it often does not. However, the potential benefits of MBD, software advancements and industry evolution may change the cost and reward calculus. DW
Couplings for high-torque, precision applications
Zero-Max has recently launched its all-new CD Power-Series of ServoRated Composite Disc Flexible Shaft Couplings. These couplings have a higher power-density, providing higher torque capacity in a smaller, more compact solution. These couplings have field-proven Composite Disc technology that has earned the trust of engineers for the most demanding motion control applications, the CD Power-Series Shaft Couplings provide precise high-torque operation in a smaller space envelope. The CD
Power-Series Couplings are suitable for applications with aggressive motion profiles that include repetitive speed changes, acceleration/deceleration, start/stop, indexing and reversing.
Leveraging the benefits of the field-proven Zero-Max Composite Disc technology, this new design targets the fast-growing and changing needs of automated manufacturing industries. It is especially suited for applications requiring high speed and higher torque where space limitations exist. The performance of
EDITED BY MIKE SANTOA
Zero-Max CD Power-Series Couplings complement the popular traditional CD Couplings for applications that require a higher power density. This higher torque capacity in a smaller package provides higher torsional stiffness, repeatable accuracy, and long operating life.
the CD Power-Series couplings is the result of user feedback for a coupling design that provides higher torque density. Application examples include: Packaging Machines, Pick-and-Place Operations, Test Stands, Indexing Applications, Specialty Machines, Automated Assembly Equipment, Off-Highway Equipment, and more.
CD Power-Series couplings complement the traditional CD Coupling Line by offering a high performance and high torque capacity solution in a smaller space envelope. The CD Power-Series
Zero-Max CD Power-Series Couplings Clamp Hub x Adaptor Mount — having a high strength Clamping Hub on one end, while mounting directly to flanged output gearboxes, actuators, etc. on the opposite end.
Couplings have torque ratings up to 130,000 in-lbs / 14,689 Nm peak torque. Standard bore sizes range up to 5.1875-in. / 130mm. Adaptor Mounts are available for ISO 9409-1 mounting bolt circles from 31.5mm to 160mm. Flange Hubs for specialized and compact installations are also offered. As with all Zero-Max products, customized solutions are also available to meet specific application requirements for performance, materials, or dimensional needs.
The new CD Power-Series complements the traditional CD couplings by featuring higher torque and higher torsional stiffness, while offering a moderate misalignment capacity and reducing the coupling’s outside diameter. Zero-Max continues to offer the traditional CD couplings that provide high torque, high torsional stiffness, and the highest misalignment capacity.
Extremely important, the CD PowerSeries’ Composite Disc withstands a range of challenging operating environments by offering vibration damping, electrical isolation, fatigue resistance for long life, and alleviating fretting corrosion issues often seen in metal disc couplings. It withstands temperature extremes from -70° to +250° F / -57˚ to 121˚ C, and resists the effects of moisture and chemicals. The robust composite disc and overall coupling design maximizes the lifespan of the shaft coupling while also helping to increase performance and throughput for the machines and equipment where the coupling is used.
The CD Power-Series is available with: (1) Split-Clamping Hubs to allow for larger bore sizes and higher
Zero-Max CD Power-Series Couplings Clamp Hub x Shrink Disc has a high strength Clamping Hub on one end and a Shrink Disc Hub for high torque transmission on keyless shafts on the opposite end.
transmittable torque, with or without keyways, (2) Integral Clamp-Style Hubs, keyed or keyless, (3) Shrink Disc Hubs for high transmittable torque on keyless shaft connections, (4) Adaptor Mounts to fit an ISO 9409-1 Flange Pattern for precision gear reducers, motors, actuators, robotic equipment and more, and (5) Flange Hubs for direct connection to machine flanges, offering a high torsional stiffness connection and the most compact solution possible.
“The CD Power-Series Flexible Shaft Couplings are specifically engineered to withstand the extreme stress and demands of highperformance applications, including those with flanged output gearboxes,” said Brian Mishuk, VP-Sales and Marketing at Zero-Max.
“The CD Power-Series offer a variety of Clamp-Style, Shrink Disc, Adaptor Mount, and Flanged Hub Options to accommodate a range of possible shaft connections on customer’s machines, while maintaining the high performance needed for challenging servo-driven applications.”
Also important, CD Power-Series Couplings are available in custom designs to accommodate unique dimensional fit requirements, or extra performance for demanding applications. Examples of Customization can include shortened or extended hubs, special disc packs to boost torque and/or torsional stiffness, alternative plating, coatings, or materials for corrosion protection, modified coupling inertia, custom flange dimensions, and more.
All CD Power-Series couplings are manufactured using the newest advances in manufacturing technology, including CNC Machinery, high precision tooling, and custom-engineered fixtures. This process provides precision machining and tight tolerancing for a precise bore-to-bore concentricity in the assembled coupling, providing the highest coupling performance. All models are environmentally friendly and are manufactured of RoHS compliant materials. DW
Zero-Max • zero-max.com
• EDITED BY MIKE SANTORA
AI on the battlefield
Overland AI demonstrates soldier-led autonomy across day and night operations.
Overland AI’s fully autonomous tactical vehicles, ULTRA, were deployed across 15 live mission scenarios to comprehensively demonstrate end-toend, Soldier-operated ground autonomy.
Soldiers from the 555th, 36th, and 20th Engineer Brigades, and the 173rd Airborne Brigade, executed these 15 missions using two ULTRAs. They also leveraged Overland’s tactical C2 interface, OverWatch, to plan, execute, and adapt operations on the fly. From pre-operation vehicle checks, payload swaps and munition loading, to mission planning and execution in OverWatch, the experimentation event was conducted almost entirely by end users.
“This was a particularly unique event,” said Chris Merz, who serves as the director of product at Overland
AI. “Nearly every phase of the operation — from munition loading to software-based replanning — was in the hands of the Soldier. We saw real independence from the operator, not just in planning and execution, but in adapting tactics in real time.”
Participating units were tasked with planning complex, multi-vehicle missions. Soldiers used ULTRA’s modular platform for kinetic and electronic warfare breaching, terrain shaping with XM204s, deception, obscuration, and delivery of third-party payloads, including uncrewed aerial vehicles (UAV) and electronic warfare (EW) capabilities.
Overland’s autonomy stack is highly adaptable in the field. Some operators re-tasked vehicles mid-mission in response to enemy activity and
adjusted payload configurations under time pressure with little notice. Other operators, planning two simultaneous terrain-shaping missions with over 20 checkpoints and five tasks per vehicle, took less than three minutes to plan.
“Our mission is to empower the Armed Forces to dominate any and all missions they need to accomplish,” said Byron Boots, co-founder and chief executive officer of Overland AI.
“This wide-ranging event showed that Soldiers both trust our autonomous land systems and can leverage our versatile capability from start to finish.”
Overland AI remains committed to advancing autonomous military technologies, having previously secured an $18.6 million contract with the U.S. Army and the Defense
ULTRA, Overland’s fully autonomous tactical vehicle, operating in dense forest and using tree line for cover during mission scenarios at Fort Leonard Wood, Mo.
Innovation Unit (DIU) to develop autonomy software for the Army's Robotic Combat Vehicle (RCV) program. The company continues to support a range of U.S. military programs, including the U.S. Army, Marine Corps, and Special Operations Command.
Founded in 2022 and headquartered in Seattle, Washington, Overland AI is powering ground operations for modern defense. The company leverages over a decade of advanced research in robotics, machine learning, and a field-test forward ethos, to deliver advanced autonomy for unit commanders. Hazardous missions in austere and electronically denied environments demand that this technology is reliable and resilient. Overland AI’s SPARK autonomy upfit and OverDrive stack enable ground vehicles to navigate off-road without GPS or direct operator control.
The company built its fully autonomous tactical vehicle, ULTRA, in-house by integrating SPARK and OverDrive into a modular and attritable platform that is currently in production. Overland AI developed OverWatch, its intuitive C2 interface, to provide commanders with the precise coordination of autonomous ground systems that is vital for complex missions to succeed. Overland AI has achieved the end-to-end integration of ground autonomy, from operator to effect, and is putting this capability into the hands of tactical operators today. DW
Overland AI • overland.ai
A Soldier from the 555th Engineer Brigade plans a series of missions with ULTRAs using OverWatch, Overland’s intuitive, tactical command and control (C2) interface.
Edited by Miles Budimir • Senior Editor
Motor manufacturers are offering designers new and improved motors to suit their ever-evolving designs.
Motor technology does not stand still (pardon the pun.) Advances in motor technology have continued at a steady pace, with manufacturers often improving upon already successful designs with new ones aimed at newer applications.
The goal is always to in some way balance power, efficiency, and weight. From motor design software to new offerings that integrate other motion and control components into one package to save design time and space, manufacturers are offering designers a slew of new motors for their everevolving designs.
Software tools for motor design
Recently, motor manufacturer ECM PCB Stator Tech announced an upgrade to their motor design software. The new PrintStator v8.3 is a major update to its award-winning Motor CAD platform. The new version enables electromagnetic motor designs and optimized datasheets in just seconds—now with automated ‘smart’ design validation and feedback. It is a significant leap in speed and interactivity for advanced motor development powered by ECM’s patented PCB Stator technology.
In fact, 2024 was a breakout year for ECM. After releasing the beta version of PrintStator, the software earned recognition from leading technology and engineering institutions—taking home awards from Automate, SXSW, CES, Design World and more. More importantly, ECM’s technology began powering real commercial products, including a new direct-drive racing wheel designed in partnership with Thrustmaster.
A number of improvements are noteworthy. For starters, electromagnetic simulations and motor performance datasheet generation now complete in as little as 1 to 2 seconds, presenting a 100x magnitude speed improvement
that enables near real-time iteration and dramatically accelerates motor design workflows. Plus, engineers can now move directly from optimized motor outputs to mechanical integration.
PrintStator v8.3 automatically generates parametric models and CAM- and CAD-ready housing designs, cutting mechanical handoff times from weeks to hours.
Another improvement leads to enhanced flux-in-the-gap modeling. Specifically, improved magnetic flux calculations within the motor air gap boost simulation accuracy without compromising speed. This update leverages robust parallelization techniques to increase model fidelity while maintaining near real-time compute performance.
Small motors with integrated features
With newer applications in robotics
A common example is a motor that integrates gearing and encoder feedback into one physical unit.
A recent example comes from FAULHABER. With a new size of its SXR motors, the powerful motor of the new GXR family, a high-precision encoder and the matching gearhead, FAULHABER presents products that are perfectly matched to one another, as they come from a single source, and all diameter compliant with 16 mm. This combination enables optimal efficiency, maximum dynamics and absolute precision suitable for high-tech industries and challenging applications in industrial automation, robotics and medical technology.
FAULHABER’s new 1627 GXR brushed motor with copper-graphite commutation features high power and
An exploded view shows ECM’s PCB Stator motor technology in Thrustmaster’s T598 simracing wheel. Thrustmaster
Allient expanded its Allied Motion SA Series Axial Flux Motors with a new 63.5 mm outer diameter size variant. As slotless motors, they have zero cogging torque for smooth, precise motion.
a wide range of equipment options that enables it to meet the requirements of modern drive solutions. It offers flexible voltage variants from 4.5 to 24 V and different bearing configurations. The motor can also be individually adjusted – from modifications on the front and rear shafts to options for use in vacuum or high- temperature environments. Optimized rotor balancing ensures smooth operation and contributes to the motor’s durability. The hexagonal winding technology with a high copper filling factor and an optimized proportion of straight lines and high-quality magnets ensures temperature stability and improves overall performance.
These are also features of the new size in the precious-metal-commutated SXR family. The existing 1218 and 1228 SXR is now joined by the new version in the size 1627 SXR. It has an outstanding power to volume ratio and is also suitable for high-tech applications. All components in the SXR and GXR families are RoHS compliant and the electrical connections offer a variety of configuration options.
It’s easy to combine the GXR motors and SXR motors with the metal planetary gearheads in the GPT family. In particular, the new, diameter-compliant 16GPT is suitable for challenging applications with limited installation space. The optimized construction allows high speeds, enabling use of the motor’s entire speed range. And the stable design ensures that extreme forces can be transferred reliably and large loads can be easily managed.
With the latest chip technology, the IEX3 and IEX3 (L) encoders offer high resolution and positional accuracy that typically reaches 0.3°. Equipped with a wide voltage range, both 3.3 V for battery-powered applications to 5 V are possible and a temperature range of -40 to 100 °C, the encoder is both flexible and robust. The IEX3 (L) is available with or without a line driver and is both compact and easy to maintain, and is suitable for use in combination with the new FAULHABER SXR and GXR motors.
Axial flux and frameless motor development
Axial flux motors, also known as pancake motors, are compact (flat) and offer high torque density in a smaller size. They are seeing expanded use and continued development, especially in applications such as EVs.
Case in point: Allient recently announced the expansion of its Allied Motion SA Series Axial Flux Motors with a new 63.5 mm outer diameter size variant. These motors are designed for low-profile applications, such as camera systems, gimbals, scanners, and imaging equipment. As slotless motors, they have zero cogging torque for smooth, precise motion.
There are a number of specification options available as standard for SA axial flux motors. These include outer diameters from 63.5 to 1,795 mm, with inner diameters from 25 to 1,541 mm. The torque range for these motors is 0.16 to 49.9 Nm with rated speeds from 90 to 6,750 rpm. Operating voltage range is 12 to 325 Vdc.
In addition to the standard offering, Allient also provides modified or completely custom solutions of SA Axial Flux Motors. The motors are easily scalable to large diameters with a seamless transition to a modular construction suitable for large gantry systems particularly in medical
applications such as MRI and CT scanning machines.
Related offerings include the company’s new ElectroFlux Series Torque Motors, designed for high torque density in a compact, low-profile form factor, suitable for a range of robotics applications; the HeiTronX Integrated Servo Motors that combine a highperformance motor with built-in drive electronics delivering compactness, efficiency, and simplified integration; and Integrated Drive Electronics, aimed at streamlining system design, reducing wiring complexity, and accelerating time to market for automation solutions.
Another type of motor that is seeing increased use is the frameless motor. These motors offer higher torque in a more compact and lightweight package for a number of uses, including robotics and various medical applications such as robotic surgery.
A number of manufacturers are offering newer designs that improve torque output and minimize size. For instance, Nanotec has added the DKA series to its portfolio of highperformance, frameless brushless dc motors designed for compact, efficient
drive systems. Featuring a modular design with separate stator and rotor, these motors allow for a maximum level of system integration.
The DKA series offers a range of motors with diameters from 25 to 115 mm, up to 7.8 Nm of torque, and speeds up to 10,000 rpm. By eliminating the need for couplings or additional mounting components, these frameless motors reduce material usage and assembly costs. The innovative design also simplifies cable management and installation, making them easy to integrate into various applications.
With their high power density and precision, the DKA motors are a suitable choice for applications with limited space, including robotics, medical technology, and others. DW
IDEC Corporation www.idec.com
ECM • pcbstator.com
Faulhaber • faulhaber.com
Allient • allient.com
Nanotec • nanotec.com
The DKA series from Nanotec offers a range of motors with diameters from 25 to 115 mm, up to 7.8 Nm of torque, and speeds up to 10,000 rpm.
Manufacturers and end users continue to push the boundaries of what’s possible with linear motion technology in extreme applications. The need for solutions that transport objects faster and with heavier payloads isn’t restricted to normal factory settings and can include a variety of unique settings.
What’s critically important though is how end users are evaluating solutions, regardless of the environment to which they’re assigned. There are fundamental components that comprise those solutions, and if the wrong one is selected, there could be negative consequences that impact operations and ultimately a company’s bottom line.
Among the standard requirements that every end user needs to measure solutions against are load, orientation, speed, travel, precision, duty and, of course, environment. What’s going to be asked of these solutions, and what are the typical conditions in which they’ll be operating? Is it a factory setting or an assembly-line facility? Maybe the application is for an outdoor process, which has requirements of its own.
Linear components are not a onesize-fits-all solution, so end users must have a comprehensive understanding of what will be asked of them, including how far they can push them in extreme conditions and when throughput demands increase.
A good example of an extreme environment is a cleanroom setting, which are categorized into different classes and have very specific requirements based on the particles that are emitted from all processes. Cleanliness is of paramount concern in cleanrooms, so the use of corrosionresistant steel is preferred. That’s because the material prevents the release of particles that would otherwise occur with incipient or progressive corrosion. The faster a process moves, the more turbulence and friction are
location location location
(dictates linear-motion design)
Linear-motion component features are key to long-term reliability in demanding environments and applications.
Eric Falasco • Product Manager • Bosch Rexroth
Linear Motion
created, which can increase the number of particles that are emitted. A similar effect is seen with payload — the heavier the load that’s transported, the more particles are released.
Lubrication is also an important consideration in cleanrooms. If there’s too little, the particles cannot be bound, and the environment can be contaminated. If there’s too much lubrication, it can increase the number of particles emitted. At a more granular level, the type of seals that are leveraged are also important as full contact seals keep dust and debris out while keeping lubrication in. All of these factors would lead to typical conclusions like
preferring belt-driven linear motion systems for cleanroom applications as opposed to screw drives, which can lead to a higher particle emission.
What’s equally critical (especially in the evaluation process) is that there’s transparency and alignment within the multiple departments of the end user and supplier. If an engineer has a conversation with the supplier to determine a specific need, it must be conveyed to purchasing, which needs to understand why a particular component or solution was requested over the other. Bypassing this transparency can have a variety of negative consequences. If the choice is made to go with a cheaper alternative, those solutions will likely break sooner and will force the end user to replace them more often. That represents a financial burden and includes valuable downtime spent operating at less-than-optimal conditions while solutions are being replaced.
It’s also vital that end users have a consistent dialogue with the supplier to help identify appropriate solutions, including those with newer technology that can withstand an even greater range of extreme environments.
Ultimately, when approaching solutions for extreme environments, it comes down to education. Do end users have a comprehensive understanding of the environment in which their solutions are operating? Are they engaged with a supplier that has equal knowledge of applicable solutions and the components that comprise them? Sometimes, all it takes is one seemingly unrelated component that’s operating in an environment it shouldn’t be to negatively impact an entire operation. End users who understand that and proactively approach solutions from a granular level are well-positioned to optimize their investment and ensure production goals are met, even under the most severe of environments. DW
The latest e-commerce and supply-chain operations involve extreme payloads and throughput requirements. So now, Bosch Rexroth
Bosch Rexroth boschrexroth.com
Food and beverage manufacturers face unique challenges in ensuring precision, hygiene, and reliability in their equipment. Ruland’s shaft collars and rigid couplings are engineered and manufactured to meet the demanding needs of food processing, packaging, and handling systems, offering solutions that enhance efficiency and reduce downtime.
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These rigid couplings are available in a variety of sizes and styles to suit the needs of food packaging applications such as case erectors, cartoners, and form, fill, seal equipment. These couplings are suitable for shaftto-shaft connections and precise servo driven applications as they do not introduce misalignment, vibration, or bearing noise into the system. They have precision honed bores, anti-vibration hardware, and opposing hardware on two-piece styles to ensure superior fit, alignment and holding power.
303 stainless steel couplings with hardware of like material are available as standard stock items. Proprietary Nypatch anti-vibration hardware is used to prevent galling, provide event seating of the screw, and allow for repeated screw installations. Rigid couplings are offered in one- and two-piece clamp styles with or without keyways in bore sizes ranging from 3 to 50 mm. Custom
dimensions, inch to metric step bore combinations, and 316 stainless steel are available by request.
Clamp style shaft collars in food processing, packaging, and handling equipment are commonly used for guiding, spacing, stopping, mounting and component alignment. Food equipment manufacturers benefit from the tightly controlled face to bore perpendicularity of these shaft collars (TIR of ≤ 0.05 mm) which is critical when they are used as a load bearing face or for aligning components such as bearings or gears. All Ruland shaft collars are machined to a fine burr free finish that reduces the likelihood of metallic system contamination and complements or enhances the appearance of food processing equipment.
Shaft collars made from 303 and 316 stainless steel use hardware of like material for consistent corrosion
Two-piece Ruland rigid coupling in stainless steel with proprietary Nypatch hardware.
resistance and to meet regulatory standards. Plastic shaft collars can be used as a cost-effective alternative to stainless steel at the expense of performance. They are supplied with stainless steel hardware for corrosion resistance. Anodized aluminum shaft collars with stainless steel hardware are also available for areas of the system where stainless steel or plastic is not required. Shaft collars are manufactured in bore sizes from 3 to 150 mm.
These shaft collars and rigid couplings are RoHS3, REACH, and Conflict Minerals compliant. They are made from North American bar stock sourced from select mills and carefully manufactured in an advanced manufacturing facility under strict controls using proprietary processes. DW
Ruland • ruland.com
PickNik Inc. recently partnered with the Japan Aerospace Exploration Agency, or JAXA, to change how the International Space Station handles cargo and equipment. The project is part of JAXA’s Payload Organization and Transportation Robotic System (PORTRS) initiative.
The goal was to demonstrate a complex, multi-armed robotic system capable of performing manipulation tasks in microgravity. These could include anything from crawling, payload swapping, to handling soft, flexible cargo transfer bags. These mundane tasks are not the most valuable use of an astronaut’s time, Dave Coleman, founder and chief product officer of PickNik, told The Robot Report.
“Some of the examples they’ve cited are just routine maintenance tasks,” he said. “A lot of these astronauts have Ph.D.s, or they’re super accomplished fighter pilots, and you’re asking them to wipe down air vents and clean surfaces, or to move cargo around when they have to resupply.”
Every hour of an astronaut’s time in space can cost as much as $200,000, Coleman noted. “There are so many other expenses that go into training and prepping and launching, and then there’s the cost of the life-support systems,” he continued. “So anything you can do to augment astronauts with robots has a huge ROI.”
“There’s a case where an astronaut’s sock floated into an air vent and was
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clogging it, which is bad for the lifesupport system,” Coleman said. “So you could conceivably have a robot go and do a pick-and-place task and clear that out. There are lots and lots of use cases that both the NASA and the JAXA side have been looking at for having a robot assisting astronauts.”
With the latest demonstration, JAXA hoped to prove that its system could meet the demands of real-world, highstakes space operations with greater speed, robustness, and readiness for practical deployment.
PickNik helps JAXA build robots for low gravity
While there are more similarities than differences in terrestrial and space use cases, many of the specific capabilities for robots in space are in the firmware layer. While PickNik doesn’t get involved in this area, the Boulder, Colo.-based company still had to create a system using MoveIt Pro that could operate in zero gravity.
Coleman said that terrestrial robots, like a typical collaborative robot arm, take gravity into account in their control systems. Shifting to zero gravity means
FOR POSITION FEED BACK ENCODERS
making a low-level change in how you tune your controls, he explained. Once you account for that difference, things run similarly.
JAXA’s robot has four arms and a non-fixed, reconfigurable base. With no gravity, the robot can use any surface to stabilize itself. The Japanese space agency’s robot can crawl around a spacecraft, like a spider. It can use any of its four arms to stabilize itself, typically on the rails that the ISS is already has for human astronauts to use.
Position, angle and speed measurement
Contactless, no wear and maintenance-free
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Linear and rotary solutions
PickNik’s software is designed to serve both terrestrial and space applications, as well as government and commercial uses.
PickNik
“You grab onto this metal railing, and depending on which appendage is attached, the fixture point changes,” explained Coleman. “So all the math behind it transforms, and the inverse kinematics, all of those things have to be very dynamic and change based on where your legs are.”
MoveIt Pro enables quick iteration
While JAXA has tested a four-armed version of its robot, the final flight model will use a three-legged configuration. Modularity and adaptable control are even more critical.
“A lot of robotics companies, they can move fast and make some assumptions and take shortcuts by hard-coding the number of joints,” Coleman said. “We’ve taken the harder approach, where all of our control systems and control algorithms automatically adjust to how many degrees of freedom or how many appendages you have. That’s really powerful, and that enables rapid prototyping.”
Designing robots for space also means taking in additional safety concerns.
“You have to do a lot more validation and verification because if a robot punches a hole into your space station, that’s really bad for all the humans living there,” Coleman said. “It’s a very brittle system up there, and so there’s a lot more safety checks on the amount of force being exerted and the speed at which each joint can run.”
PickNik also ensured that human-in-the loop functionality was strong in JAXA’s system. Real-time teleoperation isn’t possible because of latency between mission control and the ISS, and the space agencies prefer to review all commands rather than rely on full autonomy, said Coleman.
Coleman discusses PickNik’s future plans in space robotics
PickNik is in talks with other U.S.based customers that want to create similar mobile manipulators. Coleman said working with JAXA has helped the company refine its approach.
In addition, PickNik has added features around supporting multiple arms and dynamically switching between which ones are active and which ones are fixed. It has been working with JAXA to mature the technology.
“We are, admittedly, still a bit more of an experimental program for JAXA,” Coleman acknowledged. “I think we’re going to be more in their second-generation application.”
But PickNik has many other space robotics projects on the horizon. For example, it is working with the U.S. Space Force on satellite capture and grappling projects. It has also been working with NASA on a number of lunar surface applications.
NASA faces uncertainty as JAXA moves quickly
With the current administration’s plans to cut 24% of NASA’s funding and eliminate 41 science projects, the future of U.S. space robotics is in flux. Despite these challenges, PickNik plans to continue pursuing space applications.
“We’ve always had dual-use, so lots of non-space applications,” Coleman said. “That’s the bread and butter of our business. We’re making a lot of progress with some exciting customers in the space industry. It moves slowly, and there are a lot of fits and starts.”
“We’re trying to play the long game of being sustainable through non-space applications while waiting for the right timing, which can take multiple years,” he added.
There are also other changing dynamics in the industry. Coleman said that with SpaceX’s Starship maturing and hopefully having its first real missions, the cost of launching commercial payloads could drop. This would make it more cost-effective to put satellites into orbit, making satellite servicing less of a priority.
While space robotics typically moves slowly, Coleman noted that JAXA has moved quickly with PORTRS.
“One thing that’s really cool about it is just how fast they’re moving,” he said. “Their launch timeline is way faster than most programs.” RR
Japan’s space agency evaluated MoveIt Pro as the planning and control backbone for PORTRS.
PickNik
NBC’S AGT PUSHES SPOT TO PERFORM UNDER PRESSURE
Boston Dynamics is no stranger to the spotlight. Its Atlas humanoid and Spot quadruped robots have become global phenomena thanks to viral videos showcasing their agility, stability, and, of course, dancing.
Earlier this year, the company took things to a new level. It had five Spot robots perform a live, choreographed dance routine on NBC’s America’s Got Talent (AGT), one of the biggest stages in entertainment. The legged robots performed a synchronized dance to Queen’s “Don’t Stop Me Now,” and the robot arm on each Spot was used to “lip-
sync” to Freddie Mercury’s vocals.
All four AGT judges — Simon Cowell, Mel B, Howie Mandel and Sofia Vergara — voted “yes” for Spot to move on to the next round of the competition. What appeared to the average viewer as a fun robotics demo was also a technical stress test for Spot and Boston Dynamics’ robotics engineers behind the scenes.
“After 20 years, how can we see something we’ve never seen on this stage?” Mandel asked during his postperformance commentary. “This is something we’ve never seen on this stage.”
“It’s kind of blown my mind a little bit. I’ve never seen anything like this before,” said Mel B as one robot shook hands with AGT host Terry Crews. “I want to thank you for bringing this to the stage.”
Why bring Spot to AGT?
The idea to perform on AGT had been brewing for years, said Nikolas Noel, vice president of marketing and communications at Boston Dynamics. But it wasn’t until 2024’s Calgary Stampede, where Spot performed live for 14 consecutive nights, that Boston Dynamics felt confident that it could tackle the
Boston Dynamics’ Merry Frayne on a recent episode of NBC’s America’s Got Talent. Boston Dynamics/NBC
STEVE CROWE THE ROBOT REPORT
technical and logistical hurdles of a performance on AGT.
“Videos are one thing,” said Merry Frayne, director of Spot product management, who appeared on stage at AGT with the robots. “But doing this live, with millions watching, that’s a whole different level of stress on the robot and the team.”
The performance involved both autonomous and teleoperated components. During the main routine, the robots danced autonomously using pre-scripted sequences created in Boston Dynamics’ proprietary choreography software. Once the routine ended, human operators backstage took control of individual Spots to interact with the judges and crew.
“The moves in these dances are more aggressive than what most of our customers put Spot through,” Frayne noted. “From a robotics standpoint, it’s one of the best stress tests we can run.”
The choreography pushed the limits of Spot’s capabilities: high-speed spins, one-legged balancing, and coordinated group maneuvers. Behind the scenes, recent advances in reinforcement learning and dynamic behavior modeling gave Spot a more robust suite of reactions, including better obstacle avoidance and fall recovery.
Frayne noted that these aggressive movement capabilities developed for
performances like AGT translate into realworld applications. “We’ve seen these improvements pay off in environments like chocolate factories with slippery floors, where maintaining balance is critical,” she said.
The show must go on
Despite extensive rehearsals — over 100 of them — one Spot robot malfunctioned mid-routine due to a rare hardware fault. What could have been a disaster turned into a moment of authenticity and resilience.
“The robot wasn’t supposed to fall,” Frayne said. “But it was a coincidence that it happened just as I was explaining our motto: ‘build it, break it, fix it.’” The judges and audience embraced the imperfection, and the team decided not to abort the rest of the routine.
“Backstage, we had maybe five seconds of panic,” said Noel. “We had a kill switch ready to stop all the robots if needed, but based on how we’d spaced the robots out, we knew the others could keep going safely. So we made the call: Let it ride.”
That spacing was no accident. The robot formations were designed with several feet of clearance to avoid collisions if a robot were to fail midperformance. That spacing also took into account arm movement and dynamic balance requirements.
Changing public perception, inspiring the future
For Boston Dynamics, AGT wasn’t just an opportunity to demo its technical chops. It was also a platform to reshape public perception. Robotics is still too often framed by dystopian fiction, said Noel.
“We want people to see Spot and think ‘helpful tool,’ not ‘Hollywood villain,’” he said.
The team also sees performances like these as a way to inspire the next generation of engineers and roboticists. “If one kid watches this and gets interested in robotics, it’s worth it,” said Frayne, who watched the episode with her own daughter.
At press time, Boston Dynamics was waiting to hear whether Spot will actually advance to the next round of America’s Got Talent. If Spot does return, viewers can expect an even more sophisticated routine, possibly with never-before-seen behaviors.
“We’re not just building robots that can do the job,” said Frayne. “We’re building robots that can do the job with character.” RR
SCAN THE QR CODE OR USE THE LINK BELOW TO WATCH SPOT’S PERFORMANCE!
youtube.com/watch?v=ptYDWP9uTis
The Spot quadruped also took the stage at the Calgary Stampede. Calgary Stampede
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A Supplement to Design World
AUTOMATED WAREHOUSE
Mike Oitzman Senior Editor Robotics
Amazon is opening new automation opportunities by deploying its first robots that leverage force and touch sensing to improve material handling tasks.
One of the classic applications for robots at Amazon warehouses is centered around the “goods to person” (G2P) solution with the Kiva robots. The Kiva mobile robots present movable
shelves, stocked with inventory, to a stationary human picker. The human associate picks a specific item for a specific customer order and singulates it for shipment.
Over time, the shelves are depleted of inventory and need to be replenished. The replenishment task is currently done manually. To automate the replenishment task, Amazon
developed a new robot called Vulcan, designed to pick items from bulk and place them onto the movable shelves. What makes Vulcan unique is that it is equipped with force feedback sensors and AI, giving it a sense of touch. This “sense of touch” allows Vulcan to manipulate objects with greater precision and dexterity. According to Amazon, Vulcan can pick
and stow approximately 75% of the items in Amazon warehouses, moving them at speeds comparable to human workers.
The robot’s capabilities are expected to improve operational efficiency, workplace safety, and reduce physically demanding tasks for human employees. Vulcan’s endof-arm tooling and sensors enable it to manage a wide range of products, from small gadgets to larger items, by applying the appropriate amount of force.
Force sensing for robotic manipulation
AUTOMATED
Vulcan’s
includes key movement capabilities, such as sweeping items to one side.
Robot Report, to discuss the technology behind Vulcan during a keynote at the Robotics Summit and Expo in Boston. Parness explained the importance of touch and force sensing to the future of robotics at Amazon.
Parness’ team has said “force is the language of manipulation.”
“[Force sensing] is essential to how we interact with the world. It’s one of the big limitations in our field right now,” Parness said during his Robotics Summit keynote. “If you look at mobility, robots are doing back flips, but manipulation is still a very unsolved challenge. We get confused sometimes between digital intelligence and physical intelligence. We are rightly impressed when robots beat grand masters at chess. They are amazing at playing chess, but robots still kind of suck at moving the pieces on the board. And that’s the physical intelligence. That’s where [the people in this room have] lots of opportunity to make advances.”
Parness believes there are a number of new applications that will
be enabled by touch. This includes densely putting items into a padded mailer, handling groceries, and putting packages into delivery bags. These are things where you have a lot of physical contact, where you need the next wave of robotics.
“[A sense of touch] allows us to go faster so we don’t have to be as cautious, because we can move quickly and then respond when we make contact, as opposed to watching and watching and watching,” Parness said at the Robotics Summit. “And it’s a faster
gripper
Amazon Robotics
Aaron Parness (left) discussed how force sensing improves robotic manipulation at Robotics Summit & Expo 2025
Jeff Pinette
response rate. It also allows us to fill the bins to a higher level of growth cube because we can compress items. You can squeeze the pillow or the t-shirt over to the side. You can’t know that ahead of time always. So, you need to have that force feedback to know if what you’re pushing on is rigid or compliant.”
A sense of touch also helps us avoid damaging items and dropping items, Parness said. “It helps us with item eligibility. You don’t grip a physics textbook that’s very heavy with the same amount of force as you do a thin cardboard box that’s got some medicine in it. So, it’s part of everything we do.”
Parness recalled a mentor he had at NASA Jet Propulsion Laboratory (JPL), Brett Kennedy, who used to say industrial robots 1.0 were dumb and numb. They didn’t feel anything, and they didn’t have a brain.
“That’s OK for a lot of tasks, right? If you are welding a robot, you can do that dull, dangerous, dirty, repetitive task without needing to feel the world. But we want them to interact in highly cluttered environments. You should see my kids play area. If we want to sort through that pile of junk, you have to have a sense of touch. That’s my fundamental hypothesis.”
Expanding warehouse applications
Amazon currently has a number of other robotic picking applications deployed. For example, Sparrow, a robotic system that can detect, select, and handle individual products, is currently picking from totes, but it only picks from the top layer of the totes. Sparrow has a lot of intelligence to identify the items and plan the trajectories, but it (currently) doesn’t require a sense of touch.
Amazon has another robot called Cardinal, designed to fill a cart with
packages. The key for Cardinal is to get the cart as full as possible. Parness believes Cardinal could benefit from a sense of touch to help it maximize the cart load in the future.
Vulcan aims to automate the stowing of items in upper bin rows, which are hard for people to access, according to Parness. This focus on the top rows means human workers would primarily stow items on mid-level shelves, the “power zone,” potentially reducing worker injuries, Parness noted. Amazon’s injury rates have historically been higher compared to other warehouses, although the company states these rates have decreased considerably.
Vulcan represents the first of the low-hanging fruit applications for better force and touch sensing. The Amazon robotics team developed their understanding of touch sensing integration with the Vulcan development and is now looking to expand this to other target applications in the warehouse.
For now, Vulcan is only in full operation at Amazon’s warehouses in Spokane, Washington, and Hamburg, Germany. AW
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Function, purity, and process are key considerations when researching aerospace materials. Daniel Hess, applications engineer at NuSil, explains silicone’s unique characteristics and guidance for choosing the right material.
RACHAEL PASINI EDITOR-IN-CHIEF
Humans have used silicon-based materials for thousands of years, with archaeological evidence from ancient Chinese, Egyptian, and Phoenician cultures. However, Jöns Jakob Berzelius, known as “The Father of Swedish Chemistry,” is credited as being the first to isolate the silicon element in 1823. Silicones advanced significantly during World War II, starting as greases and reinforcing agents for composites. Natural rubbers were in short supply at the time, so the push for researching and manufacturing synthetic rubbers quickened.
“A carbon-based grease at cold temperature seen at high elevation can seize up and become more solid, whereas silicone can remain non-solid at the same temperature range,” said Daniel Hess, applications engineer at NuSil, a brand of Avantor. “After World War II, more silicone manufacturing took place to get scalable processes and increase the volume. Ever since, its utility and research for new materials and form factors have been increasing, and it is becoming ubiquitous.”
Today, silicones are ever-present in our everyday lives. Aerospace, automotive, medical, and consumer goods applications abound.
“I like to think that before you leave the door to go to work in the morning, you probably touch 10 different things that are either made of silicone or made with silicone in some capacity,” said Hess. “Before silicones became ubiquitous, there were traditional natural rubbers, neoprenes or polyolefins in elastomers, or for adhesives, you also had polyurethanes and epoxies, which have different uses and different utilities, but they’re generally not as soft or elastomeric. Cyanoacrylates, or super glue, that’s another one. It’s a thermoset elastomer, but it doesn’t really have that softness or stretchiness like a silicone adhesive does.”
Silicones have very low modulus, making them an excellent adhesive and creating compliant bonds and unions that experience low stress when flexed or encountering low or high temperatures. NuSil, which Avantor acquired in 2017, has been manufacturing silicone materials for the International Space Station to help address such temperature challenges.
“Our broad operating temperature portfolio of silicones is a classification of materials that has what we call glass transition temperature that goes down to about -115 or -120° C for operational temperatures,” said Hess. “That’s the point at which it will remain soft and compliant, whereas traditional plastics or other types of elastomers have a much higher temperature, so they can’t be as cold. After that point, these materials will become stiff and glassy.”
For decades, silicones have been used in aerospace for adhesives, coatings, foams, elastomers, tapes, and potting compounds. All these materials are critical for building a functional and reliable device or assembly suitable for outer space or terrestrial vehicles in low atmosphere for the aircraft industry.
Hess explained that gaseous atomic oxygen is a predominant concern in aerospace and is found abundantly in low Earth orbit atmospheres. It’s a very aggressive gas that attacks carbon-based materials and erodes and compromises the integrity of structures. Therefore, silicones act as a sacrificial coating and help prevent the degradation of critical materials underneath. This is particularly important for the exteriors of capsules and components such as solar panel arrays.
“That’s where one of our longeststanding products has been used for atomic oxygen coatings on the International Space Station,” he said. “Other popular coatings are ablative coatings that will help a craft survive reentry into the atmosphere, so the
silicone will absorb the heat and glow white. If you ever see a rover or some kind of shuttle descending into the atmosphere that’s glowing red and white, that’s ablative silicone coating absorbing the heat to help the materials and composites underneath survive.”
NuSil’s silicones characteristically have low volatility in their cured form. The company manufactures two different grades of products in this area, CV (controlled volatility) and SCV (super controlled volatility), with specific outgassing characteristics based on international standards and ASTM E595 testing, which is critical for most aerospace applications. NuSil is on the ASTM committee and manufactures, maintains, and sells equipment that ASTM E595 is based on. The team has been working with NASA and other international regulatory bodies to establish and maintain those standards for ASTM E595. They also implement additional specialized processing to develop super-low volatility materials necessary for aerospace.
“One of the reasons why very low volatility is necessary is that in a vacuum environment like space, any residual volatile materials that come from the original synthesis of the polymer can stay in there and then be pulled out in a vacuum, and that’s going to go somewhere. It can collect on sensitive surfaces like sensor housings and other glass or plastic surfaces that end up either fogging it up or making adhesive bonding a problem later,” said Hess. “So, we address that in the very beginning of the polymer synthesis and remove those low-volatile and low-molecular-weight compounds to ensure that upstream problems are mitigated.”
When selecting adhesives, coatings, or elastomers, Hess advises engineers or designers to consider three criteria: function, purity, and process. First, decide what the material should do — bonding, sealing, thermal management, electrical protection, and so on. Then, investigate the required mechanical properties and
Aerospace/Defense
the environment to which the materials will be subject. For example, consider the purity necessary in a vacuum environment near sensors, optics, or other extremely sensitive components.
“The CV and SCV have two main measurements of what’s important: the total mass loss and the collected volatile condensable materials (CVCM). The total mass loss is just what it sounds like. It’s the amount of mass that’s removed from a cured material. And in these test conditions, it’s 24 hours under vacuum at 125° C,” Hess said. “The international standard for CV grade material is 1%, and the CVCM is 0.1%. On the SCV grade, it’s just 10 times lower. So, those are even 10 times more pure than the traditional CV grades of materials.”
Lastly, on the process side, Hess advises engineers to think about scale and construction.
“If you’re making just a tiny little unit, that’s going to have different processing considerations, as opposed to building the whole aircraft. So, you might need to look for materials with specific packaging, like either side-by-side kits with easy dispensing, all the way up to drums, which might need specific types of equipment to meter it out, mix it, and then dispense it,” he said.
“There are also different types of rheologies that silicones will have, or flow
characteristics that are better suited for certain areas. If you have vertical joints or curved surfaces, you might need a thixotropic material that won’t slump or fall over and hold a nice bead shape once it’s been dispensed so that you can join two parts without it falling on your head. Other complex geometries or large surface areas might need really flowable and self-leveling adhesives that will find the level and flow out into all the nooks and crannies of a geometry.
Engineers must consider function, purity, and process when selecting silicones for aerospace applications. NuSil
“There’s also a certain class of adhesives called film adhesives that are either in a sheet or a roll, and after preparing a surface, you can apply the film and it will cure into a permanent elastomeric film, which is kind of like a permanent tape, if you will. This is really useful for large array manufacturing. That’s going to give you a nice, consistent bond line across a big array. And these arrays can be quite large, several 100 square feet at a minimum. So, this also avoids any mixing and dispensing operations, so you can instead stick a film over it and allow it to cure at room temperature, instead of having any mixing or cleanup for liquid adhesives.”
Hess asserts that silicones are here to stay for the foreseeable future. They have broad uses in aerospace for constellation satellites, space research missions with crewed capsules and extraterrestrial rovers, deep space satellite imaging programs, and beyond. The material needs for each application are unique and require early collaboration and appropriate material selections to help ensure mission longevity and success. A&D NuSil nusil.avantorsciences.com
The SpaceX Crew Dragon Endeavour took this picture of the International Space Station during a fly-around of the orbiting lab in November 2021. NASA
RACHAEL PASINI EDITOR-IN-CHIEF
MAY REVOLUTIONIZE PRECISION MANUFACTURING
Watch Out, a Montreal-based company with operations in Switzerland, France, and Canada, develops container-sized manufacturing cells that operate with minimal human intervention, addressing critical labor shortages while enabling domestic production.
Watch Out. “Number one, you capture the data with all the sensors — optical, electrical, the whole lot — and they all have been developed by us. Number two, we organized the data system to be very frugal because we're working in microns and nanoseconds. Our scales are very, very small and very, very fast. So you cannot have millions of data that take
The idea is not to reinvent the wheel or accumulate data that doesn’t add any value to the system. Mariette argues that deep learning isn’t necessary for every situation, problem, or decision, and
therefore doesn’t require collecting the millions of data it would otherwise ingest and store. Instead, as Mariette explained, “you just have to reinvent what you don't know.” In Watch Out’s system, if the data received doesn’t fit the algorithm, it is sent to a deep learning system, which runs the data and finds a solution. Then, the solution is put into action to machine a piece and check it. After about 100 pieces, the deep learning outcome becomes an algorithm.
“It's fully autonomous because we catch that at the beginning, and we control 100% of the data, which goes back into the data model. It's a datacentric system,” said Mariette. “We try to make the mathematical model, the digital model, exactly the same as the real model of the parts.”
As Olivier Chéret, Watch Out’s chief strategy and growth officer, explained, the first microfactory the team developed is for precision turned parts, including aerospace fasteners, and consists of three process modules: handling, machining, and inspection.
“When you push the button, if you will, the cell itself is performing a ton of checks autonomously, including its geometrical checks. The reason we can kick them off so fast in a new factory is because the cell is going to check that the positioning of its different parts is
aligned with its model. There is no human intervention required to kick off the operations,” said Chéret. “Then, when you give a new step file for the cell to produce, the AI software is going to write the machining program autonomously based on its experience of other parts and the expert system.”
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The AI-driven microfactory monitors its handling, machining, and inspection modules in real time. Watch Out
From there, an “AI tower” communicates with the microfactories and operators so that operators bring the right tools to the right workcells.
“Typically, we put tags on the tools so that when the operator is bringing a new tool to the microfactory, the microfactory digitally recognizes the tool that has been
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Aerospace/Defense
loaded in the cell. It's an AI-led decision process to make sure that we control the end-to-end,” said Chéret.
Once the microfactory is ready to start production, the operator places the tool in the handling module, gives the green light, and the cell automatically checks, handles, and machines the part.
“One of the big innovations is, thanks to the optical cameras we have, we know in real time the positioning of the parts and the positioning of the tool,” said Chéret. “In real time, the software is always able to match the tip of the tool with the part, and check every new part that's coming into the machining cell. And because we have this vast amount of data and cameras monitoring the tool, the software is able to adapt its machining program to the state of the tool. As the tool wears, we have numerous rules to adjust the machining parameters. So, we are regaining a ton of efficiency from that.”
Once the part is machined, it returns to the handling module and then to
inspection, which determines whether the part is compliant or not. Feedback from the inspection module is used to adjust parameters for subsequent parts, if required.
“The reality is, because we have so many sensors throughout the process, we already have clues of what's going on when the part is machined. We don't need the inspection to know if something is wrong. We might know much earlier. That's the richness of this ecosystem, and the possibilities are quite limitless,” said Chéret.
What was once a vision has become limitless due to the convergence of multiple advanced technologies that various companies and industries have developed to solve different engineering problems over the past decade, and AI is the pinnacle solution.
“Until now, we’ve tried to hide for two reasons. One, everybody was telling our founder, Sébastien, it's just impossible. It will not work. The reason it's possible is because it's at the
cross of many technologies — optical, electrical, algorithm, and AI. Without AI, we would not have been able to do it, and it's improving every day,” said Mariette. “The technology to measure is also, from a mechanical point of view and a digital point of view, totally new. We can position the part and the tool anywhere. If the machine is not flat, it doesn't matter. It autocontrols itself, not mechanically, digitally.”
Mariette explained how painful it has been to watch as others try to reinvent instead of innovate. Now, with AI, more stakeholders are getting on board with this new concept that is autonomous, economical, and frugal in terms of data and physical space.
“Our microfactory, the full system, is nearly the size you will find of a normal CNC machine. It's ecological and economical,” said Mariette.
Watch Out estimates that the microfactory has a 30 to 50% lower carbon footprint than typical machines. Real-time autonomous monitoring and
adjustments throughout the entire process reduce scrap. The small size also requires less hardware, less building space, and fewer workers driving cars to the factory, among other benefits. Additionally, it is easily transportable, reducing the costs and carbon footprint associated with delivery and installation.
“When you buy a traditional machine, it goes in many containers, and you cannot drive it with a truck. You need a special convoy, and in many cases, you need to change the big doors you have for a normal truck; you need to cut them. That's what we've done. We had a factory with doors for a normal truck, but the machine was too big, so we had to cut the wall,” said Mariette. “Our microfactory fits in a container — in one container. We can install it in about three hours. A normal stateof-the-art machine is between three days and a week.”
Watch Out’s microfactories are currently producing parts in Europe and for LISI Group, which ranks third worldwide in the creation of aerospace fasteners and assembly components.
“It's very flexible, totally autonomous. It's a way of cutting costs and waste because you don't have downtime. It's fully data-centric, and you don't need to stop the machine. The machine can change its tools, models, everything,” said Mariette. “You have 100% of the information about the part that comes out of the machine, and there's no human intervention.”
Watch Out's autonomous microfactories represent more than an incremental improvement in manufacturing automation. By combining advanced sensing, AI-driven decision-making, and complete process integration in a transportable package, the technology addresses multiple industry challenges simultaneously: skilled labor shortages, supply chain vulnerability, and the need for flexible, responsive manufacturing capabilities.
For aerospace manufacturers facing increasing pressure to reshore production while managing costs and quality requirements, such systems could provide a viable path forward. The technology's ability to operate with minimal skilled labor makes domestic manufacturing economically feasible even in high-wage markets, while the autonomous operation ensures consistent quality and productivity. A&D
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In today’s dynamic operational environments, relying on a single sensor technology, such as Global Navigation Satellite System (GNSS) or inertial measurement unit (IMU), is no longer viable. Missions increasingly occur in GNSSdenied, electromagnetically noisy, and physically complex environments where traditional systems falter.
“The world is evolving, and navigation must evolve with it. GPS is disturbingly vulnerable to challenging environments, harsh weather conditions, and cyberattacks, with rising threats of jamming and spoofing. The question isn’t if GPS will fail, but when. Operators need to build resilience now,” said Chris Shaw, CEO and co-founder of Advanced Navigation.
Robust navigation demands a layered, inertial-first and multi-sensor architecture — held together by intelligent software — that can adapt and scale to meet the unique demands of each mission. Embracing a software-defined nature means updates and enhancements can be deployed with minimal hardware disruption. This paradigm shift ensures truly resilient navigation for critical applications across defense, aerospace, robotics, and autonomous systems.
To achieve this, Advanced Navigation, headquartered in Sydney, Australia, integrated a strategic-grade fibreoptic gyroscope (FOG) inertial navigation system (INS) with a new class of navigation aid: a laser velocity sensor (LVS). The result is a fused hybrid architecture that delivers precision and reliability in the most challenging environments.
LVS is a terrestrial adaptation of LUNA (Laser Unit for Navigation Aid), a space-grade navigation technology developed for autonomous lunar landings. LUNA enables reliable navigation in the harsh environment of space by providing precise three-dimensional velocity and altitude information relative to the moon’s surface. After several years of research and development, LUNA is set to be demonstrated aboard Intuitive Machines’ Nova-C lander as part of NASA’s Commercial Lunar Payload Services (CLPS) program.
By leveraging the engineering insights gained from LUNA, LVS adapts space technology into an Earth-ready solution for terrestrial GNSS-denied navigation.
3D-rendered image with elements furnished by NASA. . Advanced Navigation
Why the LVS hybrid works
At the center of every reliable navigation platform is a trusted source of truth: the INS. The company’s FOG INS, which is sensitive enough to detect the Earth’s rotation, provides that foundation by delivering precise attitude, and the LVS uses infrared lasers to accurately measure a vehicle’s ground-relative 3D velocity. LVS performs reliably on ground and airborne platforms, as long as it maintains a clear line of sight to the ground or a stationary surface.
Beyond its role as a velocity aid, LVS also enhances navigation resilience by detecting GNSS spoofing. By comparing its independent velocity measurements against GNSS-derived velocity, LVS adds an extra layer of security to assured positioning, navigation, and timing (APNT) strategies.
AdNav OS Fusion draws on sophisticated algorithms to interpret and filter sensor data. The software is designed to dynamically weigh the input from each sensor, adjusting in real time based on reliability scores, environmental conditions, and operational context. This ensures continuous, high-
confidence state estimation even when signals are lost, degraded, or distorted. This inertial-centered, multi-sensor approach delivers a step-change in GNSS-denied navigation performance compared to traditional methods.
Testing LVS resilience with real-world data
To validate the accuracy and resilience of the LVS hybrid system, the company conducted a series of rigorous realworld driving tests. Across five trials, the system delivered exceptional performance with an average error per distance traveled of 0.053% compared to a GNSS reference.
At the starting point, GNSS on the INS was disabled in the state estimation process, forcing the system into deadreckoning mode. RTK GNSS was logged separately as a reference. This approach allows for a direct comparison between the computed dead-reckoning solution and a trusted position reference.
Figure 1 shows dead-reckoning results from a 23-km drive around Canberra, Australia. GNSS was not used at any point in
the drive for heading or position. RTK GNSS is shown as the red line, while the LVS hybrid system’s result is shown in blue.
Results from a 19.2-km drive around the Parliamentary Triangle in Canberra were also collected (not shown here). Again, GNSS was not used at any point in the drive for heading or position.
Figure 2 is a zoomed section from the first test drive, showing GNSS (red) drop out as the test vehicle drove through a tunnel, which completely denied the GNSS reference measurement. The hybrid system’s result can be seen in blue, showing it did not suffer from this error.
These drives were done repeatedly, demonstrating consistent and reliable results each time, as shown in Figure 3.
The LVS hybrid system was also tested on a fixed-wing aircraft combined with a tactical-grade INS, demonstrating a final error per distance traveled of 0.045% over the course of a low-altitude flight over 545 km. These results demonstrate the system’s ability to improve navigation performance of the INS in GNSS-denied or contested scenarios. A&D
demonstrate consistent and reliable results each time. Advanced Navigation Advanced Navigation advancednavigation.com
(TOP) FIGURE 1. Dead-reckoning results from a 23-km drive around Canberra, Australia. (BOTTOM) FIGURE 2. Hybrid and GNSS solution routes comparison. Advanced Navigation
FIGURE 3. Repeated tests
Ryan Ashdown rashdown@wtwhmedia.com 216.316.6691
Jami Brownlee jbrownlee@wtwhmedia.com 224.760.1055
Mary Ann Cooke mcooke@wtwhmedia.com 781.710.4659
Mike Francesconi
Publisher Courtney Nagle cseel@wtwhmedia.com 440.523.1685
CEO Matt Logan mlogan@wtwhmedia.com
Ken Gradman kgradman@wtwhmedia.com 773-680-5955
Technical Thinking
By Mark Jones
Finding inspiration in unlikely places
I’ve long been fascinated by the observations underlying the inspiration, the eureka moments leading to invention. But inspiration from a urinating dog came as a surprise.
A recent study on designing a splashless urinal made — and excuse the pun — a bit of a splash. Headlines such as “Physicists make a splash with a urinal that doesn’t” dragged me in. I was correctly skeptical of physicists studying urinals. The study was published by engineers, not physicists. Engineers use physics. That doesn’t make them physicists any more than using words makes me a linguist. The inventors got labeled as physicists because they presented the work in a fluid dynamics section at an American Physical Society meeting.
Dogs and nautilus shells are cited as their inspirations. Dogs do not suffer from splash-back when urinating according to the work. The dog’s leg lift creates an angle that keeps the dog’s belly fur dry (an observation I cannot independently confirm). Canids are one of a very tiny set of animals where leg lifting for urination is common, and only for half the population. Inspiration would have been missing had the inventors been cat people or exposed only to female dogs.
Inspired by the urinating dog, studies and computer models led to understanding of urinal splash. Gained understanding led to design of two designs, dubbed Cornucopia and Nautilus, that don’t splash. The study and designs were published in the academic literature, by the National Academies no less.
Urinals are infrequent topics in the academic literature. “The Urinal
Problem” offered a mathematical solution to making urinal choice while optimizing privacy. In a title more befitting physicists, there was “Creating a urine black hole.” Rather than designing a completely new urinal, these inventors found inspiration in the water capturing moss Syntrichia caninervis. Structure of the plant causes impinging streams of water to flow into the plant rather than being deflected. Duplication of the structure led to development of splashfree surfaces. Shaped into a urinal pad, any urinal can become splash-free. The moss inspired an issued U.S. patent. The patent literature is considerably more populated than the academic literature. It shows extensive innovation around urinals. Keeping urine off the floor is an active area. Poor aim and splash are both implicated as sources of floor contamination. Aad Kieboom and Jos van Bedaf created the urial fly at Schiphol Airport in the 1990s. Providing a target, in the form of a fly decal in the urinal, led to a 50-80% reduction urine on the floor and 8% reduction in cleaning cost. Patents using flexible bristles to prevent urine splashing dates back at least until 2006, predating the urine black hole by more than a decade. The first screen came to market in 2010. Today, many splash reducing products are on the market. Screens currently on the market claim 97% reduction in splash, not as good as the 98.6% reduction in the newly designed Nautilus, but pretty close. Screens containing deodorizers address issues of both splash and smell. Benefits of urinals and of keeping urine in them are many. Urinals are more space efficient and use less
(or no) water. Some suggest urine should be valued as fertilizer. Urinals allow urine collection separate from other waste. Perhaps the biggest advantage is speed, as urinals have higher throughput than toilets. Throughput is driving innovation in urinal design, especially in the design of urinals for those that don’t typically stand to pee. One company claims 90% of the lines for women’s restrooms are for those seeking only to pee. Using their urinal is 6 times faster. The innovation is said to dramatically shorten restroom lines at large outdoor festivals. Urinal technology offers something for everyone. My initial skepticism about physicists researching urinals led me to investigate a richer field than I expected. A restroom visit today while wearing shorts clearly illuminated poor urinal design and made me wish for a splashless screen. The urinal fly, splashless screens and splash-free designs are all innovations implemented in my lifetime. I don’t know what the urinal future holds, but it seems destined to be less splashy and more inclusive. DW
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