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COMPARING THE DESIGNS OF PRE-INTEGRATED LINEAR ENCODERS PG. 20

OCTOBER 2026

MOTION CONTROL

IC PA G E 1 6

ELEVATES STAGE AUTOMATION

From flying performers to shifting sets, see how next-generation motion control is engineering the magic of modern stage automation.

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COMPARING THE DESIGNS OF PRE-INTEGRATED LINEAR ENCODERS PG. 20

OCTOBER 2026

MOTION CONTROL

IC PA G E 1 6

ELEVATES STAGE AUTOMATION

From flying performers to shifting sets, see how next-generation motion control is engineering the magic of modern stage automation.

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Insights

Be bold, give your book smarts a business So far this year, I’ve interviewed incredible individuals who aren’t satisfied with the status quo. They’re positive disruptors who the world needs way more of to keep industries advancing and societies maturing. Though these individuals come from different backgrounds and have different missions, they all share a desire to make things better. Here are some notable mentions: • Dmitri Tsentalovich, cofounder and CTO of DexMat, producing Galvorn, a lightweight, flexible, carbonbased conductor positioned to replace copper in extensive aircraft signal cabling and EMI shielding applications. • Kristoffer Stokes and Philip Costanzo, cofounders of D-Glue, a debondable adhesive that makes products easier to disassemble at their end-of-life, enabling the circular economy. • David Doherty, founder of Povera Loads & Logic and developer of a new orchestration layer for aerospace projects that turns complexity into an interconnected, navigable graph. • David Helmers, founder of Wolfpack Workshop, providing design and reverse engineering services and 3D-printed prototypes and end-use products. • Mehdi Kargar, founder of Maxterial, producer of MaxShield, a coating technology designed to replace hard chrome and displace many chrome alternatives. These entrepreneurs’ journeys started by solving a problem — a materials limitation, a manufacturing bottleneck, a challenge they kept facing in their daily workflow — and the business became a vehicle so they could get the solution into the world.

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Engineers and scientists aren’t usually thought of as natural entrepreneurs, and business acumen isn’t something most engineering curricula teach. You learn all about mechanics, thermodynamics, and electromagnetism, but not how to price a job, structure a company, or say no to a bad deal. That education happens on the job, through trial and error, and the occasional expensive lesson. But here’s what I keep hearing during interviews: Business is just another skill to pick up, the same way you’d pick up a new software platform or manufacturing process. David Helmers put it well when he told me he learned his “book smarts” in school and his “street smarts” on the job, and that the second education never stops. What strikes me most (besides the technical ingenuity of what they’ve built) is that each followed the pull toward the problem they couldn’t stop thinking about, even when it meant stepping outside the role they were trained for. That’s the key takeaway here — not a formula for startup success, but a willingness to go where the work feels meaningful, and to trust that business skills will accumulate. If you’re an engineer mulling an idea or have a nagging sense that there’s a better way to do something in your field (a condition most engineers are born with), consider this your nudge. You don’t need an MBA; you just need to start from where you are and put your book smarts to work. DW

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ON THE COVER

MOTION CONTROL IC ELEVATES STAGE AUTOMATION FOR CREATIVE CONNERS | PAG E 1 6 |

DEPARTMENTS 4

Insights

Design For Industry

Design Notes

Ad Index

FEATURES

Technical Thinking

Maxterial’s MaxShield coating turns thickness and uniformity into precise, tunable design variables, offering a single coating solution poised to simplify everything from hydraulic cylinders to aerospace actuators.

PG. 32

DESIGN WORLD

TOC DW 09-26 v1.indd 6

LINEAR MOTION

Comparing the designs of pre-integrated linear encoders

Here we compare conventional wired readheads to capacitive readheads in linear-sensing technologies.

SUPPLEMENTS Aerospace&Defense

SA F E T Y

Comparing safety sensors and switches

Explore how next-generation safety switches, sensors, and interlocks are combining edge intelligence and tamper-resistant mechanics to safeguard modern industrial perimeters.

FLUID POWER

The value of unitized pistons and glands

Advances in design and materials have transformed unitized piston and gland technology from a simple assembly convenience into a highcapability solution for a wider range of hydraulic applications.

OCTOBER 2026

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Design For Industry PA C K A G I N G

Wrapping our heads around AI in packaging AI is quickly moving from concept to practical application across the packaging industry, according to two recent PMMI reports. The 2026 Building an AI Advantage in Packaging Equipment report, an update to a paper first published in 2024, credits several factors for this swift change: AI is increasingly cheaper and more accessible to companies of all sizes; increased awareness pushes projects past the pilot stage; increased confidence in the technology; and increased adoption from frontline workers who increasingly see tangible benefits from using it. The most common applications fall into five categories: knowledge transfer, machine vision, predictive maintenance, regulatory compliance, and data transparency. One expert anticipates that within five years, AI will advance from isolated optimization to coordinated, plant-wide systems

that balance throughput, quality, cost, and energy use across an entire production line. However, many challenges in AI execution remain. Top concerns include hallucinations and accountability for AI-driven errors, pushing smaller firms toward software-as-a-service models that shift risk to vendors. Cybersecurity, internal resistance to change, unclear ROI, latency, legacy data infrastructure, and job-security worries also continue to slow rollout. PMMI's report lays out a five-step path to a workable AI strategy: identify the business challenge, consult experts to find the right approach, assess system readiness, manage change to drive adoption, and build collaboration across stakeholders. PMMI's newly released 2026 Packaging State of the Industry Report situates AI within a wider set of pressures influencing equipment

investment. Workforce constraints, sustainability regulations, and rising input costs provide the greatest impetus for emerging AI applications, such as capturing institutional knowledge from retiring employees, developing specifications from past projects, supporting real-time troubleshooting, and generating content, as a growing influence on how companies choose equipment. Rather than replacing technical expertise, these tools are positioned as ways to extend the capabilities of an increasingly stretched workforce. Attendees at Pack Expo International 2026 in Chicago will see many of these AI-enabled tools, along with related robotics and automation technologies, in action on the show floor. DW PMMI pmmi.org

2026 PACKAGING MACHINERY STATE OF THE INDUSTRY

DESIGN WORLD

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Design For Industry B AT T E RY M A N U FA C T U R I N G

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

Heavy-payload conveyance gets an upgrade

BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

PRECISION NUTS & WASHERS

Moving battery modules and e-axles through an assembly line is a heavy-payload problem and a persistent bottleneck in electromobility manufacturing. Bosch Rexroth aims to address this with its new TS 7plus roller conveyor. The company calls it a freely configurable, fully electric conveyance solution for workpieces up to 3,000 kg. Instead of engineering a bespoke line for every new product variant, manufacturers can reconfigure the conveyor as production needs shift. The system runs on an all-electric, pneumatic-free drive built around a king shaft — a low-maintenance, self-lubricating design. The conveyor handles workpiece carriers up to 2,200 × 3,000 mm and moves material at speeds up to 24 m/min. Motor options include 180 W and 250 W units, with an interface for third-party motors to help manufacturers integrate the conveyor into an existing automation ecosystem rather than start from scratch. The system supports a minimum transport height of 350 mm for both longitudinal and transverse conveying, a low profile that makes manual intervention easier where operators still need to interact with the line directly, reducing awkward reaching or lifting to correct a misaligned module. Overall, the TS 7plus is a fairly direct response to current battery and e-axle production challenges, namely heavier payloads and tighter tolerances, for which engineers specifying next-generation battery or e-mobility lines can map modular configuration options onto existing layouts. DW Bosch Rexroth boschrexroth.com

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INCH and METRIC THREADS LEFT HANDED as well as RIGHT -HANDED

ADAPTER SLEEVE ASSEMBLIES

Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS Materials of: ALUMINUM and CORROSION RESISTANT STEEL NUTS & WASHERS

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

-H

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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

9/29/26 4:56 PM

Design For Industry O F F - H I G H W AY

Closed-loop hydraulics open up options

In a closed-loop hydrostatic circuit, fluid recirculates directly between the pump and motor rather than returning to a reservoir between cycles, which typically means tighter control response, less energy loss, and better efficiency under continuous, high-load operation that off-highway machines are built for. At iVT Expo USA 2026, Bonfiglioli showcased its closed-loop systems that pair axial piston hydraulic motors with planetary gear units to create complete drive assemblies for hydrostatically driven equipment, including compact track loaders, construction machines, and material handling platforms. Five configurations were on the show floor: the 705CT, 606W3T, 705C2T, 705X2T, and 706C2T, giving OEMs a spread of options across machine sizes and duty profiles. Bonfiglioli's motors use a swash plate design with single-speed, two-speed, and continuously variable displacement options, which lets engineers match a specific machine's travel requirements 10

DESIGN WORLD

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OCTOBER 2026

rather than settling for one-size-fitsall gearing. Operating pressures run up to 400 bar delta and 430 bar inlet for high-pressure, high-torque mobile equipment demands. Integrated SAHR (Spring-Applied, Hydraulically Released) dry parking brakes are built in, which enables safety-critical stationary holding. Flexible porting and customizable flushing valve options give OEMs room to adapt the system to their own hydraulic architecture. Electromobility solutions for offhighway equipment The company also highlighted its growing portfolio of electric and hybrid drive technologies, aligned with the industry’s shift toward lower-emission machines. Its electric drive solutions support traction and slew drives with integrated electric motor and gear units; pre-paired electric motors designed to work with designated inverters; high-efficiency electric motors for pump drive applications; and scalable architectures for compact equipment and heavy-duty platforms.

At the iVT Expo in Germany, Bonfiglioli had numerous electromobility solutions on display. For excavators up to 20 tons, the company highlighted its integrated electric swing drive solution combining the 700T planetary gearbox with the BPM permanent magnet motor series. The solution operates in the 400 to 700 V range and delivers up to 35 kW. The company also presented the BPM 200 liquid-cooled permanent magnet motor for high-voltage applications. Developed for hybrid and partially electrified machines, the solution addresses growing market demand for flexible electrification architectures, particularly in applications where customers are progressively electrifying selected machine functions through electric pump drive systems. For compact track loaders, there was a drive based on the 705CE gearbox combined with the BPM 240 permanent magnet motor. Engineered for compact machine architectures, ranging from 1.5 to 6 tons, the system delivers high www.designworldonline.com

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power density while meeting stringent dimensional requirements for urban and compact electric equipment. Solution for low-voltage applications For low-voltage applications, the company showed its solution for mini track loaders, integrating the 700T series with the air-cooled BPM 200 motor. Available with IP65 and IP66 protection ratings and nominal power up to 16 kW, the solution is particularly suited for mini excavators and agricultural applications, such as AGV robotic systems, where hybrid electrification through electric pump drives is increasingly taking hold. With these solutions, the company aims to help meet rising expectations for intelligent, electric, and connected equipment requiring precision, efficiency, and sustainability. DW

Beyond Components. Engineering system performance through our Integrated Systems Approach. Fluid Power Engineering. Controls & Electronics Engineering. Application & System Engineering.

One integrated approach. One performance-driven outcome. Bonfiglioli bonfiglioli.com

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Design For Industry L A B O R AT O RY A U T O M AT I O N

Robotics brings physical AI to clinical labs

Mounting strain plagues the healthcare sector as laboratories face workforce shortages, with fewer professionals entering demanding and intensive lab roles. That pressure is compounded by an aging population and a growing shift toward personalized medicine, both of which are driving an urgent need to accelerate testing and improve efficiency. With roughly 70% of treatment decisions dependent on diagnostic testing, the stakes for laboratories to keep pace are higher than ever. In response to these challenges, ABB Robotics has entered a global collaboration with Roche Diagnostics to develop and commercialize robotic solutions for clinical laboratories. The partnership is meant to establish a new generation of connected labs that are flexible, fast, and reliable enough to meet rising demands across modern healthcare.

DESIGN WORLD

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Under the collaboration, ABB and Roche will focus on building automation solutions at scale, targeting critical lab processes such as sample preparation and intralogistics to help labs deliver diagnostics more quickly and efficiently, ultimately supporting better patient care. Two initial applications will anchor the early phase of the work. Within Roche's pathology segment, ABB Robotics will develop solutions for handling and organizing slides, helping move laboratories toward more digital, connected workflows. In central diagnostics labs, robotics will deploy autonomous mobile manipulators to transport samples and materials between instruments, adding connectivity, flexibility, and consistency to speed up processing. These applications offer an opportunity to improve efficiency in clinical diagnostics

where robots can absorb repetitive tasks, freeing lab staff to concentrate on higher-value work while adding flexibility into existing automation. Both companies see the partnership as a way to bring current physical AI capabilities to laboratories worldwide, addressing obstacles that keep labs from delivering the best possible patient outcomes, while adding vital flexibility and consistency to clinical diagnostics. By automating repetitive tasks, lab staff can focus on complex analysis, directly speeding the path from diagnosis to critical treatment decisions for patients. DW

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Design For Industry MEDICAL

Advanced monitoring coming soon to a machine near you with maxon MIND Soon, a new “motion insights and diagnostics” service from Swiss precision-drive specialist maxon called maxon MIND will help machine builders and plant engineers add condition monitoring and diagnostics capabilities to their equipment. Electric motors are often the best sensor in a machine. After all, the motor signals a controller that already reads and reflects the condition of the entire drive system and its environment. maxon MIND turns those existing signals into diagnoses by monitoring the motor … and with it all the mechanical components connected downstream. Developed in-house over years by an interdisciplinary team, maxon MIND works like this: 1. 2.

There’s an application already driven by a maxon motor, gearbox, encoder, and controller(s). At the primary controller, a small software package installs and then runs a script to trigger a diagnostic cycle, generate references, record motor signals, and then enrich collected data with context and distillation for analysis. The system then sends the collected and condensed data over a secure internet connection (via MQTT, for example) to the Cloud-based maxon MIND platform. Once there, the data is analyzed by a machine-learning model and compared to the drive’s reference state. Deviations and anomalies are flagged. Integrated data, condition analyses, and historical trends are accessed through an interface made possible with an application programming

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maxon MIND is a scalable service that works with standard components, so implementation is fast. Once running, maxon MIND yields machine condition-based-maintenance and AGV fleet-management capabilities to prevent personnel injuries and unexpected machine downtime.

interface (API) from maxon. So, personnel can pull results into plant dashboards and fleet-management systems. Diagnoses from the maxon MIND system are traceable, which is necessary in safety-critical design and regulated industries. Via the API, maxon MIND also integrates with the maxon Cloud. Once maxon MIND is officially released to the industry (expected in 2027), machine builders aiming to leverage the service will first consult

with maxon on their design load profiles, usage cycles, and environmental conditions. Then rapid prototyping and early testing (followed by system testing and validation under real operating conditions) will inform changes and the calibration of models. Final implementation will include optimization and fine-tuning of parameters or reference cycles. Cybersecurity is ensured through the way collected machine data is anonymized and secured with maxon privacy measures complementing Cloud

OCTOBER 2026

DESIGN WORLD

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Design For Industry

and security services. In short, maxon MIND doesn’t need to know who the end user is or what specific application is running. To uniquely identify the corresponding machine learning model, maxon MIND only needs data that’s easily anonymized — for example, a drive’s part and serial number. Q&A with one maxon MIND For more on how maxon MIND actually works, we asked business development manager and program lead for maxon MIND Claude Jaquemet a few questions. Here’s what he had to say. Design World: Early literature about maxon MIND details how the software logs machine data during regular operation (and compares it to mechatronic system models) with a frequency that depends on the application and machine builder. But the maxon MIND system needs relatively small data volumes (not enormous datasets) thanks to the “integration of domain-specific expertise into the models” of how a motor, gearbox, and load physically relate.

What does domain-specific expertise mean in this context? Jaquemet: In maxon MIND, domainspecific expertise means incorporating the known physical relationships and operating context of the mechatronic drive system into the model. This includes knowledge of the motor, controller, mechanical load, motion cycle, configuration, and relevant environmental conditions. It is interdisciplinary application knowledge, based on the long experience of maxon. Design World: With this offering, a machine learning model is trained on the OEM’s own data about actual system behavior … plus, the models can be tuned so that a condition warning is genuinely a warning. How does maxon MIND differentiate a real problem from slight and acceptable wear over time? Jaquemet: With application-tailored models and high sensitivity. Therefore, maxon MIND doesn’t apply one universal wear threshold. It tracks the drive system relative to its application-

specific initial state and visualizes the progression over time. Together with the machine builder, the model sensitivity and the boundary between acceptable condition and actionrequired condition are validated for the particular application. The result supports condition-based maintenance decisions. Design World: We understand the architecture can be configured for different levels of complexity … and sensitivity can be adjusted for challenging situations involving cleanrooms, assemblies subject to vibrations, and extreme temperatures. How exactly does maxon MIND distinguish problems from normal operating conditions? Jaquemet: maxon MIND doesn’t rely on a universal definition of normal. A machine-learning model is created for the specific motor in its actual application and is trained on an initial reference state. Later measurements are compared with this application-specific model to detect deviations and wear trends. Also, various potential fault-modes are considered in the training of the initial reference state, to which the application is continuously compared. For example, to compensate for temperature effects, the applicable payload, the reference cycle itself, and the drivetrain configuration need to remain consistent during data acquisition.

Machine learning is commonly associated with massive data requirements, high computational demands, and expensive hardware. In contrast, maxon MIND builds models with fewer than 100 reference cycles and runs diagnostics on fewer than 20 cycles. So, a model of a design (such as the AGV shown here) can be created in less than 10 minutes … and condition diagnosis takes less than a minute. maxon

DESIGN WORLD

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maxon MIND software embeds into the machine builder’s existing user interfaces, so the latter keeps its own look and feel while maxon MIND works in the background. Through the software, end users can view recurring issues, longterm trends, and ways to optimize operations. What’s more, maxon MIND has modest computing power and memory needs. maxon

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Design World: Potential applications include those in laboratory automation (to protect sample integrity and throughput while holding quality consistent); medical devices (to prevent any situations capable of jeopardizing patient safety); and general industrial automation — for avoiding downtime, minimizing the waste of spare parts, and boosting overall equipment effectiveness (OEE). In more general terms, what are the target applications? Jaquemet: maxon MIND is designed for critical applications where an unexpected drive-system failure could affect personal safety, reliability, availability, process quality, or the user experience. Relevant application areas include medical devices, industrial and laboratory automation, and logistics. Technically, the application must allow repeatable diagnostic cycles under controlled and comparable load conditions. maxon MIND generally performs best where high sensitivity of the condition indication is required. www.designworldonline.com

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Design World: Can the motor signals reflect the condition of the whole powertrain, and how can the engineer localize a problem to one component? Jaquemet: The electrical motor signals contain information influenced by the motor, gearbox, encoder, coupling, and driven mechanics. maxon MIND therefore assesses the condition of the complete drive system rather than only the motor. Componentlevel detection of faults is generally feasible, but it depends on the particular drivetrain. Beyond general component failure patterns, application-specific validation against known faults, inspections, or service findings help with the interpretation of the condition indication. DW

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Design Notes BY LISA EITEL

Motion control IC elevates stage automation for Creative Conners

By adopting PMD’s MC58113, Creative Conners overcame technical limitations, improved motion quality, and accelerated development ... all while preserving the modular and approachable design that defines its brand.

Modern theater and concert events rely on motion control to make scenery and LED walls glide and transform — and let performers fly above stages in a precise choreography. One company that designs and manufactures motion systems that make complex stage animations safe and visually compelling is Creative Conners. The company provides modular machinery, standardized control hardware, and intuitive software that can be combined and configured by amateur and professional production teams of all types for touring shows and permanent installations.

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A vertically integrated approach allows Creative Conners to serve an unusually broad customer base. The same underlying technology used in demanding productions like Cirque du Soleil and Dave Matthews Band is also rented to schools staging productions of Les Misérables. Regional theaters represent the company’s largest market, a segment that historically lacked access to sophisticated automation tools. A philosophy based on making stage automation more approachable has heavily influenced Creative Conners’ decision to rethink its motion control

platform and turn to Performance Motion Devices (PMD) for help. At the heart of most Creative Conners systems is a standardized control box known as the Stagehand. While the machinery might be custom, the Stagehand controller remains largely the same across applications. The Stagehand interfaces with variablefrequency drives (VFDs), encoders, and safety systems while serving as the execution layer for cues created in Creative Conners’ Spike Mark software. Those cues define where elements move, how fast they travel, how long they wait, and how they coordinate with

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other stage actions. Once triggered, those commands are executed locally by the controller. Because the Stagehand sits at the intersection of hardware, software, and user interaction, the choice of motion controller IC is critical. For years, Creative Conners relied on legacy motion control chips from Texas Instruments. But over time those devices began to limit what the company could deliver. Among other things, the old ICs didn’t allow independent control of acceleration and deceleration profiles. “On the old IC, we were locked to symmetric accel/decel. Whatever you loaded for the acceleration you had to use for decelerate,” said Creative Conners senior controls engineer Christian Basse. That constraint clashed directly with the visual and safety requirements of stage motion. “We want to hurry up, get onto stage, get moving … but then we want a nice, smooth, deliberate-looking stop,” added Basse. Even more limiting, acceleration parameters could not be changed

on the fly, which was especially problematic for performer flying effects where motion characteristics change dynamically throughout a cue. Availability also became an issue. The older motion controller was both aging and increasingly difficult to source ... an issue only exacerbated by pandemic supplychain disruptions. Creative Conners needed a reliably procured solution that fit its modular design. After evaluating several options, the team selected PMD’s Magellan MC58113 motion control IC for a new version of their Stagehand control PCB. Paired with a microprocessor and a local HMI display, this board now serves as the Stagehand controller core. The single biggest improvement with the MC58113 was support for asymmetric acceleration and deceleration. Plus, the MC58113 supports use of absolute encoders. “If it’s going to move without the machine and the controls being powered, you’re not going to lose the position,” said Basse. This is critical in rescue scenarios, where a performer

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Design Notes

“We design and manufacture the machines and controls and then write the software,” said Creative Conners senior controls engineer Christian Basse. Shown here is one stage for a Dave Matthews concert that uses the company’s theater solutions.

With the new motioncontrol IC, motion behind the scenes is smooth, precise, and safe.

may need to be manually lowered using mechanical brakes while the controller is powered off. When power is restored, the system knows exactly where it is. While not required in every application, absolute encoders are essential for permanently installed infrastructure hoists and for the most demanding, high-end customers 18

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pushing the limits of stage automation. Another benefit: The ability to generate a ±10-V speed signal using an external DAC. This is necessary for hydraulic valves that interpret negative voltage as reverse motion and positive voltage as forward motion. “When we moved to a newer TI controller, we lost that bidirectional signal. Moving to the PMD controller gave us the ability to throw in an external DAC and do a bidirectional signal again,” explained Basse. Restoring this capability ensured the company would not have to turn away certain specialized applications. The MC58113 also offers built-in tracing and monitoring tools so Creative Conners engineers can visualize

motion behavior over time to diagnose issues and fine-tune performance. The controller’s highly tunable position filters also help the system stay precisely on target. “We really care about the quality of motion … not just that it looks nice but that it’s where it’s supposed to be when it’s supposed to be,” said Basse. In tightly choreographed productions, positional accuracy is just as important as smoothness. One benefit Creative Conners didn’t anticipate was PMD’s C-Motion C/C++ software library. Instead of writing low-level serial communication code and message-packing routines from scratch, the team could rely on PMD’s command-driven API. Sending a command is just a call to a C-Motion function. “That saved so much time and has been invaluable to us,” said Basse. This accelerated firmware development and let Creative Conners’ small engineering team focus on higherwww.designworldonline.com

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level functionality and user experience rather than reinventing motion control plumbing. At one point, Creative Conners needed more encoder resolution than that supported by standard implementation. PMD worked directly with the team to deliver a firmware update that met their needs in about a week. Now, Creative Conners is exploring PMD’s multiaxis motion controllers for more tightly coordinated motion as well as integrated servo solutions such as PMD’s ION/CME N-Series intelligent drives. One N-Series option in particular, with 1000-W power output, has captured the team’s interest. An integrated, higher-power solution would enable a new generation of smart machines with drive electronics mounted directly on the machines themselves. This could significantly reduce size and weight while increasing lifting capacity and speed. DW

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Linear Motion

COMPARING THE DESIGNS OF

PRE-INTEGRATED

MICHAEL DRIKER MECHANICAL ENGINEER M.SC. KAPPASENSE

LINEAR ENCODERS

inear guides support and control precision linear travel on axes in myriad machine and robotics types for modern automation. In linearmotion applications that are especially demanding, linear position feedback is needed to ensure the tool, gripper, or workpiece follows preprogrammed paths and reaches precise positions. In such machine designs, engineers often employ linear encoders on the most critical axes. Here, it’s common to source a separate linear encoder or linear guides with the encoder built-in. The latter is preferred in many if not most applications. 20

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Most manufacturers’ built-in linear encoders integrate a scale on the linear guide’s rail and integrate a readhead into its moving carriage. However, one disadvantage of such arrangements is that electrical cable tethered to the encoder readhead must move with carriage. That in turn necessitates a specialty cable-carrying arrangement that can complicate the design and maintenance routines. As we’ll explore, another linearguide sensing technology uses capacitive operation for a cable-free readhead that avoids these and other issues.

OCTOBER 2026

Wired readheads are the conventional choice In conventional linear encoders, the readhead connects to the controller and power via cables. The cables to carry the electrical signals (analog or digital) are shielded. The scale mounts in a groove machined into the side or upper face of the rail. The scale may be protected against water ingress, dust, or debris by a cover. Wired linear-encoder technologies are well established in industrial automation. Power is supplied through the same wiring harness used for signal transmission. This proven, www.designworldonline.com

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Linear feedback from some manufacturers integrate the readhead and electronics into a single housing mounted on the end of the carriage. No matter how they’re integrated, the readhead detects the scale pattern and converts the signals into usable position data.

reliable technology delivers stable signal transmission that is unaffected by wireless interference, and it is compatible with most standard motion controllers. No batteries are required because power is supplied directly via the cable. As a result, wired readheads remain the conventional choice: a reliable, cost-effective solution offering stable, proven signal transmission and broad compatibility with existing controllers and machine designs. There are limitations and drawbacks to these technologies, though. Cable routing is complex, especially in multiaxis systems or tight installations, and this complexity reduces overall system flexibility. The cables themselves are susceptible to wear, fatigue, breaks, or insulation damage from continuous movement, and long cable runs can also introduce signal noise. Together, these issues increase maintenance overhead. That’s because replacing or managing cables adds both downtime and cost. Linear encoders with hardwired readheads excel in conventional CNC machines, on the short axes of precision motion designs, and in systems for which stability is more important than flexibility. In contrast, wireless readheads excel in robotics, equipment for cleanrooms, and long-stroke axes.

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Linear guides that integrate magnetic encoders for positioning avoid the issues of optical technologies, but most still involve cabling to the guide carriage.

Linear guides with builtin encoders sometimes use flat cabling to the readhead.

ENCODER TYPE

APPLICATIONS

BENEFITS

CAVEATS

Wired readhead

CNC machines · Heavy equipment

Proven stable · low cost

Cable wear · complex routing

Wireless readhead

Robotics · Modular machines · Precision CNC equipment

Flexible · lowmaintenance

Needs power management · cost

Semiconductor · medical · harsh environments

Compact · Signal resistance to interference · Efficient · Wide installation tolerances · Absolute position available

Requires careful system design and grounding · Thermal expansion over 90°

Cable-free readhead capacitive encoder

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Linear Motion

Wireless readheads as a modern alternative As wireless communication and power technologies advance, the shift from wired to wireless encoder readheads is expected to accelerate. Linear encoders with wireless readheads fit into this trend … wirelessly transmitting signals to the controller. More specifically, data transfer occurs via a radio frequency (RF) or optical wireless link. Power is provided through a battery, energy harvesting, or inductive power transfer. This and capacitive sensing offer several advantages. The overall design can be simpler, because there’s no need for cable carriers, drag chains, or conduits … so axes are more reconfigurable. There are also no cables to wear out or replace. Machine layout is easier and oftentimes the axis assemblies can be more compact than those with traditional encoding hardware. Reliability in tough environments is also higher, as fewer connectors mean fewer disconnect points. All this helps wireless linear encoding support Industry 4.0 and smart-factory initiatives.

S H O CK

S LUTION O S N O TI & VIBR A

KappaSense linear encoders put the electronics (and cabling) on the static scale and not the readhead that moves with the carriage.

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STATIC CABLE ON SCALE

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KappaSense linear encoders measure capacitance changes between a patterned scale and a sensing readhead (inset — top). Some such encoders can pair multiple independent readheads with one scale to track travels up to 1,200 mm.

Challenges include potential signal interference in noisy industrial environments, power management requirements for battery-based heads, and higher initial system cost. Applications include long-travel moving axes, rotary stages, and modular machine setups. In CNC machines, the technology delivers high precision with reduced wiring complexity. In robotics, it enables flexible integration in articulated arms and linear actuators. In the semiconductor industry, it’s cleanroom-friendly and produces no cable dust or wear. In medical devices, cable-free linear encoder technology offers a compact low-maintenance solution. The technology is also well suited to highspeed automation systems requiring ultraprecise feedback as well as applications that operate in vacuum settings. Benefits of capacitive sensing Integrated linear encoders commonly use magnetic or inductive technologies rather than optical versions they’re more resistant to dust, debris, and liquid. They can also tolerate some variation in the gap between the sensor and the scale which can be an issue if the axis is subject to shocks or vibrations. Capacitive sensing offers these benefits plus is immune to electromagnetic interference whether of internal or external origin. DW KappaSense kappasense.com www.designworldonline.com

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COMPARISON OF ENCODER READHEAD TECHNOLOGIES COMPARISON OF ENCODER READHEAD TECHNOLOGIES Reliability 5 4

WIRED

CAPACITIVE WIRELESS

2 1

Flexibility

Cost

WIRELESS

Maintenance Linear encoders with wired, wireless, and capacitive cable-free readheads offer different benefits.

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Safety

comparing

SAFETY

SENSORS AND SWITCHES Lisa Eitel · Executive editor

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Several machineactivated sensors and switches support safety functions. These are distinct from interlocks, which mount onto machine perimeters and contact other machine parts.

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ncreased capabilities in recent years have rendered these safety (and fail-safe) components capable of tasks constituting edge computing, distributed control, IIoT connectivity, and reliability assurances exceeding that of their non-safety sensor and switch equivalents. Sensors in the context of industrial safety are feedback components that detect the presence or absence of workpiece objects or machine sections … and distill that signal into actionable data for the controller to command any number of machine responses. Switches in the context of industrial safety have a more specific function — of turning power supplies off and on. These feedback components (often mechanical) detect the position of workpiece objects or machine sections and (if conditions satisfy some preset) immediately cause a disconnect or reconnect of some machine power supply. That’s in contrast with electromechanical relays that (often using a solenoid) make or break some mechanical contact between electrical leads. In common designs, a small voltage into the solenoid prompts a relatively large current through relay contacts. These switches and sensors must be safety-rated variations to satisfy current standards preventing bypasses, failures, and defeats. Just consider how standard inductive proximity switches were once sufficient to satisfy ISO 14119 interlock requirements. Now, more stringent IEC 60947 requirements for switchgear electromagnetic compatibility largely prevent such use. Many newer designs include coded (uniquely mating) subcomponents to prevent tampering or defeating with tape or conductive objects so common in automated facilities. Or safety-rated mechanical switches might include positive-opening operation not found in comparable general-purpose switches. OCTOBER 2026

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Safety

Comparing limit switches Direct-contact limit-switch registering (via an actuator) an axis’ end of stroke prompts a breaking or making of a related electrical connection. The latter in turn connects to safety controls to prompt immediate neutralization of potentially hazardous motion. Consider one specific example — limit switches with rounded plungers. In these switches, the plunger serves as the actuator that registers forces at a right angle to their rounded-end spring-loaded rod. When forced inward, contacts are typically cut. Roller plunger limit switches are a related design that tips the spring-loaded rod with a small wheel to roll on machine sections or objects that bump into it. The contacts in such mechanical switches have slow-breaking or snapaction contacts. The former accept direct actuator force to slide in their track and then … • Break-before-make contacts open a normally closed contact and then close a normally open contact — for interruption of one function before continuation of another or … • Make-before-break contacts close a normally open contact and then open a normally closed contact — for overlapping functions Otherwise, spring-loaded snapaction contacts respond to actuator travel-direction force by accumulating spring pressure. Then moveable contacts snap from a default to a trigger set of contacts to close a circuit. Upon actuator retraction, the spring snaps the moveable contacts back to their default position. Such operation is reliable and useful for making and breaking power as well as control-signal circuits. Comparing position switches Mechanical position switches have roller levers and rod levers that register a machine axis position as an angular displacement. Rod levers have a simple metal antenna that contacts the monitored axis structure or handled 26

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Interlocks are classified by international safety standards. Switches in interlock applications allow various orientations.

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objects; roller levers have a wheeltipped lever arm that contacts and rolls on the monitored axis structure surface or handled objects. Other safety-rated proximity sensors (distinct from such sensors for nonsafety applications) use non-contact photoelectric or inductive operation. Contrary to one common misperception, induction proximity sensors detect when any metallic object has entered its monitored area …so don’t need any additional coded target or magnet to work. Many directly connect to PLCs via basic unshielded four-pole wiring. Adding certain low-cost electronics can impart muting and e-stop functions satisfying industry safety standards.

While position switches and proximity switches can be located anywhere on or in a machine, those that are part of some interlock assembly are always on the movable parts of a machine’s safety-perimeter hardware. International standards dictate their design and integration — including ISO 14119 as well as Conformité Européenne (CE) Machinery Directive 2006/42/EC. Industrial safety systems often use guard (perimeter) elements called interlocks. As already explained, these are typically electromechanical components that render machine functions mutually reliant. For example, an open interlock on a machine door might prevent startup of a machining axis or (if closed) will stop the running axis should someone open the door during operation. Such interdependency renders machines extremely unlikely to injure personnel or sustain self-inflicted damage. These interlocks are a switch subtype in that they’re activated via some preset operation sequence. What makes a design qualify as an interlock is that they won’t release their locked state without the correct reversal process. Still more capable interlocks are those touted as guard locks — essentially position switches with separate actuators that can be restrained to render the entire assembly locked until the machine comes to a safe stop. One caveat here is that in

Machine boundaries guarded by safety interlocks The boundaries around dangerous machine sections are the first line of defense against threats to worker safety. The challenge is that machine operators must often interact with dangerous machines. So, such boundaries take the form of housings, fencing, gates, and doors consisting of immovable sheet-metal panels as well as chain-link fencing — and movable chain-link doors, sliding glass panels, swinging windows, light curtains, and so much more. The safety components that mount onto machine perimeters and contact other machine parts are interlocks. Interlocks cause an interdependence between what the safety controller allows and the positions of all the movable machine-perimeter sections. In fact, interlocks are defined by ISO 12100 (and adopted in ISO 14119) as mechanical, electrical, or other devices that prevent hazardous machine operations if the guard (machine boundary section it monitors) is This limit switch open. Such interlocks are at their verifies that a core a position switch or proximity machine housing switch (or latching design called a section is closed before allowing guard lock on some more featured machine operation. assemblies) that can command a machine controller to react to a machinery-perimeter guard position. www.designworldonline.com

Safety Feature DW 10-26 v3 final.indd 27

everyday engineering parlance, it’s common for such doubly capable guard locks to be called interlocks instead of the more proper and exact guard locks. Interlock variations abound … and purely mechanical cammed interlocks do exist. In one version, such an interlock might mechanically register an unsafe condition by pivoting about an axis to catch (and lock) a dangerous machine axis. Such interlocks are rarer than electromechanical and even purely electrical and electronic variations using electronic circuits or safety microprocessors. After all, electronics impart low-cost interlock-system flexibility, reliability, and reconfigurability. Consider one such electromechanical example — that of a hinged safety interlock. These attach to (or integrate into) the hinge of a machine’s access flap, door, or other guard. Then a mechanical lever arm or pin through the interlock registers when the hinged guards open and (upon a set threshold switching angle) triggers some output to stop the hazardous operation inside the machine. In these designs, it’s usually a kinematic elbow or hinge linkage of the interlock that accepts externally applied force and prompts some solenoid action for contact. DW

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Fluid Power

Performance enhancements and reduced cost of ownership:

THE VALUE OF UNITIZED PISTONS AND GLANDS Raymond Gillies • Director of Sales • Hallite Seals Americas George Firn • Technical Director • Hallite Seals Americas

Unitized piston and gland technology has been used in hydraulic cylinders for decades, largely because they simplify the installation of what would otherwise be complex, multi-part sealing systems. But the role of unitized technology has evolved. Advances in design and materials have expanded the capabilities of these components, making them relevant to a broader range of hydraulic applications and manufacturing considerations. An assortment of unitized solutions. Hallite

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he evolution of hydraulic cylinder technology reflects a broader industry shift from optimizing individual components to optimizing performance across the entire cylinder lifecycle. As cylinders are expected to operate at higher pressures, for longer duty cycles, and in increasingly demanding environments, OEMs are placing greater emphasis on reliability, efficiency, leakage control, service life, and manufacturability. In this environment, we see a shift in how OEMs evaluate sealing technology. They are taking a long, hard look at its initial purchase and installation cost, its ability to reduce manufacturing workload, improve resource utilization, increase equipment reliability, and lower total cost of ownership over the life of the cylinder. More than simplified assembly Over the years, unitized piston and gland technology has evolved from being primarily a convenience for manufacturers and retrofit work in two distinct ways. First, they solve complex engineering challenges that once required several separate components. Second, due to modern designs and materials, they have become a critical performance platform for the hydraulic cylinder as a whole. With regard to the engineering challenges, unitized pistons address multiple performance requirements that once required a combination of sealing solutions. They can maximize side-load protection, shield seals from contamination and extrusion, and increase pressure capability, all within a single component. Combining these functions into a onepiece assembly eliminates componentrelated risks while solving demanding engineering challenges and representing a significant advancement in hydraulic sealing technology. Modern unitized designs have evolved into a critical performance platform for hydraulic cylinders. By integrating the piston, bearing, and sealing elements into a single engineered assembly, the design does more than simplify construction. It helps optimize the cylinder. Eliminating

OCTOBER 2026

DESIGN WORLD

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Fluid Power

Material advancements enable designs suitable for water-based hydraulic systems, extreme environments, and broader applications. Hallite

metal-to-metal contact while achieving tighter piston-to-bore tolerances and improved dimensional accuracy enhances sealing performance and supports reliable operation in demanding, high-pressure hydraulic systems. The result is a more robust, precisely engineered cylinder with the potential for extended service life. With hundreds of production sizes available, the Hallite 720 is one example of how unitized technology has evolved from an assembly solution into a key enabler of hydraulic cylinder performance. The unitized gland applies the same component-integration philosophy to the rod end of the cylinder. So, instead of separately installing a rod seal, bearing/guide, and other sealing elements into the gland, the sealing and guiding components are supplied

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as an integrated assembly. The gland is therefore responsible for guiding the rod, maintaining the seal against hydraulic fluid escaping from the cylinder, and helping protect the sealing system from contamination. Modern unitized glands with the integrated bearing can help control rod movement and side loading, reducing conditions that can damage the rod seal and lead to leakage. It’s important to add that in recent years, investment in automated, repeatable inspection with the aid of robotics has moved quality control closer to the production process. On the production floor of the company’s unitized solutions, machined parts are inspected at every step of the process, referencing different measurements such as tolerance, run out, and ovality. This ensures critical dimensions and features are within specifications.

Material flexibility Advances in materials are expanding the versatility of unitized designs, enabling their use in challenging applications, such as agriculture, construction, off-highway, and forestry, with specific pressure, temperature, speed, and hydraulic fluid compatibility requirements. Water-based hydraulics are an important example of advances in material flexibility as they can meet the industry’s specialized fluid needs. These include HFA (oil-in-water emulsions), HFB (water-in-oil invert emulsions), HFC (water-glycol fluids), synthetic ester fluids, and phosphate esters. In applications such as underground mining, steel manufacturing and metal processing, and offshore oil and gas, where fire resistance is critical, selecting materials that are compatible with these fluids and operating conditions is essential. Unitized designs can incorporate a wide range of seal and bearing materials, enabling them to deliver reliable performance across these demanding environments. Advances in material technology are expanding unitized piston and gland designs into applications once considered difficult for integrated sealing systems. In addition to enabling use with water-based hydraulic fluids, new polymer, elastomer, and composite formulations are allowing unitized

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pistons and glands to withstand higher temperatures, aggressive fluids, extreme wear, and higher pressures, giving OEMs greater flexibility to tailor a complete piston or gland assembly to the demands of the application rather than being constrained by a standard material package. Engineered polymers, applicationspecific material formulations, and proprietary molding processes are driving a new level of material flexibility, enabling unitized designs to perform well beyond their original capabilities. Untapped manufacturing capacity As a one-piece component, unitized designs reduce the time, labor, and cost associated with assembling multiple piston components. They simplify processes ranging from receiving and handling individual seals and wear rings to verification, inspection, and kitting. Eliminating the logistical complexity of multipart assemblies can also streamline inventory and supplychain management. As a result, more manufacturing capacity becomes available, freeing valuable floor space and resources for higher-value priorities, improving operational efficiency. For example, an OEM producing 1,000 cylinders a month could replace the receiving, inspection, inventory, and kitting of multiple individual piston components with a single ready-to-fit unitized assembly. That

consolidation reduces the number of components moving through the supply chain and removes repetitive handling and assembly steps. The resulting capacity can be redirected toward higher-value activities, such as increasing production throughput, reallocating floor space, or deploying skilled personnel to more complex manufacturing and quality tasks. A case study on reduced cost of ownership With easier assembly, maintenance, and field service comes longer cylinder performance life and uptime, and fewer premature failures and warranty claims. Ultimately, lower total cost of ownership is realized. This was the case for a major construction equipment OEM looking to reduce overall cost of ownership. The equipment manufacturer was experiencing less-than-optimal seal life in some of its hydraulic cylinder applications, leading to increased warranty costs and reduced equipment reliability. The goal was to extend seal life while improving manufacturing consistency and overall cylinder performance. Extreme temperatures and extrusion gap issues made the application challenging. The unitized piston and gland solution achieved a tightly controlled manufacturing tolerance of ±0.001 in. This significantly improved control of the

extrusion gap, one of the primary causes of premature seal failure, resulting in more consistent sealing performance and increased durability. To ensure repeatability, the solution underwent extensive validation, spanning approximately three years with dozens of units in the field at the OEM and laboratory testing at the OEM’s engineering test facilities. Combined field and lab evaluations demonstrated an average seal life improvement of more than two times compared to the previous design. This was measured in operating hours. To put this in perspective, an OEM warranty may cover 2,000 operating hours, but the calendar time represented by those hours can vary dramatically with the duty cycle, from roughly six months in high-utilization equipment to six years in lowerutilization applications. Doubling seal life effectively doubles the operatinghours buffer before seal-related failure, materially extending the period in which the OEM can operate with greater confidence that the sealing system will remain within its expected service life — regardless of how quickly those hours accumulate. Based on the test program’s success, the OEM transitioned its production to the unitized solution and is planning to expand the use of the unitized product into additional applications across its equipment portfolio. Currently, tens of thousands of units are in production, delivering on the objective to reduce cost of ownership. In conclusion, decades after their introduction, unitized piston and gland technology continues to drive meaningful gains in hydraulic performance — not only simplifying assembly, but extending service life, reducing warranty exposure, and lowering total cost of ownership. DW Hallite hallite.com

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Aerospace&Defense

replace hard chrome and reimagine what coatings can do RACHAEL PASINI • EDITOR-IN-CHIEF

Maxterial's MaxShield coating turns thickness and uniformity into precise, tunable design variables, offering a single coating solution poised to simplify everything from hydraulic cylinders to aerospace actuators.

ard chrome has been ubiquitous in hydraulics, motion components, and industrial machinery for decades. It’s everywhere from cylinders on construction equipment to the work rolls that turn thick steel slabs into automotive sheet metal. Despite its widespread use, chrome has serious trade-offs, including corrosion limitations, environmental and regulatory pressure, high energy use, and increasingly fragmented alternatives that complicate both design and supply chains. Maxterial, a California-based company, aims to change all that. Its coating

AEROSPACE&DEFENSE

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technology, called MaxShield, is designed to replace hard chrome and displace many chrome alternatives, including thermal spray coatings such as tungsten carbide. For design engineers and machine builders, this can offer a single coating system for multiple environments, geometries, and industries, while simplifying manufacturing and improving performance. “Just imagine you have a production line, and you are coating every and all of your line with one coating, rather than getting some part of it from some supply chain, some part of it somewhere else…

Here, you can simply have a one-fits-all,” said Mehdi Kargar, CEO of Maxterial. The problem with hard chrome and its alternatives Hydraulic applications are among the largest consumers of hard chrome worldwide. Piston rods, cylinders, and other components rely on chrome for wear and corrosion protection. But in corrosive environments, such as near-sea, offshore, and certain oil and gas settings, chrome reaches its limits. To survive these conditions, designers often resort to tungsten carbide and other

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Aerospace&Defense

Shown here is a hydraulic cylinder with MaxShield applied. Maxterial

thermal spray coatings. While those can offer better corrosion and wear resistance, they introduce a new set of challenges: • Cost and complexity: Depending on the process and thickness, thermal spray coatings can be multiple times the cost of chrome. • Capital intensity: Thermal spray typically requires dedicated equipment and specialized process control. • Thickness constraints: Thermal spray coatings are usually applied relatively thick, on the order of 100 µm or more as a minimum practical value, then ground down to achieve final size. • Tolerance and design challenges: Designers must build tolerances, clearances, and performance assumptions around thick, somewhat variable coatings. The coating process begins to drive the design, rather than serving it. Hard chrome itself has its own wellknown issues, including energy-intensive deposition, hazardous byproducts, and stringent environmental and worker-safety regulations. Many hydraulics and motioncontrol companies have responded by outsourcing chrome to specialized vendors to keep the associated liabilities at arm’s length. The result is a hodgepodge of coatings, suppliers, and

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OCTOBER 2026

process chains that make it harder for OEMs to design, qualify, and maintain critical components. A different approach: Coating with design in mind Thickness, as Kargar pointed out, is the number one design factor in coatings. “Thickness of the coating is equal to unit economy. The amount of labor, the amount of time, the electricity, the material — it’s all thickness,” he said. Therefore, a process that enables engineers to set thickness where they want it, rather than where the process demands, can have an immense impact. With MaxShield, thickness is no longer a constraint but a design variable. Since the coating is deposited electrochemically rather than thermally sprayed, its thickness can be controlled across a wide range, from sub-micron levels (approximately 500 nm) up into the tens of microns and beyond. That means that design engineers can tune thickness to match wear life, corrosion demands, and cost targets without being locked into a high minimum. The result can lead to reduced material and post-processing, lowering the total cost per component. It also gives designers more freedom to design for function. Instead of contorting designs to meet minimum coating thicknesses and grinding

allowances, engineers can aim for optimal geometries and use the coating for fine adjustment. Coating uniformity is another key differentiator. In conventional electroplating, “throwing power” measures how well a coating can deposit uniformly over complex geometries. High throwing power means the coating can reach internal bores, recesses, and nonline-of-sight regions, and the thickness stays highly consistent across edges, corners, and flatter surfaces. Traditional hard chrome is known for low throwing power, which is especially problematic inside hollow rods, deep bores, or intricate pneumatic and hydraulic passages. And because thermal spray is a line-of-sight process, it often cannot reach such internal surfaces at all. “Thermal spray, which is a chrome replacement, cannot coat inside… And that’s why, for many years, finding a chrome alternative for non-line-of-sight… [has been difficult],” said Kargar. By contrast, Maxterial’s coating is designed with high throwing power, enabling much more uniform coverage across external surfaces and internal features in a single process. What it looks like in practice: Industrial examples To see what these abstract properties

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mean in real-world use, it helps to look at how the coating behaves in demanding applications. Consider shock absorber components with slender, hollow geometries — a classic challenge for both plating and mechanical finishing. With hard chrome, companies commonly report non-uniform internal coatings due to poor throwing power; a recurring need for grinding and finishing operations to correct profiles, even on parts that are slender, hollow, and difficult to fixture; and higher costs and longer cycle times, driven as much by the post-processing as by the plating itself. In cases where MaxShield has been adopted, the improved internal uniformity and the ability to work at modest thicknesses (on the order of 10 µm, when appropriate) can eliminate or greatly reduce grinding for certain geometries, simplify fixture design and part handling, and shorten production routes while still meeting functional requirements. For motion and linear actuator designers,

Here is a peek inside Maxterial’s manufacturing facility located in Brown City, Michigan. Maxterial

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Aerospace&Defense

This is another example of MaxShield applied to a shock absorber. Maxterial

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that can translate to simpler tolerance stack-ups, more predictable performance, and fewer special-case manufacturing workarounds. Another example is the environment inside a cold-rolling mill, which is even more severe. After hot-rolled steel is formed into thick slabs, cold-rolling work rolls reduce the slabs to thin sheets under massive pressure and at high rotational speeds. These large rolls — often weighing many tons — are traditionally coated with hard chrome. But the combination of pressure, friction, and harsh environment causes rapid wear. In some mills, chrome on work rolls may only last a few hours before the roll must be pulled, stripped, and recoated. Because the rolls are huge and difficult to grind to the correct shape, the industry often imposes strict limits on chrome thickness (just a few microns) to avoid profile problems from uneven build-up. This low, uneven thickness shortens wear life and forces frequent line shutdowns. Here, uniformity is the critical factor. A coating that builds up significantly faster on edges and corners than on the middle of the roll will distort the roll’s profile. Any local high spots in the roll directly imprint into the steel sheet, causing defects and thickness variation. Maxterial’s coating targets this problem with higher uniformity across the roll face — even with a greater overall thickness — which can increase service life between changeouts and reduce production interruptions. For steel producers, extending the interval between roll maintenance, while preserving sheet quality, can yield substantial gains in throughput and economics.

AEROSPACE&DEFENSE

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9/29/26 5:25 PM

A pathway for aerospace and defense While Maxterial’s initial focus has been in hydraulics, pneumatics, and heavy industry, Kargar is already thinking several steps ahead about how the same technology fits into defense and aerospace platforms. He outlines a pathway that starts with demanding but less safety‑critical components on the ground, then builds the evidence base needed to qualify coatings for flight. On the defense side, that first layer of adoption is in ground vehicles and their hydraulic systems — areas where hard chrome has long been the default. He noted that the performance and corrosion demands are substantial, but the qualification burden is more manageable than for flight‑critical structures. In parallel, Maxterial is working with partners to run the extensive fatigue and durability testing that aerospace engineers require before approving any new surface treatment. “Every industry cares about fatigue, but not every industry cares to measure it… Aerospace engineers, they care about that a lot, because they put things in the sky and they don’t want people to die. That’s how their standard is built,” said Kargar. The company’s approach is to run the same coating through an additional layer of aerospace‑grade qualification, rather than developing a completely separate system for aviation. That means proving not just basic hardness and wear resistance, but how the coating behaves under long-term cyclic loading, temperature swings, and the complex stress states typical of actuators, landing gear, and control systems. From there, Kargar sees a natural expansion into rotorcraft and other aerospace subsystems, particularly where internal bores and non‑line‑of‑sight features make chrome alternatives difficult to use. His coating technology with high throwing power can reach both external and internal surfaces in one go, which is attractive for compact, integrated aerospace actuators. Kargar’s longer‑term view extends beyond retrofit and replacement into

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Aerospace & Defense Supp DW 10-26 v3 final.indd 37

designs for newer platforms such as uncrewed ground vehicles and automated defense systems. “That’s exactly where this can fit and could be part of automation systems,” he said. “Let’s put the right coating in right now, rather than putting something wrong, and having to fix it in five years.” In other words, as defense and aerospace engineers rethink systems for electrification, autonomy, and lifecycle cost, they have an opportunity to design the coating into the architecture from day one. Simplifying the supply chain and supporting sustainability Today, hydraulics and motion system designers and OEMs often rely on a mix of hard chrome for standard conditions, high-end thermal spray coatings for corrosive or high-wear environments, and specialized internal processes for niche geometries. Each additional coating type requires more vendor management, more sets of drawings and specifications, and more qualification, testing, and quality control. However, a single coating platform that can serve standard hydraulic cylinders, corrosive offshore components, internal pneumatic bores, and hollow rods has the potential to consolidate much of that complexity. One process line can address a wide range of applications,

simplifying both design and operations. Another attractive angle for OEMs is the possibility of bringing coatings in-house. Many companies have spent the last decade outsourcing chrome operations to reduce their exposure to hazardous materials and evolving regulations. A more controllable process opens the door to vertical integration, reduced reliance on external vendors and their lead times, recovery of margins currently paid out to specialty coaters, and tighter alignment between design and manufacturing teams. For engineering teams, in-house capability can also accelerate prototyping and iteration, since coating trials no longer depend entirely on external scheduling and capacity. Additionally, as OEMs in automotive, industrial automation, and aerospace face increasing pressure to reduce their environmental footprint, the coatings that protect their hardware are coming under new scrutiny. As mentioned, hard chrome is energy-intensive and closely tied to legacy chemistries and processes. Simply swapping it out for a different high-energy process does little to improve the full lifecycle footprint. The goal is to enable lower thicknesses for a given performance level and longer service life between recoats or component replacements. Kargar’s approach offers a more direct

The company’s customer base is growing across industries Maxterial worldwide.

OCTOBER 2026

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Aerospace&Defense

path to reducing total energy and material per unit of function. This is particularly relevant to electrified platforms, such as electric vehicles and next-generation automated equipment, where sustainability is a core part of the brand and design story. A coating technology that enhances performance and helps reduce embedded emissions aligns well with these broader system-level goals. “Chromium is a very high carbon footprint product. If they replace that chromium with us, they naturally are reducing the carbon footprint of the electric car,” said Kargar. A new design space for coatings For machine builders, motion-system designers, and automation engineers, coatings have often been treated as a constraint: a fixed process with fixed limitations that design teams must work around. With Kargar’s model, thickness becomes a tunable design parameter,

internal and external surfaces can be treated in one coherent process, and performance, cost, and sustainability can be balanced more transparently at the design stage. “Imagine one product fits all. How easy that becomes, right? The design becomes much more flexible because it offers very good corrosion resistance beyond chromium, control over thickness… and that high throwing power,” said Kargar. In short, the coating becomes less of a necessary evil and more of a design tool that can unify supply chains, reduce complexity, and enable more ambitious designs in hydraulics, motion, and heavy industry. As industrial sectors continue to modernize and electrify, these kinds of enabling technologies at the material and process level may quietly shape what’s possible for the machines and infrastructure that power the world. A&D

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ial

Maxterial maxterial.com

Precision Stamped Components for the Aerospace & Defense Industry Boker’s provides custom stamped component parts to accommodate nearly any aerospace and defense application, including avionics, control systems, engines, hydraulic, pneumatic and other equipment that require unique specifications. Boker’s Quality Management System is certified to the stringent AS 9100:2016/ISO 9001:2015 standard, and can comply with DFARS and RoHS, with the ability to manufacture to customer provided AN, NAS, MS and MIL spec standards. At Boker’s, we know that aerospace and defense OEMs demand manufacturing partnerships with the highest levels of precision, quality management and performance, along with a strong understanding of unique industry requirements ranging from space/non-space qualifications to AMS specifications. For over 100 years, Boker’s continues to meet the evolving design needs of the aerospace, aviation and defense industries. Bokers, Inc. 3104 Snelling Ave Minneapolis, MN 55406 612-729-9365 • www.bokers.com

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Ad Index

SALES

SALES (CONTINUED)

Ryan Ashdown rashdown@arrowfly.com 216.316.6691

Melissa Roberts mroberts@arrowfly.com 440.666.3111

Jami Brownlee jbrownlee@arrowfly.com 224.760.1055

Colton Stefanich cstefanich@arrowfly.com 331.223.2047

Ashley Burke aburke@arrowfly.com 737.615.8452

Aaron Way away@arrowfly.com 206.714.2979

All Motion .................................................................................................... 4

Adrian Nash anash@arrowfly.com 416-500-6906

Master Bond, Inc. .................................................................................. 19 LEADERSHIP

MW Industries: Servometer ............................................................. 19

Senior VP, Engineering Amanda Buehner abuehner@arrowfly.com

PBC Linear ...................................................................................................1 Rotor Clip Company, Inc. ................................................................. BC Smalley Steel Ring Company .............................................................3

CFO Ken Gradman kgradman@arrowfly.com 773.680.5955

Judy Pinsel jpinsel@arrowfly.com 630.538.2638

DigiKey Corporation ...............................................................................7 Interpower Corp. .............................................................................15,17

CEO Matt Logan mlogan@arrowfly.com

Susan Powers spowers@arrowfly.com 708.341.3370

Bodine Electric Company ...............................................................IBC Hydac Technology Corporation ..................................................... 11

Mike Francesconi mfrancesconi@arrowfly.com 630.488.9029 Jack Gillerlain jgillerlain@arrowfly.com 773.909.2718

AutomationDirect ..............................................................................IFC

Sorbothane Inc. ......................................................................................22 Spartan Scientific ..................................................................................22 Whittet-Higgins .........................................................................................9 Zero-Max ...................................................................................................... 2

Aerospace & Defense Supplement

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FULL NAMES AND COMPLETE MAILING ADDRESSES OF PUBLISHER, EDITOR, AND MANAGING EDITOR PUBLISHER: Amanda Buehner, Arrowfly LLC, 1111 Superior Ave E, Suite 1120, Cleveland, OH 44114 EDITOR: Rachael Pasini, Arrowfly LLC, 1111 Superior Ave E, Suite 1120, Cleveland, OH 44114 MANAGING EDITOR: Mike Santora, Arrowfly LLC, 1111 Superior Ave E, Suite 1120, Cleveland, OH 44114 OWNER AND COMPLETE MAILING ADDRESS Arrowfly LLC, 1111 Superior Ave E, Suite 1120, Cleveland, OH 44114 Mountaingate Capital, 1225 17th St, Suite 2575, Denver, CO 80202 KNOWN BONDHOLDERS, MORTGAGEES, AND OTHER SECURITY HOLDERS OWNING OR HOLDING 1 PERCENT OR MORE OF TOTAL AMOUNT OF BONDS, MORTGAGES, OR OTHER SECURITIES None ISSUE DATE FOR CIRCULATION DATA BELOW September 2026

EXTENT AND NATURE OF CIRCULATION 15a TOTAL NO. COPIES (NET PRESS RUN) 15b PAID/REQUESTED CIRCULATION 15b.1 OUTSIDE COUNTY PAID/REQUESTED MAIL SUBSCRIPTIONS 15b.2 IN-COUNTY PAID/REQUESTED MAIL SUBSCRIPTION 15b.3 SALES THROUGH DEALERS/CARRIERS 15b.4 REQUESTED COPIES USPS OTHER MAIL CLASSES 15c TOTAL PAID/REQUESTED CIRCULATION 15d NONREQUESTED CIRCULATION 15d.1 OUTSIDE COUNTY NONREQUESTED COPIES 15d.2 IN-COUNTY NONREQUESTED COPIES 15d.3 NONREQUESTED DISTRIBUTED BY OTHER CLASS OF MAIL 15d.4 NONREQUESTED OUTSIDE USPS 15e TOTAL NONREQUESTED DISTRIBUTION 15f TOTAL DISTRIBUTION 15g COPIES NOT DISTRIBUTED 15h TOTAL 15i PERCENT PAID/REQUESTED CIRCULATION 16 ELECTRONIC COPY CIRCULATION 16a REQUESTED AND PAID ELECTRONIC COPIES 16b TOTAL REQUESTED AND PAID PRINT COPIES + REQUESTED/PAID ELECTRONIC COPIES 16c TOTAL REQUESTED COPY DISTRIBUTION + REQUESTED/PAID ELECTRONIC COPIES 16d PERCENT PAID AND/OR REQUESTED CIRCULATION (BOTH PRINT & ELECTRONIC COPIES)

AVERAGE NO. COPIES EACH ISSUE DURING LAST 12 MONTHS

ACTUAL NO. COPIES OF RECENT SINGLE ISSUE

30,408

30,370

29,529 0 0 0 29,529

30,000 0 0 0 30,000

468 0 300 72 840

0 0 300 40 340

30,369 39 30,408 97.2%

30,340 30 30,370 98.9%

5,606

5,415

35,135

35,415

35,975

35,755

97.7%

99.0%

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 Arrowfly, 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 11 times per year: January, February, March, April, May, June, August, September, October, November, December by: Arrowfly, 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

This Statement of Ownership will be printed in the October 2026 issue of this publication. I CERTIFY THAT ALL INFORMATION FURNISHED ON THIS FORM IS TRUE AND COMPLETE. I UNDERSTAND THAT ANYONE WHO FURNISHES FALSE OR MISLEADING INFORMATION ON THIS FORM OR WHO OMITS MATERIAL OR INFORMATION REQUESTED ON THE FORM MAY BE SUBJECT TO CRIMINAL SANCTIONS (INCLUDING FINES AND IMPRISONMENT) AND/OR CIVIL SANCTIONS (INCLUDING MULTIPLE DAMAGES AND CIVIL PENALTIES). Ken Gradman (signed), CFO

Filed on: 9/15/26

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OCTOBER 2026

DESIGN WORLD

10/1/26 12:44 PM

Technical Thinking By Mark Jones

Technology right above our feet Clomping around on crampons during a January ice caving trip proved I’d chosen my boot poorly. Dr. Monaghan diagnosed I’d partially torn my plantar fascia at the heel — a diagnosis after months of painful limping. I left the office with a list of suggested shoes with rigid footbeds and supportive arches. The result was remarkable, as months of suffering a stabbing pain in my heel quickly were forgotten. The pain was gone in days. The good name-brand shoes I was purchasing were remarkably inferior to the great name-brand shoes on the list. It was eyeopening, as were the laces. Now, I’ve always purchased what I thought were good hiking shoes. In preparation for a trip to Banff and Jasper National Parks, I heeded Dr. Monaghan’s list. I hiked pain-free, but the real revelation was that my more expensive hiking shoes didn’t come untied. I’ve hiked for decades and the robust, round laces typically used on hiking shoes always came untied. Even when

DESIGN WORLD

Technical Thinking DW 10-26 v1.indd 40

double-knotted, stopping on the trail to tie my shoes was inevitable, and I know the difference between a square and a granny knot. I now have definitive proof it was never my technique, it was the laces all along. The oldest intact leather shoe we have, the Areni-1 shoe from around 3500 B.C., use laces. Shoelaces, as a technology, have been with us a really long time, longer than the wheel. Simple technology that resisted upgrading. Attempts have been made to eliminate laces, to find a better solution. Buckles and buttons had their day, but both were fashion-driven, and laces remained the leading shoe-fastening tech. Modern elastomers and Velcro remain niche options at best. Patented designs for systems with knobs are even more niche. Laces remain the dominant technology for keeping shoes affixed to feet. There have been improvements. The disputed invention of the aglet, the hard little sheath crimped onto each end of

OCTOBER 2026

a shoelace, dates back to at least the 1700s. Shoes may now incorporate carbon fiber and other advanced materials yet still use laces. Laces spread tension gradually and evenly while still allowing the fit to be tailored by tightening or slackening zones. Laces allow leaving the lower eyelets loose while cranking the ones near the ankle. Knots that stay tied are the key to the whole system. A study of the mechanics of shoelace knot failure show that the swinging of the free ends and the impact forces created as feet land both serve to loosen shoelace knots. Innovations described in the patent literature describe many variations of geometry and materials, aspects that weren’t included in the knot failure study. Beads imbedded in the lace, friction powders, special weaves, composite materials, laces with different top and bottom surfaces and more populate the patent literature. Laces that don’t stay tied are more than just an annoyance. They are a safety hazard, at least according to one purveyor. The remarkable laces on my new shoes stay tied because of a combination of shape and material. They have a flat-oval shape and are a bit rough to the touch. Previous hiking shoelaces were incredibly poorly designed. Smooth, round laces made from a slick polymer. It is as if they were designed to untie. My eyes have been opened. Shoes don’t have to come untied thanks to improved technology. Shoelaces are used by most of us every day. Our ancient forebears found a near-optimal solution. Shoelaces are largely unchanged over centuries, if not millennia. Yet, our understanding of this simple technology, shoelaces, remains incomplete. My remarkable shoelaces that don’t untie show that improvements are still possible and make my hiking noticeably better. DW

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9/29/26 5:36 PM

Soak Up the Sun

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Design World October 2026