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The real life WALL-E that visits newsrooms, tradeshows, and goes on media junkets had to look like the animated WALL-E from the movie. It appears that, like life, there’s a process that has to be gone through in order to look older. Making WALL-E Look Battered The real life WALL-E that visits newsrooms, tradeshows, and goes on media junkets had to look like the animated WALL-E from the movie. It appears that, like life, there’s a process that has to be gone through in order to look older. EE Staff Film and TV Jun 4, 2025 Because the WALL-E from the movie has been around for a long time, his body had been weather worn and beat up by the work he does – compacting trash and stacking it neatly. Computer animation allowed animators to create the look and feel of a well-worn WALL-E, but transferring that same look and feel to a ‘real’ robot was another story. Pixar utilized sophisticated computer graphics to create the digital representation of this fun-loving robot. This digital data was well suited for rapid and precise fabrication of all of the external covers that comprise WALL-E. Although, the covers could have been created in a number of ways, the Disney Imagineering team chose to have the parts created on an SLA rapid prototyping system (see sidebar on the SLA process) The form, fit and overall appearance of the prototype SLA covers were validated with a working robot. The final covers for the traveling robot needed to be significantly tougher than the initial SLA covers. Advanced cast urethane covers were reproduced using a silicone tool created from the SLA masters. The cast urethane process has been accomplished a number of ways by a variety of companies. Although we don’t have information on which method was used for the job, here’s an explanation of what the process might look like. General practices for secondary processing of the master might look similar to what some services do for their customers. Here’s one method that may be used: First prepare a master pattern — created using SLA, CNC, or PolyJet technology — that is worked to a desired surface finish. Then carefully position tape in specific areas to create joint or parting line to assist with cutting the pattern out of the mold. After this step, a mold box is built to enclose the master pattern. The box size is minimized so that the poured Platinum-based Silicone material is not wasted. The master is elevated off the floor of the box to allow the Silicone to surround the master. The material is allowed enough time to cure and then the cured mold is cut into two halves and the master pattern removed. A two-part polyurethane liquid is mixed and then poured (with a proprietary pressure differential) into the mold. The polyurethane filled mold is then placed into a proprietary pressure oven and the final cast polyurethane part is allowed to fully cure thus achieving maximum mechanical properties. Finally, the top half of the mold is removed and the final cast part is removed from the mold. The stressing and rust texture for WALL-E was reproduced from the animated production using paint. “Exterior components – including the treads and details on the inside of the WALL-E camera eyes – were based on the movie data and placed ‘on-model’ to look as authentic as possible,” according to Akhil Madhani, Principal Technical Staff Director for Walt Disney Imagineering Research & Development. “For motion, the tracks are driven using custom designed brushless DC servomotors, which operate through planetary gearheads,” Akhil said. The remaining motors are standard brushed motors using a variety of reduction mechanisms. All the mechanisms themselves were custom designed, including the tracks and treads. As with WALL-E’s panels, the tread texture was copied from the movie models. Control software, as well as all the animation software, was written in-house at Disney and Pixar. This includes the system that allows the company to play Pixar-created animation on the physical robot in order to maintain its character. Designing the ‘real’ WALL-E was, as many Disney projects, highly proprietary, allowing only for general information to be discussed. Akhil did say that “every part of the system, including electronics, was included in the CAD model.” His team used Pro/engineer CAD software for design. Previous Facebook LinkedIn Copy link Next

Building a large interactive exhibit took insight, innovation, and the perfect systems to get it right. Volcanoes Explode on Interactive Table Exhibit Building a large interactive exhibit took insight, innovation, and the perfect systems to get it right. Edited by EE Staff Museums Sep 12, 2025 Ideum recently completed an interactive exhibit for the Volcano Discovery Center located inside the Valles Caldera National Preserve. For 1.25 million years, Valles Caldera has been shaped by dramatic geological events, thriving ecosystems, and a rich tapestry of human history. These stories unfold across the 89,000-acre landscape and span vast stretches of time. To represent this significant landscape, Ideum, in collaboration with the National Park Service, created a 12-foot topographic relief map as a canvas for this rich history to be projected upon. Immersive Technologies Suspended above the map, a 4K projector brings the table to life with projection-mapped sequences that engage multiple visitors at once. Synchronized RGB lighting washes over the walls in colors, while a 6.1 surround sound system with a 15-inch subwoofer creates a dynamic audioscape that can be felt. The show control system ties into motorized roller shades that darken the room every hour for the signature volcanic eruption sequence, transforming the exhibit hall into a fully immersive, cinematic environment. All photos courtesy of Ideum. Interactive Touch Screen Displays While the large map table captivates groups, the experience is designed for multiuser interaction. Four Ideum-built 34-inch 5K UltraWide Presenter touch screen displays surround the perimeter of the table, giving multiple visitors simultaneous control of the projected animations. Each station offers games and activities tied to one of four themes: Cultural History: Traces human activity from archaic-period settlers to the present day, developed in collaboration with 38 tribes and pueblos to honor their enduring cultural connections to the Caldera. Geology: Features a scrubbable geologic timeline where guests can witness the Caldera’s primary eruption 1.2 million years ago, along with the formation of lakes, lava domes, and other dramatic landscape changes. Ecology: The exhibit’s most extensive library of animations allows users to visualize wildlife migration patterns, plant communities, watersheds, and wildfire impacts across the preserve. Scientific Discovery: Explores the scientific research that has occurred in the region, including paleomagnetics, geothermal research, and seismic monitoring efforts. Exhibit Design and Fabrication The Ideum team starts work on a project with an exhibit design phase where they collaborate closely with the customer to design an immersive digital experience that will be engaging for visitors of all ages. Using Geographic Information System (GIS) data provided by the National Park Service, the Ideum exhibit fabrication team created the true-to-life scaled model of the Valles Caldera landscape. The CNC topographic relief map model, exhibit base, and screen mounts were created entirely in-house. The floating screen mounts were a particularly fun engineering challenge—the end result being a low-profile hidden mount meant to fade away into the table. The mount is tied off to the center ring of the exhibit, allowing for structural rigidity and strength even under the weight of visitors leaning or hanging on the screen. All photos courtesy of Ideum. The topographic relief map, spanning 12-feet in diameter, was fabricated in sections using 3D milling operations on a CNC machine. The map surface was machine-milled from high-density foam, then coated with epoxy for durability and finished with projection-enhancing paint. This hard-wearing surface is easy to clean and resistant to damage. The pieces were trimmed to the outer diameter of the circle and glued together. The map was then cut apart into five organic shapes that follow the natural landscapes of the Valles Caldera. Once on site, the map was seamed together with silicone and repainted. The table’s substructure, built from steel and wooden joists, is clad in Staron and Nevamar Armored Protection, creating an ultra-durable piece designed to endure the heavy use of public spaces while maintaining a refined appearance. Beyond the Exhibit Hall Since the newly branded Volcano Discovery Center sits more than a mile from the park’s main entrance, Ideum and the NPS created a way to draw visitors into the new interactive exhibit hall. At the Welcome Station, a 65-inch Ideum Presenter is programmed to be a Digital Docent providing maps, FAQs, and other day planning tools. Most notably, it includes a countdown clock inviting guests to witness the “volcanic eruption” of the table every hour, a feature drawn from the visitor anticipation that surrounds Yellowstone’s Old Faithful geyser. For more information: Ideum Ideum Presenter Displays Innovative Design Valles Caldera National Park Previous Facebook LinkedIn Copy link Next

Motion control for the chairs in "The Voice" had to operate smoothly every time. The Technology Behind the Rotating Chairs on The Voice Motion control for the chairs in "The Voice" had to operate smoothly every time. Terry Persun Film and TV Jun 16, 2025 Stage Events The Scenic Route is a Southern California based global resource company that provides design and integration services to the entertainment, live event, and trade show industry. The company was tasked with the opportunity to work with The Voice, which required their chairs to rotate 180 degrees based on a simple push of a button. Also from Entertainment Engineering The chairs had to move smoothly and stop smoothly for the show. They chose to apply a proven motor drive to operate the motor. The operation required that the drive could sense two end-of-travel limit switches set at either end of the 180 degree movement. The company chose the AllMotion RGA440-10-CYC smart drive, which is a full-featured regenerative controller with the internal intelligence of a Programmable Logic Controller (PLC) built into the drive. When either of the end of travel limit switches would be tripped, the motor drive would stop the motor in that position. Resetting the chairs to the previous position would be accomplished by pressing a reverse pushbutton. Photo: The swiveling chair from The Voice The RGA-CYC Series provides an added logic board to AllMotion’s RGA400 controls. These controls are dual voltage, fully-featured regen drives in a rugged enclosure. As high-performance controls they maintain motor speed with automatic motoring and braking torque, while allowing high-duty cycle reversing and braking—great for limit switch applications. Included are a power on/off switch and separate forward and reverse speed potentiometers so independent speeds for each direction can be easily set. Controlling the motor is user-friendly too, by pressing a button on the membrane panel for stop, run, reverse, or jog (jog speed is adjustable). The user can also wire in remote pushbuttons in conjunction with the on-board buttons. These controls can operate in several modes with either one or two limit switches, including continuous cycling, single cycle, dwell, and more—including adjustable stop and dwell times. Although this application might appear to be very simple, it comprises many of the facets of motion control that would have previously required several components to accomplish. The AllMotion motor drive essentially replaced a PLC plus the PLC power supply. Not all applications will be this straight-forward, but as design engineers maintain an open mind about what the new smarter drives are capable of, they can apply the technology to solve applications in simpler and more efficient ways. For more information: AllMotion American Control Electronics The Scenic Route Previous Facebook LinkedIn Copy link Next

See how the Legoland Shanghai Resort integrated technology and creativity to produce fun and interesting water systems for a fully immersive experience. The Water Systems Behind the Most Technologically Advanced Legoland See how the Legoland Shanghai Resort integrated technology and creativity to produce fun and interesting water systems for a fully immersive experience. Terry Persun Theme Parks Oct 21, 2025 The core mission of nearly every theme park is to offer a dynamic blend of rides and attractions that capture the imagination while delivering an experience that feels both immersive and authentic. Legoland has achieved this vision across its ten operating parks and resorts worldwide, with four additional destinations currently in development. At the heart of these experiences lies technology that is robust, precise, and deliberately unobtrusive. Reliability and safety are paramount, enabling guests to embrace the thrill, wonder, and excitement of each attraction while feeling fully secure. The Legoland Shanghai Resort represents a milestone in this tradition, positioning itself as one of the most technologically advanced Legoland properties to date—particularly in its aquatic environments. Developed by Merlin Entertainments, creatively master-planned by FORREC, and engineered by Cloward H2O, the resort brings together world-class expertise to craft memorable experiences tailored to Legoland’s family audience. Images courtesy of FORREC. One example of this collaboration is the Water-Town Boat Tour, a signature family-friendly attraction. The ride immerses visitors in a lovingly detailed recreation of a traditional Chinese water town, where Lego storytelling blends seamlessly with cultural motifs. The journey culminates in a striking miniature Lego skyline of modern Shanghai. Each partner played a distinct role in realizing the attraction: FORREC shaped the thematic narrative and guest journey, Merlin designed operations to accommodate large visitor volumes, and Cloward H2O provided the aquatic engineering—integrating propulsion systems and water technologies that make the experience both seamless and safe. The technical backbone of the Water-Town Boat Tour reflects this integration. Hydraulic pumps maintain consistent water levels and stabilize docking platforms while ensuring full accessibility compliance. Flow within the canal is carefully regulated to eliminate turbulence, and water circulation systems operate continuously to preserve clarity and quality. To achieve this, the ride incorporates eccentric reducing strainers, sand filters, regenerative media filters, up to eight chlorination systems, and UV sterilizers—all working in concert to maintain safety and visual appeal. Beyond individual attractions, Legoland Shanghai Resort is designed as a fully immersive experience. Its diverse lands include Lego City, the Legoland Hotel, and Lego Friends. Within the Lego Friends area, highlights such as the Friends’ Water Party combine interactive play with aquatic fun, featuring water races, beach parties, and build-a-boat challenges. Each of these experiences is underpinned by the same principles: precise engineering, guest safety, and seamless operational efficiency. For example, flow rates across all water features are meticulously calibrated to balance fun and safety. Splash zones are engineered for predictable spray patterns, ensuring guests enjoy refreshing play without becoming uncomfortably drenched. The resort’s waterways are carefully engineered to prevent stagnation, ensuring water remains clear, clean, and safe for guests. Integrated hydraulic systems further enhance efficiency by reducing energy consumption while maintaining reliable performance. In practice, the resort employs everything from two 4-horsepower pumps to larger 30- and 40-horsepower systems where needed. Circulation zones across the park are strategically designed to prevent stagnation, keeping water consistently clear and safe. Integrated hydraulic systems connect lagoons with surrounding waterways, reducing pumping energy requirements and contributing to sustainability. Images courtesy of FORREC. These and more achievements were only possible through the close collaboration of FORREC, Merlin Entertainments, and Cloward H2O, whose combined expertise shaped both the creative vision and the technical precision behind the resort’s aquatic design. FORREC defined the spatial and thematic design, Merlin oversaw gameplay mechanics and operational logistics, and Cloward H2O engineered the hydraulic and electrical systems that controlled propulsion and splash timing. The result is a resort that stands out for both its creativity and its technical sophistication. The ability to coordinate such a wide range of components into a streamlined, reliable operation is what ensures Legoland Shanghai Resort can deliver joyful, safe, and lasting memories for its guests. For more information connect with the firms below: Cloward H2O Merlin Entertainments FORREC Read more about theme parks >>> Previous Facebook LinkedIn Copy link Next

An animatronic is more than a handfull of actuators stuffed inside a furry package. True animatronics must look authentic and move in a realistic manner, producing smooth motion across a range of operating speeds. Building High-End Animatronics An animatronic is more than a handfull of actuators stuffed inside a furry package. True animatronics must look authentic and move in a realistic manner, producing smooth motion across a range of operating speeds. Terry Persun Theme Parks Jun 7, 2025 Cool Stuff Romaire Studios leveraged in-house expertise for the artistic design, engineering, manufacturing, testing, programming, and installation efforts required for each of their projects. They leave no detail unresolved, which is critical to the successful design of unique products, purpose-built for a specific applications. Clients typically provide key references to the studio, including a creative direction and technical requirements, but it is the responsibility of the studio to take those references and develop a robust and reliable design. In the case of animatronic figures, these references can include a list of anatomical functions that the figure must possess, such as facial expressions, head movement, limb movement, body twists, and more. All functions, regardless of speed or range, are approached with the same attention to detail and engineering precision. In this article, we will discuss the design and fabrication of five animatronic figures the studio built for a THEA-award-winning attraction operating in a major Hollywood theme park. One particular figure is considered one of the most complex animatronic characters the theme park has ever commissioned in terms of function count and packaging density. Each of the five configurations of the figures had to fit within the unique storyline of the scene in which it was located. The animatronics were mainly constructed from CNC-machined aluminum parts, but they often incorporate steel components when additional strength was needed. The shells that form the organic body shapes of each figure were designed to be fabricated using 3D printing technology. Photo: Romaire Studios offers a world class research and development team incorporating sophisticated engineering practices. Maxon motors are used in many designs for their robust quality and long life. Each animatronic incorporates multiple motion systems that must be accurately controlled for position and speed so that the figures can be programmed to play back show-specific animation profiles. An animation is typically generated via live puppeteering or derived from a digital animation using Maya software. The animation is then streamed to the motors via an animation controller. If the motors cannot keep up with the motion, the system will produce a fault. Using reliable high-performance motors is the only approach that ensures the system will run flawlessly. After the studio’s team of engineers have designed the mechanisms for a figure’s functions, they use multi-body dynamic simulations to calculate the torque and speed required to meet the creative performance of each figure. The whole process is highly iterative because the figures are so densely packaged. The motors selected to achieve the required motions must fit into compact spaces alongside various other mechanisms; oftentimes, the character must be redesigned using different mechanisms, alternate motors, or both. Adjacent mechanisms often affect each other as they battle for space until the final product is achieved. Motor Selection The motors used in Romaire Studios’ animatronics must offer high-performance, high-reliability, and long life; the minimum lifespan of a figure is typically 20 years, operating for 16 hours per day, 365 days per year. This means that the motor manufacturer must be as detail-oriented, and quality-focused as the studio. This is why maxon precision motors are often selected to be incorporated into their designs. It is important to note here that the motors are not used like they might be when incorporated into a manufacturing setting where constant speed or torque is required. Rather, the motors must follow an animation curve that is delivered using 16-bit position data at 100 frames per second. For the award-winning Hollywood project, the company purchased 63 motors for the project, using up to 24 maxon motors in a single animatronic. The main components used were brushless DC motors. EC-max motors of various sizes from 16mm to 30mm were combined with integrated planetary gearboxes of various reductions. At times, the motors interfaced with maxon motor’s EPOS4 50/5 drives, depending on the application. The engineering team at Romaire Studios used EPOS Studio to commission the drives, which made implementation fairly straight-forward. The hurdle was in developing the animation controller to work with the EPOS drives, which took additional firmware updates and troubleshooting before it was developed into a reliable system. Maxon motors offer a wide range of advantages to Romaire Studio’s projects. For example, the DC brushless motors provide a high torque value from a very small package. The line offers a wide variety of speed and torque combinations, as well, which allows for an ideal motor package to be available within a very confined space. This goes along with the availability of various gearboxes with very high ratios (>300:1), allowing for extremely high torque in a small package when required. Most importantly was the smoothness of the motion the motors are able to provide, even at slow speeds, due to the non-cogging motors. Compactness is a valuable feature of maxon’s motor drivers and controllers as well, which allows the company to package them within the figures, rather than externally. Great design and performance are important, but so is customer service. Maxon sales engineers were available to help the studio specify the required motors whenever there was a concern about proper fit and performance. Questions about the full capabilities available to them were answered quickly and with backup information when needed. All aspects of the working relationship were up front and quickly handled. Challenges Overcome Packaging all of that equipment inside an already full mechanical structure can definitely be a challenge. During the design stages, Romaire Studios engineers must come up with innovative solutions to achieve the desired motion within very tight spaces. In fact, the company was awarded a patent for a curling ear mechanism designed for this particular project. Another unique challenge they faced was the combination of performance with creative intent. Every customer has a particular vision for their project, and often meeting their vision with mechanical and motor solutions creates new ways to approach a project. Every animatronic must look as good as it performs. Through the use of realistic artistic designs and highly innovative mechanical and electrical engineering, Romaire Studios has helped to set the standard for movie-quality realism in theme park animatronic figures. Incorporating the highest quality mechanical systems and motion components helps keep the company at the forefront of the industry. For more information: Romaire Studios, Inc. maxon motor Previous Facebook LinkedIn Copy link Next

Augmented virtual reality ride helps customers be ‘in the moment.’ Virtual Reality Ride Experience Augmented virtual reality ride helps customers be ‘in the moment.’ Terry Persun Theme Parks May 21, 2025 When looking for automation challenges to solve, you don’t always have to look for industrial applications. AllMotion distributor Heitek Automation, located in Arizona, certainly thought outside the box when they helped develop and build a unique Virtual Reality (VR) experience ride for Dave & Busters, the well-known restaurant and entertainment business. Also from EE: How Jurassic World Rebirth Captured the Nostalgia of Film The VR experience was made with design cues from the Jurassic World trilogy and consists of a roller coaster-style carriage that guests sit in while wearing virtual reality googles. The ride’s carriage is supported by various actuators that lift and shift the carriage in multiple axes to provide the user with the sense of immersion during the experience. In the ride experience, the AllMotion DCH403-10 was used to drive several variable speed 24VDC fans that were wired in parallel and directed toward guests. The drive received speed command signals from a central computer that synced the action seen through the googles with the motion and airflow, providing an immersive VR experience. The DCH403-10 combines an AC to DC switching power supply with a regenerative PWM drive, creating an all-in-one solution to applications requiring control of 12 to 48 VDC motors when only 115 or 230 VAC power is available. The true lower output voltage will run your motor cooler and prolong brush life. The DCH403-10 is capable of speed or torque control, as well as cycling and positioning control when used with limit switches or resistive feedback devices. However, the microprocessor allows the drive to be programmed for custom applications or routines to meet OEMs requirements and the built-in isolation keeps PLC interfacing safe and simple. The DCH403-10 is perfect for those needing a wide range of low voltage motor control with quick braking or on-the-fly reversing when only AC line power is available. Contact: Heitek Automation: https://www.heitek.com/ AllMotion: https://www.allmotion.com American Control Electronics: https://www.americancontrolelectronics.com/ Dave & Busters: https://www.daveandbusters.com/us/en/home Previous Facebook LinkedIn Copy link Next

Pulled from aviation technology for pilot feedback and arcade games like Astro’s Playroom and Cyberpunk 2077, haptic feedback is used in movie trailers — among numerous other applications. Haptic Feedback Rumbles Your iPhone for the F1 Movie Trailer Pulled from aviation technology for pilot feedback and arcade games like Astro’s Playroom and Cyberpunk 2077, haptic feedback is used in movie trailers — among numerous other applications. Terry Persun Film and TV Aug 13, 2025 Sports The latest trailer for F1:The Movie , when viewed in the Apple TV+ App on an iPhone running iOS 18.4 or later, uses haptic feedback to provide the feel of the car engine as it rumbles into life in the pitlane. Keep watching because additional feedback synchronizes with gear changes and tire squeals as the car races around the track. All photos courtesy of AppleTV You’re familiar with haptic feedback by how your smartphone buzzes when someone calls and how game controllers shake, buzz, and rumble to make your experience feel more real. Haptic feedback has been around since the 1970s and is the feedback used on surgical robots so that doctors can maintain their feel of what’s going on during surgery. For this reason, the technology is also used in training simulators where soon-to-be doctors can experience how tissues, veins, and organs feel without using a human body. The automotive industry has incorporated haptic feedback as part of their Advanced Driver Assistance Systems (ADAS) for safety reasons—such as alerting drivers to potential hazards like lane departure and collision warnings. In manufacturing, haptics is used as feedback on robots allowing them to detect when there are product inconsistencies. Subtle variations in the texture of specific products can alert the robot to send an alarm to the supervisor to employ a human to inspect the anomaly. Even interactive product displays are using haptic feedback to allow customers to feel the texture, weight, or other physical properties of a product in a virtual setting. This adds to the information companies can now provide a customer before a purchase is made. The haptic technology market is estimated to be worth over $3.9 Billion. As companies like Apple explore its many applications, this market will only grow larger. And to that end, the new F1: The Movie trailer may be the start of a new experiential way to enjoy all sorts of entertainment. For more information: Apple F1: The Movie Previous Facebook LinkedIn Copy link Next

Unique dispenser technology can produce various types of sushi at the press of a button. Printing Sushi in Space? It's Not As "Out There" As You Think Unique dispenser technology can produce various types of sushi at the press of a button. Muge Deniz Meiller Cool Stuff Oct 21, 2025 The phrase “micro fluid dispensing” is generally associated with applications like medical device assembly or battery manufacturing. It certainly doesn’t conjure up visions of sushi—at least not yet. If engineers at IHI Aerospace and Yamagata University have their way, though, 3D printed sushi will be served to space tourists as they circle in low Earth orbit. IHI Aerospace is involved in developing a commercial space platform that could be used to carry civilians into orbit. The company is already looking ahead to enhancing all levels of the experience, including meals—in particular, sushi. IHI had to look beyond specialty chefs, sharp knives, and coolers of fish and seafood and decided to print the sushi with a lightweight countertop micro dispensing system. Considering that adventurers looking for the thrill of orbital spaceflight will expect an unforgettable experience which includes something more exotic than just a sandwich, IHI Aerospace reached out to Yamagata University, which has a strong aerospace engineering program and an equally well-regarded culinary arts program. After some brainstorming, the University team chose proteins in a paste form rather than as solid fish or seafood. Uni (sea urchin) and other fish pastes are common food items in Japan and many parts of the world. Thus, the concept of sushi made with uni paste is familiar. Pastes have benefits for both quality and logistics. The proteins are harvested and packed at the peak of flavor. Plus, packaged pastes are shelf stable with no leftover food waste to generate odor. Protein pastes are also compatible with non-contact micro fluid dispensing technology, making it possible to automate the sushi preparation. All photos courtesy of Nordson. The Challenges Developing printable sushi was an innovative concept and presented a number of challenges. The application required a specific volume of uni paste to be dispensed on a bed of rice in a specific pattern and location. Uni paste is a high-viscosity fluid that requires well-controlled pressure to dispense. The nozzle needed to be wide enough to discourage blockages but narrow enough to provide controlled deposition. In addition, the goal of the program was to create a system to produce four different kinds of printed sushi in paste form: uni, white fish, crab, and shrimp. The system needed to be able to toggle from one to another without flavor residue. Further, in the event of blockage, the nozzles needed to be cleanable. To tackle these challenges and build their prototype, the Yamagata University team turned to Nordson EFD Japan. By integrating a Nordson EFD PICO Pulse piezo jetting valve technology with a compact robot, the group created a precision micro fluid dispensing system capable of printing sushi that rivals products from the local sushi bar. The unit can be installed in a galley and produce various types of sushi with the press of a button. All photos courtesy of Nordson. Piezo valves are very high-resolution and reliable, with long lifetimes. These characteristics enable the user to tailor stroke length, precisely controlling the amount dispensed. This characteristic equips the PICO Pµlse jet valve to optimize deposition to achieve a uniform appearance for sushi pastes with different consistencies. The PICO Pµlse is a modular product, offering great flexibility and enabling it to be configured ideally for each application. A tool-free latch enables the fluid body to be exchanged rapidly and easily. Rapid exchanges are as useful during prototyping as they are once the product is in operation. The ability to swap out fluid carrying parts quickly allows the valve to serve its purpose of dispensing different types of pastes and being easy to clean. The IHI Aerospace/ Yamagata University team combined the PICO Pµlse valve with the Nordson EFD PICO Touch valve controller and fluid reservoir for an end-to-end solution that combined ease of integration with accurate, reliable operation. The next step was to choose the optimal nozzle to handle the protein pastes. Nordson EFD recommended a flat nozzle with a 300-micron orifice. This nozzle has a wide enough aperture to ensure smooth, controlled deposition of the protein pastes while minimizing the risk of blockages. This nozzle was covered with a special hydrophilic coating used for sticky fluids. It reduced surface tension of the wetted pathway for improved micro dispensing consistency. While printable sushi for orbital meals is an admittedly exotic use case, printable food in general could have a much broader impact. The Yamagata University team, for example, hopes to continue to explore the technology for food service in facilities like hospitals, nursing homes, and long-term care facilities. For more information: Nordson EFD Nordson Pico Pulse Valves IHI Aerospace Yamagata University Read more about food technology >>> Previous Facebook LinkedIn Copy link Next

To ensure the integrity of production data in real time, producers need a backup system that facilitates high-capacity and high-performance data transfers. How Do Filmmakers Back Up Their Data When Filming On Location? To ensure the integrity of production data in real time, producers need a backup system that facilitates high-capacity and high-performance data transfers. Film and TV Jul 28, 2025 The demand for secure storage is on the rise because filmmakers are often using live-action short films as a test bed for virtual production technology. For example, Ripple Effect is a short film and research project created through the Entertainment Technology Center (ETC) at the University of Southern California (USC). The production team for Ripple Effect relied on a relatively low-bandwidth internet connection on set—which meant that streaming backups to the cloud was not feasible. In order to ensure the integrity of the production data in real time, the producers chose to back up all their cameras using Lyve™ Mobile arrays from Seagate®. This storage-as-a-service solution enabled the production team to physically transport backups to an off-set data center. The ability to move production footage into the cloud enabled remote access to the data. ETC was founded with the support of filmmaker George Lucas, and has become a proving ground for movie studios to test new production ideas and experiment with innovative workflow strategies. The center’s work on remote production best practices is detailed in a white paper that discusses how Ripple Effect pushes the limits of virtual production. Improving production workflow is a big deal for studios that are investing in productions that cost millions or even hundreds of millions of dollars. All photos courtesy of Seagate. In an effort to develop a safe production environment, the ETC embarked on an ambitious live-action short film that was envisioned as a test bed for virtual production technology. The producers hope to debut their movie, Ripple Effect , at a film festival later in the year. But then COVID-19 happened. One of the major challenges for the entertainment industry in the wake of the COVID-19 pandemic had been figuring how to keep new productions in the pipeline while ensuring the safety of cast and crew. Although most movie theaters and live entertainment venues shuttered for more than a year, consumer demand for new in-home programming skyrocketed. One of the cornerstones of a virtual production environment is data. But managing large amounts of data while filming on a set—or on location—requires the orchestration of technology tools that can store and transport data flowing from cameras. Further, that data must be safe and secure, both at the edge and in the cloud, which is why the team turned to Lyve Mobile Arrays from Seagate. The filmmakers used Alexa LF large-format cameras during production. They produced about 2TB per hour of HDR and ARRIRAW footage. At its peak, the project was generating about 12TB of data per day. Three backups were created after every scene, with two files ultimately stored in the cloud and one remaining on portable drives. All photos courtesy of Seagate. Storing the data in the cloud wasn’t just for archiving. The ability to move all the production footage in the cloud enabled the Ripple Effect producers to provide their editing team with remote access to the data. One of the goals of the project was to reduce post-production costs by doing as much editing and related work as possible during production. The Ripple Effect project demonstrated that Seagate storage can meet high performance demands to support fast data transfers and streaming. It also supports enterprise-level media workflows that ensure the integrity of creative content. Moreover, support for open standards eliminates vendor lock-in obstacles. Today, the full data transfer service is integrated and available for a flat fee to any cloud. The service also offers a growing list of accessories which includes a Lyve Mobile Rackmount Receiver, with redundant power and network- or direct-attached server interfaces; a Lyve Mobile PCIe Adampter to connect your Lyve Mobile Array directly to an external PCIe port on your computer using an optional SFF-8644 converter; or a mounting chassis that allows you to quickly ingest and remove your Lyve™ Mobile Array. Watch Ripple Effect For more information, visit Seagate . Previous Facebook LinkedIn Copy link Next

The most powerful standalone telescope in the world uses modern miniature drives commonly used in industrial automation World's Largest Binoculars Allow Astronomers to Achieve Sharper Images The most powerful standalone telescope in the world uses modern miniature drives commonly used in industrial automation Edited by EE Staff Cool Stuff Nov 3, 2025 Astronomers are particularly interested in setting sights on distant galactic systems, young double stars, and newborn suns. A definitive way to proceed with such goals includes the Large Binocular Telescope (LBT) located on Mount Graham in Arizona. The telescope has a height of over 20 meters and weighs over 600 tons and is the shape of an outsized pair of binoculars. The LBT’s two reflectors each have a diameter of 8.4 meters, and together they make up an approximately 100 sq. meter dish for collecting light. In this way it can even collect the radiation from weakly illuminated objects at the limits of the universe being observed. The interaction of the two reflectors mounted 14.4 meters apart provides the telescope with a resolution that would correspond to that of a pair of binoculars having a diameter of 23 meters. Each reflector resembles a giant "honeycomb" made from borosilicate glass and weighs 15.6 ton. All photos courtesy of Faulhaber. The design of the telescope and its integrated optical systems provides scientists with a high level of flexibility when making their observations. That way they can use each of the reflectors independently of one another to view the same object, but also study different objects by tilting the viewing axes slightly or use both reflectors to observe the same object at maximum resolution. In order to achieve the unusually high definition, the rays of light reflected by each reflector are superimposed—brought to a state of interference. Consequently, the resolution is nearly ten times better than with conventional standalone telescopes. However, the requirement that has to be met to ensure the LBT works smoothly is that individual components made in the three partner countries—the US, Italy, and Germany—interact perfectly and under adverse conditions. After all, Mount Graham is approximately 3,300 meters high. The climate is characterized by temperatures below freezing, humidity of up to 90%, and extreme temperature fluctuations. Positioning unit for interference generation If a high-resolution image is to be created by the generation of interference, the optical assemblies attached to the two reflectors for bundling and superimposing the reflected light have to be positioned with an accuracy of 5 µm. For this purpose, the Feinmess company in Dresden (Germany) developed a three-axis positioning system that moves the appropriate optical system on the two reflectors of the LBT into the correct position. Horizontally, distances of up to 200mm have to be covered (longitudinal positioning), and vertically, for focusing purposes, there are distances of up to 50mm. At the same time the optical assembly has to be rotated through an angle of up to 36 degrees. In order to ensure the required positioning accuracy, the system has to operate with as little play as possible. That is why great importance is accorded to the drives on the spindles. In this case, the drive solutions included traditional bell-type armature motors with coreless rotor coil from FAULHABER. The small DC drives operate reliably even under hostile ambient conditions such as ambient temperatures between -30°C and +125°C. The devices are not affected by a high level of humidity (up to 98%) when specified appropriately. An important basic criterion for motor selection included instant, high torque starting for the DC motor after application of voltage, which ensures a direct response to control signals. The coreless copper coil allows an extremely lightweight motor design with a high efficiency of up to 80%. The motors used on all three spindles of the positioning system have a diameter of 26mm and are only 42mm long. At speeds of up to 6,000 rpm they provide a power output of 23.2 W. All photos courtesy of Faulhaber. A Compact Unit In the LBT application, the motors were combined with two-stage planetary gearheads with a ratio of 16:1. Flanged to the end of the motor, gearhead performance is extremely impressive, not only due to their compact design but also because of their steady running and durability. Gearhead backlash was factory optimized for use on the positioning system. Instead of the values of about 1 degree, customary on standard gearheads, these planetary gearheads have a backlash of only 12 angular minutes, measured at the output shaft. Knowing the actual position of the motors is an essential prerequisite for precision positioning. With the positioning systems employed on the LBT it is detected at each motor by an optical pulse encoder that generates 500 pulses per revolution. Using a metal disk, a transmitted-light system generates two phase quadrature output signals. The index pulse is synchronized with output B. For each of the three channels there are inverted complementary signals. The pulse encoder is fitted to the free end of the motor shaft and fixed with three screws. Supply voltage for the pulse encoder, the miniature DC motor, and the output signals are connected via a ribbon cable and a 10-pin connector. Since the drive units, comprised of the motor, gearhead, and pulse encoder, are extremely compact, they are easy to integrate into three-axis positioning systems. For more information: Faulhaber Miniature DC Motors Planetary Gearheads Feinmess Company Large Binocular Telescope Observatory Read about more cool applications >>> Previous Facebook LinkedIn Copy link Next

Special lighting with various accessories and optimized controls are used by one creative boutique to light multiple scenes easily and effectively. Three Light Units Help Create Cinematic Visual Effects Special lighting with various accessories and optimized controls are used by one creative boutique to light multiple scenes easily and effectively. Film and TV Jul 21, 2025 Aaron Sims Creative (ASC) is a full-service creative boutique that focuses on cinematic visual effects (VFX). ASC has provided iconic characters and worlds for a broad number of high-profile projects, including the Netflix drama “Stranger Things” and the Warner Bros. movie “Ready Player One.” ASC has adopted Litepanels’ Gemini 2x1 Soft LED panel. Gemini delivers precision color control along with a broad array of dynamic lighting and cinematic effects in a highly portable, battery operated, and lightweight LED panel, providing the ASC team with newfound flexibility and versatility in creating unique lighting applications. According to Mauricio van Hasselt, production manager for ASC (see photo below), “Lighting plays a critical role in our work, enabling us to add real-world components to our computer-generated visual effects for enhanced realism. We need highly versatile lighting tools that are not only dependable but offer fine-tuned control. I had heard about Gemini, but once I saw it for myself, I knew I’d found the ‘all-purpose utility knife’ we needed for lighting our projects.” All photos courtesy of Litepanels “Gemini produces true, full-spectrum white light and offers an extensive choice of control options for most lighting applications the team might dream up. The light’s exceptional color and realistic skin tones virtually eliminate the need for color correction, saving our clients time and money in post-production. And since I’m no stranger to Litepanels—their Astra LED panels have been my mainstay lighting kit for many years—I knew I could count on the product’s durability, performance, and outstanding light quality.” Gemini delivers flicker-free light for any frame rate, shutter angle, or intensity, making it ideal for high-speed photography, with smooth dimming from 100 percent to 0.1 percent for the smallest glint of light. The ASC crew is able to set Gemini’s correlated color temperature (CCT) anywhere from 2,700 to 6,000K to get accurate color rendition and add or subtract green with the turn of a dial. The crew can select virtually any color in the different color modes from the 360-degree color wheel in HSI Mode or create specialty colors in RGBW Mode by controlling each color independently. With Gemini’s new firmware release, the units now offer a broad array of dynamic special effects ranging from emergency lights, lightning, and fire, to pulsing, square, and strobe, just to name a few. In one on-location example, the ASC crew can use Gemini to generate on-set muzzle flashes that the actors and environment can react to, making the scene much more realistic than if the effect were added later in post-production. In another example, a scene with a laser beam, the crew was able to use Gemini to change the color of the laser instantly to support the director’s creative vision as he tried different scenarios for the scene. ASC also uses Gemini to generate interactive lighting on location that will later be motivated by sources created in CG. Van Hasselt added. “We were especially impressed with Gemini’s extremely light weight. I can carry the light with me to any location, and we can easily mount the panel on a boom—a phenomenal advantage when dealing with tricky top-lighting situations. Also, with Gemini’s highly intuitive and easy-to-use control interface, we can achieve a desired effect almost instantly. We’ve been able to save multiple USB presets for a variety of different looks, such as action or horror, and then trigger them any number of times with the touch of a button.” ASC VFX continually pushes the boundaries of cinematic visual effects, and its otherworldly creatures and setting have brought chills and thrills to audiences all over the world. Through the use of Gemini, from Litepanels, this single lightweight piece of equipment provides the ASC visual effects team with greater flexibility than they’ve had in the past—and with a wider range of solutions. For more information: Litepanels Aaron Sims Creative Videndum Previous Facebook LinkedIn Copy link Next

Bionic and the Wires uses bionic arms, bio-sensors, and electronic instruments to create music from plants and fungi. Mushrooms Playing Music? How an Engineer and a Musician Turn Bioelectric Signals into Art Bionic and the Wires uses bionic arms, bio-sensors, and electronic instruments to create music from plants and fungi. Nicole Persun Music Nov 11, 2025 Cool Stuff Somewhere in the woods outside Manchester, a mushroom is hooked up to electrodes and bionic arms and given a synthesizer. In response to the fungi’s bioelectric signals, the mallet-like arms knock on the synthesizer and create music. Bionic and the Wires is an artistic project that blends technology and nature. It was created by Jon Ross, a multi-disciplinary eco-artist, technologist, and environmental thinker, and Andy Kidd, a musician with a background in electronic music. Jon brings the “how” with the technology, and Andy brings the “what” with the sound design. The result is strange, otherworldly music that’s intended to make the viewer think differently about the natural world. The inspiration for the project came, Jon says, “from two key areas: the emerging scientific understanding of non-human intelligence (e.g. in fungi and plants), and a desire to experiment with music.” Jon and Andy have made music together for nearly ten years, but things changed when they started running simple bio-sonification experiments by connecting sensors directly to synthesizers. “The critical leap came when I had the idea for the bionic arms in 2024,” Jon says, “enabling plants and fungi to play real life instruments.” This allowed these organisms to become active creators rather than simply passive subjects. “By giving plants and fungi ‘hands,’ we challenge the exclusive human claim to artistic creation and invite profound reflection on the unique essence of human consciousness versus the intelligence found throughout nature.” At its heart, Bionic and the Wires is meant to “foster a deeper connection with the living world.” Andy Kidd (left) and Jon Ross (right) playing music with a peace lily plant. All photos courtesy of Bionic and the Wires . How it works The music is created through various components, including bio-sensors, bionic arms, electronic instruments, and — of course — the plants and fungi. The primary sensor is a biosonification device (MIDI Sprout) from Electricity for Progress, which operates on a galvanometer-style circuit. When clipped onto a leaf or the bell of a mushroom, the sensor detects minute magnetic fluctuations in the plant or fungi’s electrical conductivity, which is impacted by the nutrients and water that make up its physiological state. In other words, the sensors detect the plant’s “mood” based on its electrical charge. The electrical activity of the plant is then translated into MIDI signals, which are fed into bionic arms custom-engineered by Jon. This allows the plants and fungi to “control” the motion. The final piece is the music technology. “We utilize a combination of traditional and electronic musical instruments as the final output devices for the plants' signals,” Jon says. While the rhythm comes from the plants and fungi, Andy’s artistic role is in deciding how to translate the motion with the synthesizers. For routing, they use Ableton Live, a digital sound software. Aloe with a keyboard. All photos courtesy of Bionic and the Wires. The intersection of technology and nature Different plants and mushrooms yield different results, and Jon and Andy have experimented with a wide variety. “Some have a much faster signal response than others,” Jon adds. “We choose the plant/fungi based on what type of music we want to make.” Bionic and the Wires shares music on YouTube and other social platforms. “Our art serves as a bridge, making complex scientific concepts about bio-electricity and plant cognition accessible and understandable,” Jon says. It’s the intersection of nature and technology that makes it possible. Their vision for the future of Bionic and the Wires stems from its original idea: “We hope to continue pushing the boundaries of what it means to be an artist and who gets to create,” Jon says, “with a future goal of solidifying the recognition of plants and fungi as creative entities.” For more information: Bionic and the Wires Bionic and the Wires on YouTube Electricity for Progress Ableton Live Read more articles about music >>> Previous Facebook LinkedIn Copy link Next