R E C O G N I Z I N G F I R M S T H A T A R E D R I V I N G I N N O VA T I O N A N D M A K I N G A D I F F E R E N C E
WWW.DESIGNWORLDONLINE.COM JANUARY 2026
PLUS:
2025 LEAP Award Winners
PAGE 44
S T O B O RARE BUILDING E S U O H R U O Y PAGE 39
ALSO INSIDE:
Power -dense motors enable supersonic flight PAGE 14
The many layers of performance & specifications in motion control
PAGE 32
Final Cover DW 01-26.indd 1
1/13/26 4:19 PM
Specify a Bodine Gearmotor in Your Design Satisfy All of Your Resolutions with One Decision As a design engineer you have a lot on your to-do list. With more than 1500 stock models to choose from, and an infinite number of custom modifications possible, the engineers at Bodine Electric can help you select a gearmotor that checks all your boxes. Which might just give you that extra time you need to get back to the gym.
www.bodine-electric.com
BOD-DW-Jan-2026.indd 1 Bodine - DW 01-26.indd 5
| info@bodine-electric.com
| Peosta, IA USA
| 773.478.3515 (USA)
12/3/25 4:07 PM 1/12/26 2:57 PM
Versatility + Efficiency = Productivity
e ug
Tim e er sav
H
Low-cost PLCs engineered to perform!
USER DEFINED INSTRUCTIONS
Software Efficiencies
Hardware Versatility PLCs starting at ONLY $123.00
The Productivity family of PLCs offers three distinct series with rack-based and stackable hardware style choices. Each series offers different I/O capacities but all use the same programming software, allowing you to easily scale your control up or down depending on the application or machine build.
Productivity Suite is the FREE user-friendly programming software for the Productivity family of controllers. It is packed with tools designed to reduce development time and headaches. The NEW! User-Defined Instructions (UDIs) simplify programming, boost efficiency, and standardize logic. This powerful feature lets you package complex logic into a reusable block, making your code: • Easier to Read: Your main program becomes cleaner and easier to follow. • Faster to Develop: Drag and drop your custom instructions instead of copying and pasting code. • Simpler to Maintain: Update your logic in one place, and the changes apply everywhere.
• NEW! Productivity1000 Mini series PLCs are the first-ever standalone models for the Productivity family. These models combine a powerful CPU with analog or discrete I/O in a single unit, and with a $123.00 starting at price, they provide significant cost saving for any smaller project.
Order Today, Ships Fast! * See our Web site for details and restrictions. © Copyright 2022 AutomationDirect, Cumming, GA USA. All rights reserved.
Automation Direct - DW 01-26.indd 5
45-day M
ey-BackG on
45
ee rant ua
• The Productivity1000 series PLC is the super compact yet highly capable member of the Productivity controller family. This series is packed with numerous features including multiple communication ports, built-in data logging, and easy expansion, but is housed in a smaller, slimmer design.
www.ProductivityPLCs.com
1-800-633-0405
the #1 value in automation
1/14/26 1:47 PM
PRECISE. ROBUST. AVAILABLE.
SERVO RATED
CD® Couplings • Zero-Backlash & High Torsional Stiffness • Engineered Performance for Reliable 24/7 Operation • Servo-Rated for Reversing, Positioning & Precision • Single-Flex, Double-Flex, Floating-Shaft Solutions
www.zero-max.com 800.533.1731
• Standard Models / Fully Customizable • Engineering Assistance / Fast Delivery
Zero-Max ZeroMax -Full DWPage 01-26.indd ads 2025 2026 5 r7 Design World.indd 1
4/16/25 12/15/25 1/12/26 3:15 2:57 3:15PM PM
A
RY
VERSA NI N CATALOG
ED
ITION
Keystone - DW 01-26.indd 5 DW K-Blog_SS_Radar_1-26p.indd 1
1/12/26 10:40 2:58 PM 12/3/25 AM
Insights
Figuring out AI for engineers how engineers can and should use AI, The explosion of generative AI over along with educational content from the last couple of years has changed both brands. You’ll find information a lot in the business world. Workers in on fundamentals, terminology, AI industries from computer programming in products you’re using, and best to accounting have found ways for practices for using generative AI in LLMs to make their work lives easier. design. In journalism, for example, fears of AI Nearly two-thirds of engineers say simply doing all the writing persist, they struggle to verify AI-generated although we don’t use these tools to information accuracy, which is why we’re write here at WTWH Media. Instead, we endeavoring to bring all our humanuse it as sort of junior level assistant. written content on AI and engineering Interviewing an industry leader? into one simple place for you to access. ChatGPT can be a good start to Over the coming months, we’ll suggesting interview questions; plug be building more educational tools that person’s details in and give it some for both mechanical engineers and angles you’d like to cover. Working electrical engineers including premium on a business plan for a new editorial content that includes quarterly reports, product? Gemini can offer some bullet deep dives, webinars, and videos. points to help you flesh out the details. We’ll also be pulling more of our sister Crafting a new special section for print? engineering brands into the fold, to Perplexity might give you some good give you more breadth of information. ideas for a catchy name or a tagline. And perhaps most importantly, we For engineering professionals, these sorts of administrative level tasks will add interactivity to the collective, including the opportunity to connect can be helpful, but from the engineers with your fellow engineers in a forumI speak with, there is a great deal of like environment. Our goal is to be in this (legitimate) concern about using AI together with you, our engineer readers, tools or LLMs for anything approaching component selection, system design, or and make this a group effort. Don’t get left behind in this new age the like. Initial results of a reader survey of an AI-enhanced workforce. We’re we’re conducting shows that emerging here to help you dig through the clutter technologies and AI in automation and make sense of what makes sense are the top things you’re interested for engineers, what you can trust, and in seeing more coverage of in our how you need to adapt to be the best publications. engineer you can be in 2026, 2030, To help meet that need, we’re launching a new cross-brand site among and beyond. DW two of our core engineering brands, Design World and EEWorld, called the AI Engineering Collective. The beta version of AI Engineering Collective is located at designworldonline.com/ aiengineeringcollective (or Paul J. Heney • VP, Editorial Director scan the attached QR code) pheney@wtwhmedia.com and already has some core content on Connect with me: linkedin.com/in/paulheney 4
Insights DW 01-2026 v2 final.indd 4
DESIGN WORLD
JANUARY 2026
www.designworldworldonline.com
1/12/26 3:02 PM
maxon - DW 01-26.indd 5
1/12/26 2:58 PM
1 • 2026 | VOL 21 NO 1 | D E S IG N WO R L D O N L I N E .C O M
ON THE COVER:
ROBOTS ARE BUILDING YOUR HOUSE DEPARTMENTS 4
Insights
12
Design For Industry
18
Design Notes
63
Ad Index
64
Technical Thinking
PAGE 39
FEATURES 26
32
M OT IO N C O N T R O L
A simple PID loop tuning technique: Part 2 of 2
Proportional, integral, derivative (PID) position servo-loop tuning can be daunting. However, one simple technique works well for most systems. L I N E A R M OT IO N
The many layers of performance and specifications in motion control
Achieving true precision in motion control applications requires a deeper understanding of the full motion control system from the mechanics to the motors, drives, and controls.
39
M E C H A N IC A L
Robots are building your house
Robots are reshaping disaster recovery by rebuilding wildfire-ravaged homes faster and smarter. ABB Robotics is using mobile robotic microfactories to deliver high-quality, resilient housing in a fraction of the time.
CONGRATS WINNERS! PAGE 44
6
DESIGN WORLD
TOC DW 01-26 v1.indd 6
JANUARY 2026
www.designworldworldonline.com
1/16/26 6:44 AM
251215_SYPAYP_DW_US.indd 1 DigiKey - DW 01-26.indd 5
12/12/25 1/12/26 5:07 2:59 PM PM
SECURE YOUR SUCCESS GROWTH SPACE DESIGN QUALITY ASSEMBLY BEARING INNOVATION CONNECTOR SEALS RELIABILITY IDEAS TM
As the inventor of the edgewound wave spring with 100+ years of innovation, here’s why Smalley is The Engineer’s Choice®:
ᘩ 11,000+ standard parts in stock
ᘩ Customizable with No-Tooling-Charges™
ᘩ Trusted performance in 25,000+ applications ᘩ Award-winning quality backed by leading industry certification
Smalley Wave Springs
ᘩ Same Force, Same Travel as a coil spring
ᘩ Lightweight and compact
ᘩ Diameters from .118" to 120" in 40+ materials
Buy Now or Request Samples at smalley.com or Call 847-719-5900
Smalley - DW 01-26.indd 5
1/12/26 2:59 PM
Don’t Compromise use MAIN Manufacturing The hydraulic flange you want, when you want it. Informed - MAIN’s engineers are active in SAE, NFPA, & ISO tech committees
Dependable - Over 60 years of service to the industry
Quick - MAIN has over 200 tons of raw material
and over $5 Million SAE J518/ISO6162 flanges and adapters
Main Mfg - DW 01-26.indd 5
MAINmfg.com
Made in Grand Blanc, MI
800.521.7918
info@mainmfg.com
1/12/26 3:00 PM
JA N U A RY 2 0 2 6 • D E S I G N W O R L D O N L I N E . C O M
ENGINEERS
2026
EDITORIAL
DIGITAL MARKETING
VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com
VP, Marketing Annie Wissner awissner@wtwhmedia.com
Editor-in-Chief Rachael Pasini rpasini@wtwhmedia.com
Digital Marketing Manager Taylor Meade tmeade@wtwhmedia.com
Managing Editor Mike Santora msantora@wtwhmedia.com
Engineering.com partnered with Energage to recognize excellence in engineering companies around the U.S. Congratulations to this year’s Top Workplaces for Engineers!
Digital Production Manager Reggie Hall rhall@wtwhmedia.com Digital Production Specialist Nicole Johnson njohnson@wtwhmedia.com
PRODUCTION SERVICES
Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com
Executive Editor Lisa Eitel leitel@wtwhmedia.com
Customer Service Rep Tracy Powers tpowers@wtwhmedia.com
Senior Editor Miles Budimir mbudimir@wtwhmedia.com
PEOPLE DRIVEN. ENGINEER APPROVED.
DIGITAL PRODUCTION
Marketing Graphic Designer Hannah Bragg hbragg@wtwhmedia.com Digital Production Specialist Elise Ondak eondak@wtwhmedia.com
Customer Service Rep JoAnn Martin jmartin@wtwhmedia.com
Senior Editor Mary Gannon mgannon@wtwhmedia.com
Digital Design Manager Samantha Goodrich sgoodrich@wtwhmedia.com
WEB DEVELOPMENT
PRINT CREATIVE SERVICES
Customer Service Rep Renee Massey-Linston renee@wtwhmedia.com
Web Development Manager B. David Miyares dmiyares@wtwhmedia.com
VP, Creative Director Matthew Claney mclaney@wtwhmedia.com
Customer Service Rep Trinidy Longgood tlonggood@wtwhmedia.com
Front End Developer Melissa Annand mannand@wtwhmedia.com
Art Director Allison Washko awashko@wtwhmedia.com
Software Engineering Manager David Bozentka dbozentka@wtwhmedia.com
AUDIENCE DEVELOPMENT
Director, Audience Growth Rick Ellis rellis@wtwhmedia.com Audience Growth Manager Angel Tanner atanner@wtwhmedia.com
WTWH.ME/ENGINEERTOPWORKPLACE
Join the conversation
on LinkedIn www.linkedin.com/company/design-world-online
As a reminder, nominations are welcome all year round! Visit topworkplaces.com/engineering-com to nominate your company for consideration on next year’s list.
2023
2023
SILVER REGIONAL AWARD
BRONZE REGIONAL AWARD
asbpe.org
asbpe.org
asbpe.org
2020-2024
2011 - 2020
2014 - 2016
2013 - 2017, 2021
Medical Design & OUTSOURCING 10
Staff Page DW 01-26 v1.indd 10
2023
SILVER NATIONAL AWARD
DESIGN WORLD
JANUARY 2026
www.designworldworldonline.com
1/13/26 8:16 AM
deltron.com 800-245-5013
Linear Motion Specialists
PROUDLY made in the Micrometer Positioning Stages • Available with Ball or Crossed Roller Technology • Single and Multi Axis Configuration Available From Stock • Offered in Inch and Metric Sizes • Subminiature and Low Profile Models Available Del-Tron’s micrometer positioning stages and crossed roller positioning stages are available with travels ranging from .25” to 2.0”and are available in X, XY and XYZ configurations carrying loads ranging from 4 lbs to 160 lbs. All model numbers are available with inch or metric micrometers and mounting holes. Most models are available with locking micrometers and all models can be supplied with our Posi-Lock friction locking mechanism to secure the table. Positioning accuracies range from 0.0005” per inch of travel straight line accuracy on our ball slide positioning stages to 0.0001” per inch of travel straight line accuracy on our crossed roller positioning stages.
Ball & Crossed Roller Slides • 250 Models to Choose From • Lightweight Aluminum Construction • Factory preloaded for High Precision • Long Life, Needs No Lubrication Del-Tron’s linear ball slides and linear crossed roller slides offer engineers and designers the flexibility to choose the right linear slide technology for their application offering several levels of precision ranging from a straight line accuracy of 0.0005” per inch of travel to 0.0000040” per inch of travel straight line accuracy. Available with inch or metric holes and hole locations these factory preloaded, low friction, light weight linear slides are ready for installation right out of the box. For vertical applications involving higher speeds and cantilevered loads please consider our Anti-Creep linear ball slides. These linear slides contain a one piece ball retainer to maintain the position of the ball bearing retainer.
Posi-Drive Stages • Lead Screw with Anti-Backlash Nut Design • Compact, Accurate, Repeatable Linear Motion • Motor mount and Motor Coupling Included • Available with Ball or Crossed Roller Technology Del-Tron’s Posi-Drive™ lead screw actuators are compact and economical, taking the work out of designing linear motion systems. Available in 3 size profiles, our lead screw actuators require no alignment of components and install with standard fasteners. They are fitted with anti-backlash lead screws and multi-beam couplings with high speed misalignment capability and standard NEMA motor mounts. Available in one, two or three axis configurations these stages travel up to 12”. The crossed roller slide option increases load capacity up to 180 lbs. and 100 million inches of travel is possible at 1/2 rated load.
ISO 9001:2015/AS9100D CERTIFIED
MADE IN USA
Order Today! 800.245.5013 • deltron.com Del-Tron - DW 01-26.indd 5
1/12/26 3:00 PM
Design For Industry MEDICAL
AI inference system creates neural hub for medical devices Advanced robotics and AI-driven medical systems require real-time intelligence, functional safety, and reliable sensor-to-processor communication to enable autonomous decision-making in safety-critical environments. Meeting these demands requires purpose-built computing platforms that can handle highbandwidth data flows with ultra-low latency. Advantech launched its MIC-735 AI inference system, built on NVIDIA IGX Thor. Strengthening its collaboration with NVIDIA and ecosystem partners, Advantech aims to drive the adoption of physical AI in robotics and healthcare environments.
The company’s system integrates the NVIDIA Holoscan platform with its proprietary Holoscan Sensor Bridge, enabling high-bandwidth sensor connectivity and ensuring interoperability for real-time communication between multiple sensors and AI processors. This architecture transforms the MIC-735 into the “neural hub” of next-generation robotics and medical systems, connecting cameras, sensors, and AI models through the NVIDIA IGX T5000 module to deliver safety-critical AI inference and ultra-low latency control. Designed for industrial robots, autonomous mobile robots (AMRs), and AI-driven medical devices such as
endoscopic and surgical visualization systems, the MIC-735 ensures stable operation from -30 to 60° C. It supports functional safety MCU modules and 5G/ QSFP 4×25 GbE interfaces, ensuring high-speed, coordinated sensoractuator communication so robots and instruments can sense, think, and act safely and autonomously. The MIC-735 features a MIPI interface that enables direct camera connectivity or integration with Advantech's Holoscan Sensor Bridge, allowing connection to multiple imaging sensors and ensuring high-throughput data exchange between sensors and the NVIDIA IGX Thor. Advantech's robotics portfolio also includes the MIC-742-AT Edge AI System, embedded with the NVIDIA Jetson T5000 module, designed for high-performance vision and sensor fusion applications. The MIC-742-AT features a flexible I/O design that supports both direct MIPI connections and MIPI-to-8+ port GMSL camera inputs, enabling robust, synchronized multicamera perception crucial for robotic navigation, object recognition, and spatial awareness. Integrated with the Holoscan Sensor Bridge using GPUDirect Remote Direct Memory Access (RDMA) technology, the platform allows network adapters and storage devices to directly read from or write to the NVIDIA IGX Thor, ensuring highspeed, deterministic data flow between camera sensors and AI processors for real-time vision analytics and control. DW Advantech advantech.com
12
DESIGN WORLD
DFI DW 01-26 v3 final.indd 12
JANUARY 2026
www.designworldworldonline.com
1/12/26 3:12 PM
Design For Industry OFFSHORE
POWER TRANSMISSION
RETAINING DEVICES & maintenance & assembly tools
Corrosion-resistant encoder stands up to saltwater
BEARLOK
SHOELOK
BEARLOK Shrink Disc
BEARHUG
CLAMPNUT
TANGENTLOK
PRECISION NUTS & WASHERS
Marine environments expose components, such as encoders, to saltwater, temperature fluctuations, pressure variations, and corrosive conditions that rapidly degrade standard optical and capacitive sensing systems. These harsh operating conditions require specialized materials and sealed construction to ensure reliable angular position feedback in ship propulsion systems, offshore platform equipment, and subsea robotics, where encoder failure can compromise safety-critical operations. Austria-based Flux recently released its IND-MAX-100 Marine Grade inductive angle encoder, a new variant within the IND-MAX family designed specifically for naval and offshore environments. The series uses inductive technology to deliver noncontact, wear-free measurement. This helps ensure reliability and resistance to shock, vibration, and environmental contaminants, such as dust, oil, and moisture. The encoders are available in thousands of standard configurations, with outer diameters ranging from 125 to 375 mm. Flux also customizes encoders to exact customer specification requirements. The IND-MAX-100 specifically features a housing made of marine-grade stainless steel, providing the necessary corrosion resistance for continuous saltwater immersion. The corrosion-proof design makes it suitable for subsea equipment, including underwater robotics and remotely operated vehicles (ROVs), hydraulic actuators, oil and gas exploration equipment, heavy-duty industrial machinery, and marine steering and stabilization systems. DW Flux flux.gmbh
www.designworldworldonline.com
DFI DW 01-26 v3 final.indd 13
INCH and METRIC THREADS LEFT HANDED as well as RIGHT -HANDED
ADAPTER SLEEVE ASSEMBLIES
Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS Materials of: ALLUMINUM and CORROSION RESISTANT STEEL NUTS & WASHERS
HARDENED TONGUE WASHERS
SPLIT COLLAR
RETHREADING DIES
ADJUSTABLE SPANNER WRENCH
BEARING ASSEMBLY SOCKET
W
HI
TT
ET
-H
IG
GI
NS US
A
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. 33 Higginson Avenue, Central Falls, Rhode Island 02863 Telephone: (401) 728-0700 • FAX: (401) 728-0703 E-mail: info@whittet-higgins.com Web: www.whittet-higgins.com
DESIGN WORLD
13
1/12/26 3:12 PM
Design For Industry A E R O S PA C E & D E F E N S E
Power-dense motors enable supersonic flight Astro Mechanica is a Californiabased engineering collective on a mission to make supersonic travel flexible, accessible, and sustainable. To achieve this, the company is integrating its advanced airframe and engine technologies — including Duality, its proprietary dual-use propulsion
14
DESIGN WORLD
DFI DW 01-26 v3 final.indd 14
JANUARY 2026
system — with a new flight operations model. With the Duality engine and an advanced airframe design, the company aims to unlock supersonic aircraft with near-term military and civilian applications, including national defense, orbital launch, and long-range cargo delivery.
Currently, Duality uses powerdense electric motors to separate the propulsion unit from the turboshaft core. The turbogenerator uses a gas turbine to generate electricity via two motors, which power four Helix SPX242-94 motors in the propulsors that control the fan and compressor.
www.designworldworldonline.com
1/12/26 3:12 PM
This hybrid-electric architecture enables it to mimic a turbofan at subsonic speeds, a turbojet at lower supersonic speeds, and transition to a ramjet at very high supersonic speeds. This adaptability optimizes performance across a wide range of flight speeds and profiles, creating a combined-cycle turboelectric adaptive engine that is efficient from takeoff to Mach 3. Paired with an advanced airframe design, Astro Mechanica is developing the world’s
first supersonic aircraft with transpacific capability. At the heart of Astro Mechanica’s fourth-generation engine prototype are the four Helix SPX242-94 motors, which power the two-stage compressor of the propulsor unit. These motors can deliver 400 kW of peak power with a maximum torque of 470 Nm, and can continuously output 300 kW and 286 Nm of torque. Critically, this is achieved in an incredibly power-dense package. Helix is also designing custom motors for the fifth generation of Astro Mechanica’s propulsion system. These motors will be used to power the turbogenerator in this full-scale engine. The new motors are expected to output 900 kW of continuous power in either generator or propulsion modes. Peak power is 950 kW operating at up to 20,000 rpm with a maximum torque of 575 Nm. The new motor isolation system is designed for extreme-altitude operation. Astro Mechanica is currently testing the fourth generation of its engine prototype and targeting first flight within three years. Within a decade, Astro Mechanica aims to make ondemand, supersonic passenger travel as accessible and affordable as commercial air travel is today. DW
CONNECT TECHNOLOGY WITH CONFIDENCE
Harwin’s connector products are proven to perform in extreme conditions, with shock, vibration and temperature range rigorously tested.
Helix ehelix.com
WITH OUR QUALITY, SERVICE, SUPPORT, AND HIGHLY RELIABLE PRODUCTS, YOU CAN DEPEND ON HARWIN.
Astro Mechanica
www.designworldworldonline.com
DFI DW 01-26 v3 final.indd 15
JANUARY 2026
WWW . H A RW I N .C O M DESIGN WORLD
15
Harwin third page vertical Sept 25 Design World.indd 1
29/08/2025 14:55 1/16/26 10:32 AM
Design For Industry FOOD & BEVERAGE
All-in-one palletizing kit cuts engineering costs According to a 2025 report from Data Intelo, the global gantry palletizing market is growing at a compound annual rate of 9.4%, reaching $2.7 billion USD by 2032.1 Data Intelo reports, “The adoption of Cartesian (gantry) palletizing robots is rising because of their capability to handle repetitive tasks with high precision and speed, which minimizes human error and lowers operational costs.” While attention today seems focused on the low cost of acquisition for cobot palletizing solutions, gantry palletizers deliver advantages over cobots and light payload industrial robots, including: • Higher payloads and 100% workspace coverage • Higher speed and cycle rates • Minimized space requirements • Axes and tooling tailored to the customer’s range of packaging, pallet pattern, and future needs
16
DESIGN WORLD
DFI DW 01-26 v3 final.indd 16
JANUARY 2026
• • •
Worker-safe, high-speed operation Simple linear mechanics for less wear and high reliability Long service life with fewer maintenance issues
The Festo FPaKit is as close to a gantry palletizer-in-a-box as possible, combining preassembled mechanics, controls, and software in a single kit. The two standard and one custom FPaKits are predesigned and preconfigured for loads up to 110 lb (50 kg) and speeds from four to 10 boxes per minute. Compared to starting from scratch, every FPaKit can potentially reduce engineering expenses and commissioning hassles for the machine builder, while potentially shortening timeto-market and delivering a faster return on investment (ROI) for customers. Machine builders select an FPaKit by load capacity: 44 lb (20 kg) for the LW2x kit, 66 lb (30 kg) for the LW3x
kit, and up to 110 lb (50 kg) for the MW4x customized kit. Builders receive preset, sized, and assembled axes and motors (Z-axis motor with a brake), multiprotocol servo drives, a hybrid controller with preinstalled palletizing software, cables, a software license, and a user interface. The hybrid edge controller features discrete and motion control with connectivity to the new generation Festo CPX-AP-A integrated valve terminals and AP-I remote I/O systems. The kits can include an electric or pneumatic 90° rotary unit for the endof-arm tool. Once the machine builder assembles the unit to the frame and performs the electrical installation, the software setup is fast. The user interface guides the builder through a step-by-step commissioning process and provides prioritized information and prompts for necessary actions.
www.designworldworldonline.com
1/12/26 3:12 PM
The new Festo palletizing software lets users choose their preferred web browser (Chrome, Edge, or Firefox) with no programming knowledge required. There is a one-click auto-generate function to calculate optimal pack patterns. Automatic plausibility and limit-value checks are built in to ensure the pack pattern is functional. Users gain a 3D view of the pallet that can be rotated and zoomed for visual checks, and they can reposition packaged goods using a mouse. This system ensures operators are aware of the necessary interventions. Festo offers the AX Motion Insights Electric and Pneumatic subscriptionbased predictive analytics packages to increase uptime. Customers can reduce inventory requirements by ordering replacement parts before on-machine component failure. They can also include Festo AX Data software, which enables the IT department to access data from operational technology. CODI Manufacturing a machine builder in Littleton, Colorado, recently applied the FPaKit and estimated that it saved 20 to 30 hours of engineering work and another 10 to 15 hours of assembly on its first machine. CODI offers the FPaKit-based Flex Stack Pro twin-pallet palletizer for high-throughput operations — when one pallet is being loaded, the other discharges — and the Flex Stack line of single pallet palletizers. The Flex Stack is also suitable for depalletizing and for palletizing mixed product pallets, thirdparty logistics (3PL), food, beverage, and consumer goods companies. DW Festo festo.com 1 Source: dataintelo.com/report/cartesianpalletizing-robots-market
www.designworldworldonline.com
DFI DW 01-26 v3 final.indd 17
17
1/16/26 10:32 AM
Design Notes EDITED BY MIKE SANTORA
Where the rubber meets the conveyor
Fenner Conveyors, a member of the global Michelin Group, is a world leader in the manufacturing and supply of conveyors for mining and industrial applications. Fenner needed a solution to correctly identify the bonding layer on its rubber products — without disrupting the manufacturing process. LEIBINGER’s IQJET printer took on the challenge. Fenner Conveyors supplies state-ofthe-art conveyor solutions. As a Michelin Group company, Fenner is committed to an all-sustainable approach. Fenner has been manufacturing in Australia since 18
DESIGN WORLD
Design Notes DW 01-26 v2 final.indd 18
JANUARY 2026
1890. At its facility in Melbourne, the company produces uncured rubber for splice kits and conveyor products and has processed over 200,000 kilos of rubber compound. LEIBINGER’s IQJET — mastering the idiosyncrasies of rubber for Fenner Rubber is a unique substance to print on and reliable ink adhesion to the rubber surface had to be guaranteed. It was very important to select ink that is ‘fit for purpose.’ LEIBINGER’s IQJET helped Fenner meet the challenge by clearly
identifying which side is the bonder, while introducing effective branding onto the product. “LEIBINGER’s range of ink is extensive. We tested a multitude of inks on different rubber products. LEIBINGER’s support through the entire process was amazing. We sent our material samples to Germany and had the printing samples results back within two weeks. We were then able to quickly decide on implementing the IQJET with the perfectly matched ink,” explained Jeremy Van Kaathoven, Extrusion Manager at Fenner Conveyors. www.designworldworldonline.com
1/12/26 3:30 PM
IEC Jumper Cords and Accessory Power Strips with 1-Week U.S. Lead Times? U.S.A. Made.
During ongoing production, the IQJET printer marks the Fenner logo and the correct side of the bonding layer directly on the rubber compound. Paul Leibinger GmbH & Co. KG
LEIBINGER’s IQJET –Where innovation meets reliability The IQJET printer from LEIBINGER is sound solution for coding & marking in many different industries, offering Plug & Print performance for high print quality and availability without cleaning. This cutting-edge technology revolutionizes the Continuous Ink Jet (CIJ) experience, providing five years of hasslefree operation without scheduled maintenance. With its exceptional performance, cost savings of up to 30%, and focus on sustainability, the www.designworldworldonline.com
Design Notes DW 01-26 v2 final.indd 19
IQJET helps businesses reduce their ecological footprint while greatly increasing productivity. LEIBINGER’s unique nozzle sealing technology is innovative. While conventional printers must be cleaned after production breaks, the ink remains in a closed circuit in the IQJET. This prevents the nozzle from clogging and dramatically reduces the need for solvents. Production lines remain clean, maintenance is reduced, downtime is kept to a minimum and the printer is always ready for use. As JANUARY 2026
DESIGN WORLD
19
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.
Made in America.
®
®
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
1/12/26 3:30 PM
NO BOUNDARIES, JUST CONNECTIONS CUSTOM CABLE FROM COAST TO COAST
Since 1898, we've partnered with the most innovative companies around the world to solve complex challenges and advance technology. As industry leaders, you can depend on our decades of experience, unrivaled reliability, and custom cable solutions that power technology from coast to coast and around the globe.
New England Wire - DW 01-26.indd 5
Manufacturing Custom Wire & Cable Solutions Since 1898 603-838-6624 • newenglandwire.com Lisbon, New Hampshire USA
1/12/26 3:31 PM
Jeremy Van Kaathoven, Extrusion Manager at Fenner Conveyors, values the IQJET printer’s high-quality ink range and maintenance-free operation. Paul Leibinger GmbH & Co. KG
the most economical overall concept, LEIBINGER’s IQJET delivers a low cost of ownership. Even in everyday use, the IQJET demonstrates its strengths, as Ashley Burge, Leading Hand at Fenner Conveyors, explained: "As an operator, I find the printer very easy to use. Because of the printer’s Stop & Start feature, it idles whenever not in use, greatly reducing costs and energy usage. An innovative recovery technology returns evaporated solvent to the system — saving up to 50% of the solvent used." Result Group – LEIBINGER’s local partner in Australia Result Group is a supplier of equipment & materials that help Australian businesses achieve better efficiency in their manufacturing and distribution processes. The Group, which opened its doors in 2009, has several partnerships with European and American brands, many of which are the largest companies in their field and offering unique innovative solutions — as is the case with LEIBINGER. Fenner was delighted to work with Result Group, LEIBINGER’s distributor
in Australia – especially praising the company’s great support staff. "To deliver the result our customers are aiming for, we work closely with them to understand the idiosyncrasies of their products and their businesses. This is what we achieved on this project for Fenner and for many other facilities across Australia and even beyond, “reports Michael Dossor, Group General Manager at Result Group. A great partnership with outstanding results Fenner Conveyors is the only company in Australia that can manufacture a complete conveyor system from head to tail — and all in-house. LEIBINGER and its gamechanging IQJET printer are now further streamlining the process for Fenner. DW
Interpower® Accessory Power Strips & Jumper Cords for Worldwide Designs. U.S.A. Made. 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.
®
®
LEIBINGER leibinger-group.com
Toll-Free Phone: (800) 662-2290 E-mail: info@interpower.com Business Hours: 7 a.m.–5 p.m. CST
Order Online! www.designworldworldonline.com
Design Notes DW 01-26 v2 final.indd 21
JANUARY 2026
DESIGN WORLD
21
www.interpower.com
1/12/26 3:30 PM
Design Notes EDITED BY MIKE SANTORA
Lifting America: the drive systems powering the nation’s heaviest work Whether it’s moving a coil of sheet steel to a stamping line or setting a massive cast iron forging onto the bed of a CNC boring mill, manufacturers depend on cranes, trolleys, and hoists to lift and transport heavy objects. This is the job of OMi Crane Systems, a company that’s been designing, building, and servicing industrial lifting systems since 1969. Founded in Dallas, Texas, the manufacturer has long since moved
to nearby Royse City, where it now has a 76,000-sq.ft. manufacturing facility, more than 100 employees, and a support network that includes three full-service branches in Houston, Dallas, and Alabama, along with satellite service teams operating out of Florida and Ohio. OMi sells many of its cranes to companies in its home state, but as Vice President of Operations Brandon Rue pointed out, the manufacturer has
customers in New York, Washington, Ohio, and many places in between. “We ship all over the country,” he said. Unlike companies focused on ports or marine work, OMi specializes in indoor overhead cranes — mainly electric overhead traveling cranes that operate inside steel warehouses, coil handling plants, and metal fabrication facilities. Its products aren't massproduced, however. “Everything we make is engineered to order,” Rue
For OMi Cranes and its customers alike, having a reliable drive system supplier isn’t just about convenience, it’s about keeping material moving efficiently and without fail.
22
DESIGN WORLD
Design Notes DW 01-26 v2 final.indd 22
JANUARY 2026
www.designworldworldonline.com
1/12/26 3:30 PM
explained. “That’s because every facility is different, and every customer calls for different lifting capacities, travel speeds, duty cycles, and so on. That said, probably 95% of the gearmotors on our heavy-duty OEM components come from NORD DRIVESYSTEMS.” Tightly focused It’s a relationship that spans more than 25 years. At first, OMi began using NORD gearboxes and motors on a fairly selective basis, but the partnership deepened around 2011 when OMi started building its own hoists. That move called for bigger gearboxes and more horsepower — and it made ready-made drive solutions even more critical. NORD provides a complete, preassembled unit that fits neatly into OMi's production flow. “We didn’t start using NORD almost exclusively until we started offering a complete hoist that we build inhouse," Rue said. “A lot of suppliers in this industry will make a gearbox and then put a motor on it, and sometimes vice-versa, but not only does that slow everything down, it also makes it harder to get parts. We didn't want to go that route, so we decided to standardize on NORD gearmotors — motor, brake, and gearbox — roughly 15 years ago. Since then, we’ve found that using preengineered drive units directly from the catalog makes it easy to customize to our customers’ needs, which is where we differentiate ourselves from the competition.” At its core, OMi specializes in the design and manufacturing of electric overhead traveling cranes. Unlike many suppliers that offer off-the-shelf systems, OMi takes a customized approach, tailoring every crane to the exact specifications of the building and the application it serves. "Yes,
www.designworldworldonline.com
Design Notes DW 01-26 v2 final.indd 23
there are similarities between jobs and customers, but every crane fits a specific building layout and a specific application, so the ability to optimize each one is hugely important." Most of Omi’s cranes are designed for indoor environments such as manufacturing plants and coil handling facilities. While the company can also produce outdoor gantry cranes, its primary focus remains on precision indoor lifting, with steel processing and warehousing centers representing its largest market share. The demands of these industries are unique. Steel coils, for example, can weigh tens of thousands of pounds, and facilities often run 24/7 operations where a stalled crane can halt production. Many of OMi's customers require cranes that not only lift heavy loads but also perform a high number of cycles each day without overheating or wearing down prematurely. That makes the engineering behind each crane and its components critical to long-term reliability. One of the standard and most requested options on an OMi crane is the company’s “built-up hoist and trolley” system. As Rue explained, these assemblies are often the most customized and technically demanding parts of the crane. “The hoist does all the work, which is why we’ll often use one of the bigger NORD units, such as the SK 10 with a hundred horsepower motor.”
THIN ENOUGH? BXR Brakes • Up to 480 in-lbs static • Up to a 1.125'' bore • 19 watts or less • Very thin profile reduces weight & saves space • Modified–Standard brakes available for special needs • 1000’s in use world-wide
Customization conundrum This broad horsepower range — from half-horsepower travel motors to the 100-horsepower hoist drive just mentioned — gives OMi the ability to spec out each crane's lifting capacity exactly to the application. Yet speed is also crucial. In high-throughput environments like coil warehousing,
JANUARY 2026
DESIGN WORLD
800.533.1731 www.mikipulley-us.com
23
12/15/25 3:45 PM
Miki Pulley Design World BXR Brake ad 2026 1/12/26 3:30 PM
Design Notes
even minor differences can significantly impact production, which is why it’s not uncommon for customers to request lifting speeds tailored to the flow of their assembly lines or staging areas, where even seconds shaved off a cycle can add up to meaningful gains over time. “We cater the hoist to our customers’ needs,” said Rue. "For instance, a couple of feet a minute on a hoist, when spread out over several days or a week, makes a big difference in the number of picks they can make. So, if they want the hoist to go 21-ft per minute instead of 19-ft per minute, we make it go 21.” As any manufacturer knows, delivering this level of customization day after day can be expensive. Piecing together motors and gearboxes from different vendors wasn’t an option for a company focused on delivering made-to-order systems at scale. Eliminating assembly steps inside Omi’s factory also reduces risk during final crane assembly, since every matched set arrives from NORD already configured for integration. “To remain competitive, we need to build a crane as quickly and efficiently as we can,” Rue said. “Ease of manufacturing played a big role in our decision to partner with NORD.” Using standardized components also helped to streamline Omi’s engineering process. The company’s design team can size and select drives from NORD’s catalog without relying heavily on external technical support, and they routinely use myNORD online customer tools to quote units, download 3D models, and generate drawings directly compatible with Omi’s internal CAD libraries. “We size it, we pull the drawings, and we drop it into our models,” Rue explained. “It’s simple and it saves a lot of back and forth.” Prove it Several recent projects show the scale of their partnership. One job in Bowling Green, Kentucky, required eight cranes and 56 NORD units, with motor ratings from three to 100 horsepower. Another in nearby Brandenburg involved 16 cranes and 110 NORD gear motors across six bays, while a third — this one supporting an aluminum processor — used five cranes and 50 NORD units. Each facility came with its unique challenges. In Bowling Green, for example, OMi built the cranes for
24
DESIGN WORLD
Design Notes DW 01-26 v2 final.indd 24
JANUARY 2026
Each of the lifting systems at OMi Cranes is precisely calibrated and tuned to meet the customer’s unique specifications.
www.designworldworldonline.com
1/12/26 3:30 PM
a completely automated coil handling system where cranes communicate with the facility’s ERP software to manage inventory movements without human input. In Brandenburg, the facility required high-speed coil stacking capabilities and extremely high service levels able to withstand the company’s continuous operation. And the aluminum processor project, though smaller, demanded precision movement with fine load control to protect delicate material during handling. In every case, OMi designed each crane to fit the customer's plant layout, throughput needs, and uptime goals. "If a customer loses a motor or gearbox, NORD can usually get us a replacement very quickly, sometimes within a day or two,” said Rue. The service side has been just as strong. “With some
vendors, we might have to call several times before we can get somebody on the line,” he added. “With NORD, we don’t have that problem. Even when our primary contact is unavailable, we quickly get routed to someone who can help, avoiding costly downtime.” OMi has never had to use NORD’s 911 emergency breakdown hotline despite running a high volume of the company's products over many years. Instead, their engineers work independently, sizing components, pulling drawings, and submitting orders directly through myNORD, NORD’s online customer portal, without having to stop and make phone calls to sales or technical support. If a crane goes down, production can grind to a halt, Rue concludes. For OMi Cranes and its customers alike, having
AMERICA’S FIRST SPRINGMAKER More than just a manufacturer. We set the standard for world-class precision springs.
a reliable drive system supplier isn’t just about convenience — it’s about keeping material moving efficiently and without fail. “We’ve enjoyed very steady growth over the years. I attribute most of this to our employees — our engineering team, the sales and quoting people, and our team on the production floor. That said, NORD deserves at least some of the credit. “They’ve been great to work with and have an equally solid product line. We’re quite pleased with the partnership.” DW
NORD DRIVE nord.com
Constant Force Springs
Spiral Torsion Springs
Helical Isolators
Power Springs
Helical Springs
Torsion Bars
Wire Forms
Mechanical Assemblies
Spring Reels
Stampings
Variable Force Springs
SpringCompany.com | 1 Spring Ave. Lansdale, PA 19446 215.368.7700
Design Notes DW 01-26 v2 final.indd 25
1/16/26 10:34 AM
Motion Control
A SIMPLE
PID
CHUCK LEWIN FOUNDER AND CEO PERFORMANCE MOTION DEVICES INC.
PART 2 OF 2
LOOP TUNING TECHNIQUE Proportional, integral, derivative (PID) position servo-loop tuning can be daunting. However, one simple technique works well for most systems.
T
he first installment of this twopart series detailed a simple technique called step-response tuning that helps identify good PID-gain settings in motor-positioning applications. This manual tuning method uses repeated instantaneous ‘step’ moves to determine whether the system is underdamped, critically damped, or overdamped. Repeated iterations can identify optimal PID loop settings. The step-response tuning session should ideally yield PID gain settings that provide smooth, quiet, and accurate 26
DESIGN WORLD
Motion Control DW 01-26 v2 final.indd 26
JANUARY 2026
position control. Now, let’s consider some methods to further improve system performance. Verifying PID settings with real trajectory profiles Instantaneous step profiles simplify analyzing the servo loop behavior, but they almost never represent the profiles that the controller machine will use in the actual production application. On the contrary, as much as possible, the actual profiles should try to avoid instantaneous changes of position (or www.designworldworldonline.com
1/12/26 4:40 PM
www.designworldworldonline.com
Motion Control DW 01-26 v2 final.indd 27
JANUARY 2026
DESIGN WORLD
27
1/12/26 3:39 PM
Motion Control
Commanded acceleration This is a position PID loop with feedforward.
Commanded velocity
KAff KVff gain P
Profile generator
Commanded position
Position error
To current loop
D
Actual position
Static bias Position sensor
Performance Motion Devices’ ICs are suitable for use in medical, laboratory, semiconductor, robotic, and industrial motion control applications. MC58113series ICs are a PMD Magellan offering for advanced position control of stepper, brushless dc, and dc brush motors. Capabilities include field-oriented control, trapezoidal and S-curve profiling, and direct encoder and pulse and direction input.
velocity, or even acceleration) to minimize resonant vibration being injected into the machine mechanics. ION/CME N-series drives Whether trapezoidal, S-curve, are ultra-compact PCBor some other trajectory profile mountable intelligent drives meant to simplify shape, confirm the stability machine building. They of the final selection of PID execute advanced servo loop settings with the actual and stepper motor control, trajectories the machine will see. S-curve point-to-point Acceleration setting — If profiling, field-oriented control, downloadable user the current command to the code, and general-purpose amplifier reaches 100% of the digital and analog I/O. programmed current limit the motor actual position will rapidly fall behind the commanded position leading to an excessive position error value. Related to this, high accelerations may exceed the current output capacity of the power supply being used, potentially for a drop in the supply voltage. The remedy for both conditions is to lower the trajectory acceleration. Deceleration setting — Similar phenomena can occur during deceleration. The amplifier command can saturate 28
DESIGN WORLD
Motion Control DW 01-26 v2 final.indd 28
JANUARY 2026
www.designworldworldonline.com
1/12/26 3:39 PM
01012026_Design_World_EtherCAT_Ad(HalfPageVertical-3.625x10).pdf 1 12/17/2025 4:08:30 PM
Drive Forward with EtherCAT from Delta Motion with a negative value and depending on the design of the power supply the supply voltage can increase to a dangerous level. The later occurs when the motor acts as a generator. Many controllers provide a feature called shunt regulation to address this. Shunt regulation uses a special circuit that ‘shunts’ current through a resistor to absorb the excessive supply voltage. Maximum velocity setting — With motor-rpm increases come ever-higher induced voltage opposing the drive voltage. Called back electromotive force or EMF, this limits the top speed at which a given motor driven at a given voltage can rotate. Trajectories approaching or exceeding this top speed won’t keep up with the commanded position, so excessive position error will occur. The remedy is to lower the trajectory velocity or change the system with increased supply voltage or choosing motors with lower back EMF per rpm.
C
M
Acceleration and velocity feedforward Feedforward techniques improve real-world servocontroller performance — especially if positioning accuracy during the move is important (as in machine tools, 3D printing, and tracking applications). Feedforward has no effect on system stability and so is a kind of free pass for boosting axis performance.
Y
CM
MY
CY
CMY
K
Frequency-based motion analysis tools and filters The step-by-step tuning process represents a common and straightforward approach to tuning PID loops. But there are more quantitative approaches — particularly for verifying the behavior of a specific position loop controller and load. Many controls vendors provide frequency-based tools such as Bode plots to support these approaches. Bode plots can help characterize mechanical systems and determine control-loop characteristics such as bandwidth and phase margin. One Bode-plot output may be the identification of natural resonances in the mechanical system. While a properly tuned PID can help reduce the impact of this, active filtering within the servo loop, often in the form of biquad filters are the compensating mechanism of choice. Many controllers provide general-purpose biquad filters inside the position loop. A treatise on characterizing system mechanics and compensating for resonances is beyond the scope of this article but good references abound — and include George Ellis’ Control System Design Guide. www.designworldworldonline.com
Motion Control DW 01-26 v2 final.indd 29
DESIGN WORLD
SENSORS
HYDRAULIC VALVES
MOTOR DRIVES
ONE AXIS OR FIFTY. Servo hydraulic or servo electric. Position, velocity, or force control. Direct connection or through EtherCAT. Delta RMC Motion Controllers and graphical RMCTools software make complex motion easier, smoother, and more precise. Drive over to deltamotion.com or call +1 (360) 254-8688 Get your next project moving forward more quickly than you thought possible!
29
1/12/26 3:39 PM
Motion Control
Input
Output
This is a control flow diagram of biquad filter.
IMPROVE THE
FINISH, FIT & FUNCTION
OF CRITICAL METAL PARTS
Position-loop gain scheduling Again, for many machines it’s unlikely one set of PID gain parameters will be optimal for all design functions. Some modes may need very stable and smooth operation; others may need endpoint accuracy; and yet others may need high-speed strokes for quick point-to-point transfer. To handle different operating priorities even within the same mechanism a technique called gain scheduling may be used. While ‘gain scheduling’ has specific connotations in the field of nonlinear system control, here it means activating different sets of gain parameters while the machine is operating in different modes or carrying different loads. Gain scheduling should be used in moderation but usually it’s useful to have more aggressive servo gains for moving and then less aggressive ‘at settle’ gains for holding the axis in place. Many controllers have a software-accessible ‘in motion’ flag to automatically triggered gain-value changes when the axis is moving ir arriving at specific positions, velocities, accelerations, or time. DW
Performance Motion Devices pmdcorp.com
Send us your part, we will electropolish a sample for FREE!
LEARN MORE 30
Motion Control DW 01-26 v2 final.indd 30
DESIGN WORLD
JANUARY 2026
1/12/26 3:39 PM
Supreme Performance for Small-Scale Applications
Compact Series Actuators
• 6 & 10 mm lead screw and 8 mm ball screw options • MAX stroke length up to 1000 mm • Integrated NEMA Mini-Rail Linear Guides 17 or 23 motor
• 5 sizes: 7, 9, 12, 15, & 20 mm • Self lubricating FreelonGold® • Withstands vibration & shock • Rail lengths up to 3,600 mm • Corrosion resistant
Miniature Ball Screws
• Metric sizes: 6 x 1, 6 x 2, 8 x 1, 8 x 2, 8 x 2.5, & 10 x 2 • Grades 5, 7, & 10 • Flanged and cylindrical nut configurations • Lengths up to 1,650 mm
Request a FREE Sample at bit.ly/BallScrew2026 Ball Screw
bit.ly/MiniRail2026 Mini-Rail 6402 E. Rockton Road Roscoe, Illinois 61073 USA +1.800.962.8979 • pbclinear.com
PBC Linear - DW 01-26.indd 5
1/12/26 3:32 PM
Linear Motion
THE MANY LAYERS OF
PERFORMANCE & SPECIFICATIONS IN MOTION CONTROL
ACHIEVING TRUE PRECISION IN MOTION CONTROL APPLICATIONS REQUIRES A DEEPER UNDERSTANDING OF THE FULL MOTION CONTROL SYSTEM FROM THE MECHANICS TO THE MOTORS, DRIVES AND CONTROLS.
The 400XR standard series linear positioners from Parker feature convenient mounting for XY table combinations to be quickly and easily constructed. The XR series are suitable for industries such as life sciences, fiber optics, and instrumentation, where the highest degree of precision is required.
Corey Foster Director of Automation Sales & Application Engineering Valin Corporation
I
n high-precision motion control, system performance is often judged simply by the specifications of the mechanics alone. The actuators are typically sorted by a standard set of specifications such as repeatability, accuracy, and load capability. For many applications, this is all that’s required. Others will need an understanding of those specifications to make sure the basic assumptions for them are met during installation. Achieving true precision, however, requires a deeper understanding of the full motion control system from the mechanics to the motors, drives, and controls. This is the first in a series of articles
32
DESIGN WORLD
Linear Motion DW 01-26 v3 final.indd 32
that will explore how each layer of technology contributes to the overall systems performance. First, we look at the mechanics, examining critical factors that are often overlooked: bearing deflection, body stiffness, and structural smoothness. In the second part of the series, we’ll discuss how motor design and construction can cause torque ripple which affects everything else. Next, the discussion will surround the importance of the designs and features of drives and controls for the system, and finally, we’ll end with the critical elements of the system integration itself. In all cases, there are details that do not show up on data sheets but can
JANUARY 2026
make or break the high-performance expectations of the entire system. As motion systems push beyond micronlevel accuracy, traditional specifications start to lose their typical meaning and relevance, making nuanced engineering decisions essential. This series aims to help engineers, designers and system integrators recognize just how important each decision is in putting a highprecision motion system together. What level of performance are you designing for? There are three general tiers of performance to consider in a motion control system; basic, specificationwww.designworldworldonline.com
1/12/26 3:48 PM
with certain assumptions — a certain life level, and span, a particular location of the load, a pushing-beyondgiven temperature, and even how it is the-specifications mounted. If these assumptions are not performance. met upon installation and during the In the level application, then the product won’t hit requiring just basic the expected specifications. functionality, there is Then there are the applications minimal concern about that require performance beyond the the specifications and data sheet’s specifications. These are integration of the products, often complex high-performing systems because whatever they do that need to be well understood will be good enough. Sometimes but are also an opportunity for the applications just require an actuator designers to understand the data to move something. In these cases, sheet’s specifications and what they it’s understood that something will actually mean as rules, and what are just work just by throwing it in there. Other guidelines (to quote a famous pirate). times, it is obvious that the actuator advertising 20-micron repeatability is Mechanics: The foundation of quite good enough for the application performance where 100 microns of repeatability is all For many applications, simply choosing that is needed. an actuator from the catalog with Many applications need the specified performance well above what’s performance in the data sheets. These AWad25printready.pdf 10/8/25 9:09 required AM works perfectly fine. The specifications, however, are 1derived
requirement may be an accuracy of 100 microns so selecting an actuator with a specification of 10 microns will work even if it is mounted to a wavy surface in a dirty environment. This is great for quick prototypes, proof-of-concepts, and applications where the performance isn’t critical. Some applications need the performance of the actuator specified in the datasheet. In these cases, special attention must be paid to the mounting requirements, the location of the load, and the expected lifespan in comparison to the listed assumptions for that actuator’s stated performance. For the most demanding applications, things become complex quickly. For example, if an engineer wants an XY system with the Y-actuator stacked on top of the X and the load cantilevered off to the side of the X, what is the repeatability of the load? Can you take the repeatability of the Y
C
M
Y
CM
MY
CY
CMY
K
Linear Motion DW 01-26 v3 final.indd 33
1/12/26 3:48 PM
Linear Motion
Franklin, Massachusetts
800-528-8650 www.eagletube.com
ISO 9001 & ISO 13485
STAINLESS STEEL TUBING MAKING A DIFFERENCE IN YOUR DESIGN
Distribution
Eagle ships products from inventory, including tubing, bar stock, hollow bar, wire. Stocking both seamless and welded tubing, from an extensive inventory.
Precision Cut-to-Length Eagle’s manufacturing facilities enable the cutting and deburring up to 2” diameter of fractional, metric, pipe, and hypodermic tubing.
Custom-Fabricated Components
Working to customer specifications and specializing in Bending, CNC and EDM/ ECG machining and Laser machining. Eagle can produce close-tolerance parts for the medical industry as well as other industries.
Rob Bubencik Jr. VP Operations “Eagle’s philosophy has always been that quality can only be realized through the meticulous care of our employees and the consistency of commitment” says Rob Bubencik Jr. VP Operations
and add it to the X so that 10 microns for the Y plus 10 microns for the X gives a 20-micron repeatability? Well, that doesn’t work because those directions are orthogonal to each other. So then, what if we take the geometric resultant of them using the classic A2 + B2 = C2 equation? That means that the diagonal C = SQRT (102 + 102) which gives us a repeatability of just over 14 microns. That’s great if the vertical element of the load’s location is irrelevant. The assumption of the actuator’s repeatability is usually that the load is located directly over the carriage where bearing deflection caused by the cantilevered load isn’t considered. A Y-actuator causing a cantilevered load on the X-axis is going to cause bearing deflection which may be an issue if not accounted for nor expected. In extreme cases there can even be body and base deflection to consider. Sticking with that same scenario but in a more extreme and demanding application, vibration and stability become factors as well. Having a load bouncing around uncontrollably at the end of an arm is adverse to most applications at this level of performance. The typical solution is to support the cantilever load with an outrigger bearing or a follower X-axis of some kind, all of which introduce their own variables that need to be considered. Is the Y-axis with its supporting brackets stiff enough to firmly support the load? Is it stiff enough to keep the X and X′ aligned? Or should there be a drive shaft between the X and X′ ? Or perhaps motors on both of the X and X′? One high-precision solution is to put air-bearings on granite under the cantilevered load. However, the minimal friction of air bearings can present an unforeseen difficulty in tuning the system. One application required reducing the air pressure to induce friction just so the motion of the load on XY linear motors would actually settle into position. In that application, settling within one second was acceptable 34
Linear Motion DW 01-26 v3 final.indd 34
www.designworldworldonline.com
1/12/26 3:48 PM
DznWrldMachShaft_NB4hirz.pdf
1
7/1/15
10:14 AM
End Your Machining Headaches …With Tapped or Threaded Shafts Off-The-Shelf. Our Most Requested Diameters And Pre-Cut Lengths Are Now Available, With Ends Precisely Machined.
Case Hardened Carbon or Stainless Steel*. • We never anneal so O.D. is ultra precise. • Travel length sections 6˝ – 36˝. • Reliable O.D. tolerances. • 1/4 – 1½˝ diameters. *Externally threaded shafts • Saves you time. are only available in case • Fast delivery. hardened Carbon Steel.
NB Corp - DW 01-26.indd 5
1/12/26 3:52 PM
Linear Motion
because the resulting precision was the most important requirement. Other applications will require much faster settling times. Knowing what is most important about the application will dictate which design option to pursue. Each of these design decisions affects the options available for the drives and controls. Some decisions require the controls to be more sophisticated than others. For example, a gantry with motorized X and X′ axes will require another drive plus controls that can synchronize the two in some fashion. There are factors to be considered there as well, which will be discussed in future articles in this series. Some electronics may be able to control the motion but won’t be up to the task of hitting the desired goal the mechanics were designed for. High-precision applications require a holistic approach to the entire system from the mechanics to the electronics to the integration by a knowledgeable design team who understands the goal of the application and the ramifications of all of their design decisions. This is why sharing the goal of the application with the product experts is important and not isolating them with specification requirements. DW Valin Corporation valin.com
Linear Motion DW 01-26 v3 final.indd 36
The three general tiers of performance to consider in a motion control system; basic, specification-level, and pushing-beyond-the-specifications performance.
1/12/26 3:48 PM
Veljan - DW 01-26.indd 5
1/12/26 3:51 PM
When Every Minute Counts, We’re Here To Help “If we hit a roadblock, Mitsubishi Electric is very responsive. They get on the phone with us and work things through so we can put out the highest quality product possible.” – Product Manager, Major Industrial Fan Co.
Downtime costs you time and money. That’s why Mitsubishi Electric Automation is committed to keeping your operations running – before, during, and after installation. When challenges arise, we get you back on track quickly.
Get the support you need, when you need it. Visit us.mitsubishielectric.com/fa/en/support/heretohelp/
AD-VH-00191 us.MitsubishiElectric.com/fa/en ©2025 Mitsubishi Electric Automation, Inc.
Mitsubishi - DW 01-26.indd 5
1/12/26 3:51 PM
Mechanical
ROBOTS EDITED BY: MIKE SANTORA
ARE BUILDING YOUR HOUSE
A
BB Robotics is enabling faster, safer, and more cost-effective rebuilding in areas devastated by the 2025 Southern Californian wildfires through a collaboration with Cosmic Buildings — a construction technology company
www.designworldworldonline.com
Mechanical DW 01-26 v3 final.indd 39
that uses proprietary mobile robotic microfactories. After the wildfires burned thousands of acres, destroying homes, infrastructure, and natural habitats, this initiative will deploy the microfactory in Pacific Palisades, California, to build modular structures
onsite, offering a glimpse into the future of affordable housing construction. “Together, Cosmic and ABB Robotics are rewriting the rules of construction and disaster recovery,” said Marc Segura, President of ABB Robotics Division. “By integrating our robots and JANUARY 2026
DESIGN WORLD
39
1/12/26 3:55 PM
Mechanical
digital twin technologies into Cosmic’s AI-powered mobile microfactory, we’re enabling real-time, precision automation for remote and disaster-affected sites. In the face of labor shortages and rising costs, this shows how automation can transform housing construction, by building faster, safer, and smarter.” At the heart of the innovation is the integration of ABB’s IRB 6710 robots and RobotStudio digital twin software with Cosmic’s Robotic Workstation Cell and AI-driven Building Information Model (BIM) — an end-to-end platform that handles design, permitting, procurement, robotic fabrication, and assembly. Housed within an on-site microfactory, these systems fabricate custom structural wall panels with millimeter precision and deliver them just in time for assembly at the construction site. Launched in response to the devastating Palisades and Eaton
A finished Cosmic housing unit with microfactory behind.
Innovative Automation Solutions
SENSORS: Inductive and Capacitive Proximity Sensors • Photoelectric Sensors • Level Sensors • Ultrasonic Sensors • Magnetic Sensors • Limit Switches • Interlocks
SWITCHES: Solid State Relays & Contactors • Soft Starters • IEC Contactors & Overloads • Switching Power Supplies • Miniature Circuit Breakers • Electromechanical Relays
CARLO GAVAZZI has the solution for your application needs, whether it’s our industry leading solid state relays & contactors, energy meters, monitoring relays, soft starters or sensors, available with or without IO-Link.
CONTROLS: AC and DC Energy Meters and Transducers • Universal Web Platform • CurrentVoltage- and 3-Phase Monitoring Relays • Current Transformers • Timers • Panel Meters
Contact us today, and one of our field sales representatives will show you why we are one of the fastest growing automation companies worldwide. We’ll even provide a free evaluation sample to qualified OEMs.
GavazziAutomation.com • 847.465.6100 • Sales@CarloGavazzi.com Mechanical DW 01-26 v3 final.indd 40
1/12/26 3:55 PM
Rapid Prototyping Services
• Quick to configure • Quick to build • Quick to deliver
Custom Designed Geared Motor Solutions Over 75 years’ of expertise creating the perfect combination of motor and gearbox to match a wide range of applications. We offer thousands of standard options and can easily customize any motor or gearbox to meet your exact requirements. Our product range includes AC, PMDC, and BLDC options for applications in industrial automation, material handling, and mobility solutions. Parvalux can help your products really start to motor! Contact us today to ask about our Rapid Prototyping Services. Learn more: https://www.parvalux.com/us/modular-range
sales.us@parvalux.com
Parvalux - DW 01-26.indd 5
+1 508 916 6620
www.parvalux.com
1/12/26 3:51 PM
Mechanical
Robotic cell cuts building costs by 30%.
fires, which destroyed more than 16,000 structures, Cosmic’s mobile factory marks a turning point for resilient, fast, and affordable housing solutions, aiming to build 100 homes by 2027. Cosmic integrates ABB’s RobotStudio into their AI BIM allowing the entire build process to be simulated and optimized in a digital environment before deployment. Once on location, Cosmic’s AI and computer vision systems work handin-hand with the robots, making realtime decisions, detecting issues, and ensuring consistent quality. Cosmic’s homes are built with non-combustible 42
DESIGN WORLD
Mechanical DW 01-26 v3 final.indd 42
Cosmic Buildings’ robotic cell slashes build times by 70%.
materials, solar and battery backup systems, and water independence through greywater recycling and renewable water generation. Each home exceeds California’s wildfire and energy efficiency codes. By delivering a turnkey experience from permitting to final construction, Cosmic is redefining what’s possible in emergency recovery.
JANUARY 2026
The global construction robotics market is expected to grow by 20% CAGR until 2030*. Cosmic’s mobile microfactory reduces construction time by up to 70% and lowers total building costs by approximately 30% compared to conventional methods. Homes can be delivered in just 12 weeks at $550 – $700 per square foot, compared to www.designworldworldonline.com
1/16/26 9:12 AM
z
Los Angeles’ typical $800 – $1,000+ range. The process also minimizes waste and improves build quality, easing the burden on homeowners facing underinsurance and inflated rebuilding costs. “We’re not just building homes; we’re rebuilding the playbook,” said Sasha Jokic, Founder and CEO of Cosmic Buildings. “Our mobile microfactory is fast enough for disaster recovery, efficient enough to drastically lower costs, and smart enough not to compromise on quality. By integrating robotic automation with AI reasoning and on-site deployment, Cosmic achieves construction speeds three times faster than traditional methods, completing projects in as little as three months.” The initiative in Los Angeles is part of a global movement to transform construction through automation, driven by ABB Robotics. By equipping partners with advanced tools and expertise, ABB is addressing the most pressing challenges in the construction industry, such as labor and skills shortages, excessive waste, sustainable resource use, and the growing need for affordable housing. Through real-world applications such as Cosmic Buildings, ABB is redefining how buildings are designed and delivered — making construction more resilient, resource-conscious, and accessible where it’s needed most. DW
ALL WE NEED ARE
YOUR SPECS WE'LL DO OUR PART. S TA M P I N G S , WAS H E R S , S PAC E R S & S H I M S M A D E TO O R D E R S I N C E 1919
125
0.80
REQUEST YOUR FREE
2026 BROCHURE & CALENDAR (800) -WASH ERS
bokers.com
S H O CK
& VIB
SOLU RATION
NEED A STANDARD VIBRATION ISOLATOR?
We Have A Solution for That!
ABB • new.abb.com/products/ robotics/industries/construction
800.838.3906 | sorbothane.com www.designworldworldonline.com
Mechanical DW 01-26 v3 final.indd 43
T IONS
43
Sorbothane_DesignWorld_Ad_E.indd 1
MADE IN THE U.S.A. 1/8/24 10:48 AM
1/12/26 3:55 PM
ADVANCED MATERIALS
In the category of Advanced Materials, this year’s LEAP Award winners are…
GOLD
SILVER
SiTime sitime.com Product: MEMS based precision timing technology As AI expands beyond cloud data centers to edge, mobility, and LEO satellites, SiTime’s Precision Timing technology becomes foundational. Its latest ClkSoC innovation, Chorus, integrates resonator, oscillator, and clocking functions into a single die, which eliminates quartz entirely and cuts development time by weeks. The result is more synchronized, smarter, and safer electronics everywhere.
HP Printing and Computing Solutions S.L. hp.com Product: HP 3D HR PA12 Flame Retardant (enabled by Evonik)
HP 3D HR PA12 FR, developed in collaboration with Evonik for HP’s Multi Jet Fusion platform, is a halogenfree, flame-retardant material engineered specifically for additive manufacturing. This material allows manufacturers to rethink product design by enabling the creation of lightweight, complex geometries that optimize both safety and performance — advantages that were previously difficult to achieve with conventional manufacturing methods.
44
DESIGN WORLD
Leap Award Winners DW 01-26 v3 final.indd 44
JANUARY 2026
www.designworldworldonline.com
1/12/26 4:00 PM
2025 WINNERS
BRONZE
Aeluma aeluma.com Product: Wafer-Scale SWIR Photodetector Platform Aeluma’s wafer-scale SWIR photodetector platform solves one of the most persistent barriers in photonics: how to scale the performance of shortwave infrared (SWIR) sensing without the cost, yield, and volume limitations of traditional materials. By enabling the heterogeneous integration of compound semiconductors on 12-in. silicon wafers, Aeluma brings highperformance SWIR capabilities into the realm of modern, CMOS-compatible, semiconductor manufacturing. ai175146660980_JSXawADPrint Ready.pdf
1
7/2/25
10:30 AM
C
M
Y
CM
MY
CY
CMY
K
Leap Award Winners DW 01-26 v3 final.indd 45
1/12/26 4:00 PM
COMPUTER HARDWARE & SOFTWARE
In the category of Computer Hardware & Software, this year’s LEAP Award winners are…
GOLD
Advantech Advantech.com Product: UNO-2271 V3 Advantech’s UNO-2000 series of embedded automation computers are highly rugged, fanless systems. The modular design offers strong computing performance and flexible scalability with various I/O ports for IoT Connectivity. UNO2271G V3 designed as IoT edge gateways, its pocket size design features versatile I/O ports and expansion options to support wire/wireless communication, and AI accelerators for IoT edge data analysis and processing. UNO-2271G V3 IoT edge gateway enables various industrial applications across multiple industries.
SILVER
GoldLeaf App Inc. goldleaf.app Product: GoldLeaf App hose configuration web application The GoldLeaf App is a cloud-based software designed specifically for hose assembly manufacturers. It streamlines the process of configuring hose assemblies, generating engineering drawings, work orders, and customer quotations. Key features include a customizable product library with more than 50,000 standard catalog items from major brands, allowing users to easily create and configure hose assemblies.
46
DESIGN WORLD
Leap Award Winners DW 01-26 v3 final.indd 46
JANUARY 2026
www.designworldworldonline.com
1/12/26 4:00 PM
IT IS NOT JUST A SPRING, IT IS AN APPLICATION DRIVEN SOLUTION
Rotor Clip Wave Spring
Coil Spring
IT IS Lighter, IT IS Smaller: IT IS a Wave Spring Rotor Clip Wave Springs are engineered to save space and weight by reducing spring heights up to 50%. Our experienced engineering team is ready to assist you in specifying a standard spring or developing a custom design in the material and size you require. From prototype to production, we'll provide you with the perfect spring solution for your application.
DREAM IT DESIGN IT MANUFACTURE IT SHIP IT INSTALL IT
IT IS THE RIGHT CHOICE rotorclip.com Rotor Clip - DW 01-26.indd 5
1/12/26 3:51 PM
High performance materials in custom converted quantities
CONNECTIVITY
In the category of Connectivity, this year’s LEAP Award winners are…
GOLD
Adhesive Tapes Polymer Films Industrial Fabrics Silicone Rubber
Marvell marvell.com Product: Marvell 1.6 Tbps LPO Optical Chipset The Marvell 1.6 Tbps LPO Optical Chipset ushers in a new era of data center connectivity by enabling short-reach optical links to replace bulky, power-hungry direct-attach copper cables. This purposebuilt chipset, comprised of a high-linearity 200 Gbps TIA and a matching laser driver, delivers ultra-low-power optical transmission at scale, creating a disruptive new class of linear-drive pluggable optics.
SILVER
Astera Labs asteralabs.com Product: Scorpio Smart Fabric Switch
• Slit to Width Roll Slitting • Custom Adhesive Lamination • Sheeting • Prototype Die Cutting
800-461-4161 www.cshyde.com
Astera Labs’ Scorpio Smart Fabric Switch portfolio is the industry’s first family of fabric switches built from the ground up for demanding AI workloads. Scorpio Smart Fabric Switches are optimized for AI dataflows to deliver maximum predictable performance per watt, high reliability, easy cloud-scale deployment, reduced time-tomarket, and lower total cost of ownership.
48
Leap Award Winners DW 01-26 v3 final.indd 48
DESIGN WORLD
JANUARY 2026
www.designworldworldonline.com
1/12/26 4:00 PM
2025 WINNERS
BRONZE
TeraSignal terasignal.com Product: TeraSignal TS9802 Intelligent TIA with TSLink Diagnostics The TeraSignal TS9802 addresses a longstanding challenge in high-speed optical connectivity: the lack of diagnostics in linear pluggable optics (LPO). As hyperscalers move toward LPO to power AI and ML clusters with 1.6T modules and 200G/lane performance, they’ve had to compromise on visibility and manageability — until now.
Leap Award Winners DW 01-26 v3 final.indd 49
1/12/26 4:00 PM
EMBEDDED COMPUTING
In the category of Embedded Computing, this year’s LEAP Award winners are…
GOLD
SILVER
Axiado
Morse Micro
axiado.com Product: AX3080 TCU — AI-Driven Platform Security in a Single Chip
axiado.com Product: MM8108 Wi-Fi HaLow System-on-Chip (SoC)
Modern cloud and AI infrastructure faces unprecedented cyber threats, especially at the platform level where firmware, Baseboard Management Controllers (BMC), and Root of Trust elements have historically remained vulnerable. These control plane components have become prime targets for sophisticated supply chain, firmware, and insider attacks — exploits that traditional, software-based or fragmented hardware security solutions cannot preemptively address. The AX3080 Trusted Control/Compute Unit solves this by embedding AI-powered, silicon-native security directly into the platform itself. It is the world’s first single-chip solution that merges the functionality of a BMC, Trusted Platform Module, Root of Trust, cryptographic core, secure networking, flash, DRAM, and an AI inference engine into one unified, compact system-on-chip.
The Internet of Things and Industrial IoT continue to demand wireless solutions that are power-efficient, long-range, and easy to deploy. Traditional Wi-Fi falls short in range and battery performance, while proprietary LPWAN alternatives sacrifice speed, IP compatibility, or ease of integration. Morse Micro’s MM8108 Wi-Fi HaLow SoC redefines embedded connectivity by solving these challenges, bringing unmatched scale, performance, and power savings to embedded systems. Based on the IEEE 802.11ah standard, the MM8108 operates in the sub-GHz spectrum, enabling 10x the range, 100x the coverage area, and 1000x the connected devices compared to legacy Wi-Fi, while using significantly less power.
50
DESIGN WORLD
Leap Award Winners DW 01-26 v3 final.indd 50
JANUARY 2026
www.designworldworldonline.com
1/12/26 4:00 PM
2025 WINNERS
BRONZE
Infineon Technologies infineon.com Product: PSOC Edge PSOC Edge is Infineon’s Machine Learningenhanced sensing, low power, secured, and advanced HMI high-performance microcontroller family and enables designers to deliver unmatched, highly usable end-user experiences for next-generation devices.
Leap Award Winners DW 01-26 v3 final.indd 51
1/12/26 4:00 PM
The Gold Standard in Live Swivels.
FLUID POWER
In the category of Fluid Power, this year’s LEAP Award winners are…
GOLD
INLINE & 90° NO KINKS
NO TWISTS
FULL FLOW
Danfoss danfoss.com Product: X1P Open Circuit Pumps The Danfoss X1P open circuit pump is built on the all new X1 Platform, designed to deliver increased performance and power density over the competition and previous generations. The first release of X1P includes nominal displacements of 60 and 75cc and is built around a patent pending swashplate installation technique which delivers both the shortest 75cc pump in the market, and up to 80% lower control hysteresis. This means that X1P fits into very tight spaces while being ready for advanced electronic controls of the future. These advantages come from a class-exclusive roller element cradle bearing, which also enables the highest temperature rating of the Danfoss lineup and contributes to elevated circularity and ease of remanufacturing.
SILVER
IMI norgren.com Product: IMI Norgren KIP Series Proportional Valve
SuperSwivels.com
The new IMI Norgren KIP series proportional valve offers variable and precise control of air and fluid flow in a compact, cost-effective design. Engineered for accuracy and responsiveness, the valve delivers smooth, precision flow control — suitable for applications that require exact dosing, mixing, or modulation. Its ability to adjust flow dynamically helps reduce energy and material waste by eliminating the need for constant full-flow operation.
Made in the USA. Patent #5547233. 52
Leap Award Winners DW 01-26 v3 final.indd 52
DESIGN WORLD
JANUARY 2026
www.designworldworldonline.com
1/12/26 4:00 PM
2025 WINNERS
INDUSTRIAL AUTOMATION
In the category of Industrial Automation, this year’s LEAP Award winners are…
GOLD
SILVER
AutomationDirect
Beckhoff Automation LLC
automationdirect.com Product: C-more CM5 Headless HMI
beckhoff.com Product: MX-System
AutomationDirect has added the CM5-RHMI headless HMI, which has all the powerful functionality of the C-more CM5 touch panel HMIs but without display size restrictions. This HDMI-enabled device works with televisions, monitors, projectors, and most any other HDMI display device of any size to display real-time operational data or messages. Or users can skip the local display entirely and use the remote access feature, which supports any windows PC (web browser) or Apple iOS and Android smartphones and tablets with the C-more Remote HMI mobile app.
The cabinet-free MX-System is a completely new approach to automation system design and is set to transform how machines are designed across industries. As a modular control cabinet replacement that can also be decentralized on the machine or line, the IP67-rated MX-System dramatically cuts down on engineering, assembly, installation, and maintenance work for wide-ranging applications.
www.designworldworldonline.com
Leap Award Winners DW 01-26 v3 final.indd 53
JANUARY 2026
DESIGN WORLD
53
1/12/26 4:00 PM
BRONZE
TE Connectivity te.com Product: Solderless Terminal solution to drive reliability and efficiency connection for Fan Motor Application The program is to develop a miniaturized solution that can cover the same wire range of existing MAG-MATE terminal but with much smaller body size to replace soldering process and improve customer efficiency in Fan motor application requirement. The magnet wire in coil and external lead wire are both connected by solderless solution.
MECHANICAL
In the category of Mechanical, this year’s LEAP Award winners are…
GOLD
Ogura Clutch ogura-clutch.com Product: Micro Holding Brakes: SpringApplied Holding Brakes — Down to 10mm OD Ogura’s new Micro-sized, MCNB Series holding brakes are changing the way robotics, medical, and aerospace equipment designers look at power-off holding brakes. The product offering is smaller (down to 10mm OD), lighter, uses less power, generates less heat, has ultra-fast response times, and simply improves the equipment around it. These are typically used for both safety and precision motion control. For surgical robotics, other end of arm robotics applications, aerospace applications, and more, the opportunity is to make products safer, more efficient, faster, lighter, and more reliable.
54
DESIGN WORLD
Leap Award Winners DW 01-26 v3 final.indd 54
JANUARY 2026
www.designworldworldonline.com
1/16/26 9:14 AM
2025 WINNERS
SILVER
ABB abb.com Product: ABB Baldor-Reliance SP4 Motors The ABB Baldor-Reliance SP4 motor line delivers NEMA Super Premium (IE4) efficiency in standard and severe-duty AC induction motor designs, reducing energy losses by up to 20% and extending equipment life. Originally launched in rolled steel open drip proof and TEFC configurations (¼ to 20 hp), the SP4 line now includes new cast-iron, totally enclosed fan-cooled (TEFC) models (25-300 HP) built for harsh environments. Certified for Division 2, Class I Groups A–D and Class II Groups F & G, and IP55 rated, these motors are suitable for explosive or dusty settings.
BRONZE
Bodine Electric Company
SOLVENT RESISTANT
bodine-electric.com Product: The Gearmotor Of Automated Things
EPOXY ADHESIVE
The Bodine Electric Company has applied lessons learned from past applications in warehouse robots to develop a new gearmotor for all kinds of automated machinery. They started by creating a new brushless DC motor dubbed the 42B and integrated it with Bodine’s industry-standard FX gearbox. The 42B is a 24 volt 8-pole brushless DC motor with 120° commutation and rated for a continuous load of 210 oz-in at 2400 rpm (1/2 hp).
EP41S-5 Two Part System Exceptional resistance to
METHYLENE CHLORIDE
• Also withstands acids, bases & solvents • Serviceable from -60°F to +300°F
Hackensack, NJ 07601 USA ∙ +1.201.343.8983 ∙ main@masterbond.com www.designworldworldonline.com
Leap Award Winners DW 01-26 v3 final.indd 55
DESIGN WORLD
55
www.masterbond.com
1/12/26 4:00 PM
MOTION CONTROL
In the category of Motion Control, this year’s LEAP Award winners are…
GOLD
SILVER
Sun Hydraulics, LLC
Joral LLC
sunhydraulics.com Product: ENERGEN
joralllc.com Product: Multiturn Position Sensor for Danfoss Hydraulic Motors — A Drop-In Motion Control Upgrade Joral introduces a motion control breakthrough: a multiturn absolute position sensor that mounts directly to Danfoss hydraulic motors equipped with the EMD (Electronic Motor Displacement) speed sensor pickup. By leveraging the existing mechanical interface, this innovation converts a traditional speed sensor port into a high-resolution, multiturn position feedback system — unlocking advanced motion control capabilities without altering the motor housing.
ENERGEN is designed to convert hydraulic power from an application into electrical power. Composed of an integrated generator, ENERGEN delivers a robust approach to local and remote electrical power generation. By removing failure points associated with electrical power transmission in traditional hydraulic systems, the ENERGEN provides a new solution for existing pain points. With an output power capacity of 40W, it provides reliable power for sensors, wireless communication, and smart monitoring without the need for external energy sources.
56
DESIGN WORLD
Leap Award Winners DW 01-26 v3 final.indd 56
JANUARY 2026
www.designworldworldonline.com
1/12/26 4:00 PM
2025 WINNERS
BRONZE
Delta Motion deltamotion.com Product: EtherCAT MainDevice with Redundancy Port The RMC200 motion controller from Delta Motion, combined with the ECAT EtherCAT communication module, delivers high-performance, real-time control for complex motion systems. The ECAT module enables the RMC200 to act as an EtherCAT MainDevice, providing seamless communication with electric drives, sensors, and actuators over a fast and reliable industrial Ethernet network.
POWER ELECTRONICS
In the category of Power Electronics, this year’s LEAP Award winners are…
GOLD
Infineon Technologies infineon.com Product: World’s first 300m GaN wafer technology Infineon is the first company in the world to master this groundbreaking technology in an existing and scalable high-volume manufacturing environment. The breakthrough will help substantially drive the market for GaN-based power semiconductors. Chip production on 300 mm wafers is technologically more advanced and significantly more efficient compared to 200 mm wafers, since the bigger wafer diameter offers 2.3 times more chips per wafer. GaN-based power semiconductors find fast adoption in industrial, automotive, and consumer, computing & communication applications, including power supplies for AI systems, solar inverters, chargers and adapters, and motor-control systems.
www.designworldworldonline.com
Leap Award Winners DW 01-26 v3 final.indd 57
JANUARY 2026
DESIGN WORLD
57
1/12/26 4:00 PM
SILVER
Dukosi Ltd dukosi.com Product: Dukosi Cell Monitoring System (DKCMS™) The Dukosi Cell Monitoring System (DKCMS) is a contactless, cell-level monitoring solution that is transforming high-power battery management. It significantly enhances performance, reliability, safety, and scalability, while supporting a sustainable battery value chain. At its core, DKCMS uses chip-on-cell technology for taking accurate, synchronous voltage and temperature measurements of every cell. This in-depth data is communicated to the Battery Management System with deterministic latency, greatly improving State of Charge and State of Health estimates and extracting more usable energy.
BRONZE
MOOG Construction moogconstruction.com Product: Adaptive Electrification Management System (AEMS The Adaptive Electrification Management System (AEMS) is a modular, integrated power electronics platform designed to simplify and accelerate the electrification of off-highway vehicles. Developed and tested with leading OEMs like Doosan Bobcat and CASE Construction, AEMS is a production-ready solution that delivers performance, scalability, and cost efficiency.
58
DESIGN WORLD
Leap Award Winners DW 01-26 v3 final.indd 58
JANUARY 2026
www.designworldworldonline.com
1/16/26 6:53 AM
2025 WINNERS
SWITCHES & SENSORS
In the category of Switches & Sensors, this year’s LEAP Award winners are…
GOLD
SILVER
DGD Fluid Power
Infineon Technologies
dgdfluidpower.com Product: CFT-Max (J1939 w/temp)
nfineon.com Product: Low power digital PDM XENSIV MEMS Microphone
DGD Fluid Power introduces the new CFT-Max-T18A-T to its CFT product line. This J1939 compatible cartridge flow meter features temperature outputs on the CAN-bus for reporting system temperatures. By consolidating two data packets in one sensor, it reduces installation costs and enables data acquisition using DGD's patented cartridge technology.
Our digital single backplate XENSIV MEMS Microphone IM68D128BV01, the first of Infineon’s new generation of single backplate microphones, represents a significant advance in MEMS microphone technology with a combination of high performance, low power consumption and robustness that has not been achieved before. The bottom-port PDM microphone IM68D128BV01 features low power consumption (580 µA), a high SNR (68 db(A)), extremely low audio signal distortions, a compact form factor, an IP57 rating, and high robustness against stressors like air blows and drops.
www.designworldworldonline.com
Leap Award Winners DW 01-26 v3 final.indd 59
JANUARY 2026
DESIGN WORLD
59
1/12/26 4:00 PM
BRONZE
Advantech advantech.com Product: EVA-2310 EVA-2310 is capable to measure temperature and humidity at different kinds of application, such like office, hospital, classroom, warehouse, etc. With its wide range, high penetration rate LoRa connectivity, the data transmission range can up till hundred or thousand meters away. EVA2310 can be installed directly on the walls, metal box or poles. EVA-2310 is powered by 2 AA 3.6v Li-ion batteries, battery life can last 5 years, based on certain conditions.
TEST & MEASUREMENT
In the category of Test & Measurement, this year’s LEAP Award winners are…
GOLD
Liquid Instruments liquidinstruments.com Product: Moku:Delta Liquid Instruments’ Moku:Delta is the first test and measurement device to introduce Generative Instrumentation, combining an advanced multi-instrument test platform with the power of agentic AI. This entirely new approach to test enables engineers to design and deploy custom instruments and automatically configure complex systems with natural language prompts. Instead of hours spent manually optimizing numerous parameters or creating custom code, users simply describe what they want and Moku:Delta with Generative Instrumentation configures itself. Moku:Delta delivers the highest-resolution, 2 GHz Oscilloscope and the only Spectrum Analyzer providing full 2 GHz bandwidth down to 0 Hz for precise 1/f noise measurements to fully characterize device performance. The platform also includes the highest-channel count, ultra-low noise, microwave Lock-in Amplifier for advanced research.
60
DESIGN WORLD
Leap Award Winners DW 01-26 v3 final.indd 60
JANUARY 2026
www.designworldworldonline.com
1/16/26 6:53 AM
2025 WINNERS
SILVER
BRONZE
Pico Technology
ITECH ELECTRONICS
picotech.com Product: PicoScope 3000E Oscilloscope
itechate.com Product: IT2700 Multi-channel Modular Power System
The PicoScope 3000E Series redefines PC-based oscilloscopes with up to 500 MHz bandwidth and 5 GS/s in a compact, portable, USB-powered package. PicoScope 3000E oscilloscopes are small, portable, and deliver highperformance specifications suitable for engineers working on advanced electronics and diverse embedded system technologies, either in the laboratory or on the move. Offering four analog channels with a choice of 100 MHz, 200 MHz, 350 MHz, and 500 MHz bandwidth options, plus 16 digital logic analyzer channels on MSO models, there's a model to suit every application and budget.
www.designworldworldonline.com
Leap Award Winners DW 01-26 v3 final.indd 61
The ITECH IT2700 series multi-channel modular power system, as a next-generation power testing solution, is designed to provide engineers with more flexible and efficient testing options, driving advances in power electronics and battery technology. The IT2700 multichannel modular power system integrates high precision, multifunctionality, and modularity, taking innovation to the next level. It is suitable for R&D and production lines, enhancing productivity, improving energy efficiency, and actively contributing to global green and low-carbon development.
JANUARY 2026
DESIGN WORLD
61
1/12/26 4:00 PM
Timing Pulley Stock We guarantee your pulley stock order* ships within 72 hours or we pay the UPS ground freight charges.
Pulley stock available in aluminum, steel, food-grade stainless steel, and additional materials upon request. Custom lengths available.
*Exclusions apply
Email or call to get your Pulley Stock 72-Hour Shipping Program Catalog.
PLEASE VISIT OUR WEBSITE
Manufacturer of Power Transmission and Motion Control Components
Custom Machine & Tool Co., Inc. 800-355-5949 sales@cmtco.com www.cmtco.com
Precise. Reliable. Trusted. CMT 3-21_PULLEYSTOCK_Vs7.indd 55
CMT_ads_QRcode.callout_update.indd CMT_ads_QRcode_4-11_update.indd CMT-TimingPulleyStock.indd CMT - DW 01-26.indd 5 1 32
American Engineering | American Made © Custom Machine & Tool Co., Inc.
12/13/23 11:12 AM
12/10/24 4/16/25 1/12/26 10:22 3:46 3:50 2:57 PM AM
SALES
LEADERSHIP
Ryan Ashdown rashdown@wtwhmedia.com 216.316.6691
CEO Matt Logan mlogan@wtwhmedia.com
Jami Brownlee jbrownlee@wtwhmedia.com 224.760.1055
CFO Ken Gradman kgradman@wtwhmedia.com 773-680-5955
Mary Ann Cooke mcooke@wtwhmedia.com 781.710.4659 Mike Francesconi mfrancesconi@wtwhmedia.com 630.488.9029 Jim Powers jpowers@wtwhmedia.com 312.925.7793
DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care. DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright © 2026 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher. Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only. Subscriber Services: To order a subscription or change an address visit our website at: www.designworldonline.com
DESIGN WORLD (ISSN 1941-7217) USPS PUBLICATION #25146 is published monthly by: WTWH Media, LLC; 1111 Superior Ave., Suite 1120, Cleveland, OH 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices. POSTMASTER: Send address changes to: Design World, 1111 Superior Ave., Suite 1120, Cleveland, OH 44114
2026 LEADERSHIP IN ENGINEERING PRESENTED BY
Ad Index Able Electropolishing .......................................................................... 30 AllMotion ..................................................................................................... 4 AutomationDirect ....................................................................................1 Binder USA .............................................................................................. BC Bodine Electric Company ...............................................................IFC Boker’s, Inc. .............................................................................................43 Carlo Gavazzi ......................................................................................... 40 Clippard ..................................................................................................IBC CMT .............................................................................................................. 62 CS Hyde .....................................................................................................48 Del-tron Precision Inc. ........................................................................ 11 Delta Motion ............................................................................................ 29 DigiKey ..........................................................................................................7 Eagle Stainless Tube Corp. ................................................................34 Harwin ........................................................................................................ 15 Industrial Profile Systems ................................................................. 36 Interpower .........................................................................................19,21 ITT Enidine ...............................................................................................49 John Evans’ Sons, Inc. ........................................................................ 25 Keystone Electronics Corp. ..................................................................3 Main Manufacturing ...............................................................................9 Master Bond ............................................................................................ 55 maxon ............................................................................................................5 Miki Pulley, Inc ....................................................................................... 23 Mitsubishi Electric Automation .......................................................38 NB Corp .....................................................................................................35 New England Wire ................................................................................20 Nitto Kohki ............................................................................................... 17 Parvalux, by maxon .............................................................................41 PBC Linear ................................................................................................31 PI (Physik Instrumente) LP .............................................................. 51 Rotor Clip .................................................................................................. 47 Smalley .........................................................................................................8 SMC Corporation of America ...................................................33,45 Sorbothane ..............................................................................................43 Super Swivel ............................................................................................ 52 Veljan .......................................................................................................... 37 Whittet-Higgins ......................................................................................13 Zero-Max, Inc ............................................................................................ 2
RECOGNIZING FIRMS THAT ARE DRIVING INNOVATION AND MAKING A DIFFERENCE VOTE FOR THE OUTSTANDING LEADERS IN OUR INDUSTRY IN 2026 LEADERSHIP.DESIGNWORLDONLINE.COM
www.designworldworldonline.com
Ad Index DW 01-26 v1.indd 63
JANUARY 2026
DESIGN WORLD
63
1/16/26 10:38 AM
Technical Thinking By Mark Jones
Boiling frogs and problematic spatulas I hit cancel rather than send. The boiling frog cartoon on a friend’s newsletter invoked an urge to correct. I overrode it. It is often said mistakes are how you learn. Everyone is prolearning, but no one likes making mistakes. Human nature means we like having them pointed out even less. Pointing out errors doesn’t endear you to people. Use of a flawed analogy, complete with cartoon frog, did not impact the newsletter’s conclusions. I elected to let it slide fearing it would be received like a grammar correction, more likely to annoy than to be wellreceived. I’ve been on a crusade to get flawed studies retracted. Once I started looking for problematic science to correct, it quickly became overwhelming. Errors are easy to find, far in excess of my capacity to address. I was taught that science was inherently self-correcting. I came to falsely believe that once pointed out, corrections would replace erroneous conclusions. I’ve come to realize the errors live on, zombie facts, that simply refuse to die. The case of the boiling frog was adjudicated convincingly more than 20 years ago. As a habituation analogy, it remains startingly common. It is also bunk. A frog in cold water that is slowly being heated will stay in the water and eventually perish while a frog placed in hot water will jump out, so the story goes. The slowly changing temperature, it is said, is imperceptible to the frog. Unable to perceive the danger, cooked frog. Experiments in the mid-1800s with decerebrated frogs, frogs with their brains removed, seem to be the source. German physiologist Friedrich
64
DESIGN WORLD
Technical Thinking DW 01-26 v2 final.indd 64
Leopold Goltz in 1869 published his experiments of slowly heating brainless frogs, reporting twitching observed upon immersion in hot water did not occur in slowly heated water. The fact the frogs must be brainless was lost. Brainless frogs led to an enduring zombie fact that continues to be retold in spite of multiple published corrections. My recent quests have fared no better. I took on the viral story that toxic flame retardants were found in 85% of analyzed products and exceeded the EPA reference dose, used as an estimate of normal exposure from dust and diet. The reporting led to spatula-geddon, the rampant disposal of black kitchen spatulas. I remain convinced the paper confuses hazard and risk, conflating any presence of a troublesome material with a likelihood of exposure to that troublesome material. My previous column and article failed to stop the paper from being quoted. I set out to get the paper retracted due to the serious errors of both math and method. The paper now bears two corrections. The first over miscalculating the reference dose. That was initially reported low by 10X. The second correction, prompted
JANUARY 2026
by my letter to the editor, deals with miscalculation of exposures. The correlation used to turn concentration into exposure was incorrect. The exposures are much lower than initially reported. My peer-reviewed letter to the editor describing the errors accompanies the paper. I argue, using the paper’s data, that less than 0.5% of the collected samples present a risk of exposure from intended use, a far cry from 85%. In spite of the errors, the paper has not been retracted. The response I feared for pointing out the boiling frog fallacy is pretty much what I got when I contacted the journal. Human nature fights retraction. Retraction isn’t good for the authors. It is a blackeye for the journal. It doesn’t make money for the publisher. The incentives for retracting a flawed study don’t often lead to retraction. When there is fraud, it is a different story. 2023 set a record with more than 10,000 retractions but the vast majority were for fraud. In spite of my efforts, a paper with errors in both math and methods is still there, still being quoted. Black spatulas remain imperiled by a zombie fact. DW
Good Studio | Adobe Stock
www.designworldworldonline.com
1/12/26 4:04 PM
Precision Pressure & Flow Control Designing efficient systems is about more than components and specifications—it’s about understanding how real requirements come together in the real world. By taking the time to understand the specific demands of your system, we bring decades of engineering experience and a people-first mindset to develop solutions that perform better, last longer, and fit exactly where they need to. Have a challenge you’re working through? Call or email us today and let’s connect our engineers with your engineers.
• Electronic Valves • Proportional Valves • Isolation Valves • Pinch Valves
Precision Pressure & Flow - DW.indd 1 Clippard - DW 01-26.indd 5
• Precision Regulators • Toggle & Stem Valves • Needle Valves • Electronic Controllers
• Pneumatic Assemblies • Special Manifold Designs • Pneumatic Circuit Design • Fittings, Hose & Tubing
877-245-6247 UNITED STATES • EUROPE • CHINA
1/8/26 3:09 PM 1/12/26 3:50 PM
M12 K- and L-Coding Voltage & Power supply Compact design Currents up to 16 A
www.binder-usa.com Binder - DW 01-26.indd 5 binder_USA_M12-K-L_22,225x28,2575cm_8.75x11.125Zoll.indd 1
1/12/26 3:50 PM 17.04.24 11:59