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Entertainment Engineering co-founder Terry Persun shares his thoughts on innovation and failure for December 2025's editor's note. Editor's Note: You Can't Have Innovation Without Failure Entertainment Engineering co-founder Terry Persun shares his thoughts on innovation and failure for December 2025's editor's note. Terry Persun Editor's Note Dec 1, 2025 I’ve always been interested in how innovation happens and how problem-solving often leads to success. There has been a lot of research completed about learning from failure in order to eventually turn a creative approach into a success. We all know the stories about Walt Disney (we are still running articles about that company’s innovations), Steve Jobs, Oprah Winfrey, and as far back as Thomas Edison. For all of these people, multiple failures—often significant failures—eventually led to something innovative and successful. By giving your engineers the space to fail, you also allow more space for innovation, which can eventually carry your company to the forefront. In order for a company to be innovative, for a company to branch out and do more with their products and services, even to find new avenues for sales, some measure of failure must happen. But here’s the rub: how do you know when to stop and when to continue forward? How do you know when it’s just not the right time for the idea, or the move into a new market, or the acceptance for a new approach? You don’t. But at the same time, if you never break out from the crowd, you will never be able to offer something innovative or unique. Sometimes a result may even look like a failure at first but with some consistency will turn into a success. It’s a fact that people generally like to live in some amount of equilibrium, where change is minimal. This means that new ideas can be shut down before they get the chance to take off. But an engineer can't innovate without the freedom to experiment and—yes—fail; by giving your engineers the space to fail, you also allow more space for innovation, which can eventually carry your company to the forefront of your industry, rather than trailing behind or being average. If you’re an engineering manager, this means that you must protect your engineering staff. To be innovative, you have to present a safe and psychologically secure environment for them to try new approaches. Then you have to help your team learn from their failures while providing a positive memory of the experience—which makes them even more able to innovate further. Today, the most successful endeavors are a result of past failures, where the people and company learned from mistakes in order to clear a better path forward. Previous Facebook LinkedIn Copy link Next

How engineers made the loading conveyor for Ain Dubai — the world's biggest observation wheel — faster, safer, and more efficient. Climb Aboard the World's Tallest Ferris Wheel How engineers made the loading conveyor for Ain Dubai — the world's biggest observation wheel — faster, safer, and more efficient. Edited by EE Staff Attractions Feb 24, 2026 Theme Parks With a diameter of 250 meters, the “Ain Dubai” is the largest and highest Observation wheel in the world. The world’s first concave loading conveyor belt from Sunkid allows around 1,750 visitors an hour to take in the views above Dubai. The Austrian manufacturer Bruckschlögl GmbH is a global market leader in the supply of small ski-lifts and chose inverter drives from Yaskawa for this challenging task. Named after the Arabic word for “eye,” “Ain Dubai” — or "Eye of Dubai" — is a magnificent attraction in the largest city in the United Arab Emirates (UAE). Over 11,000 tons of steel were used in its construction. Each of its spokes are longer than a football field. And each of the 48 luxuriously fitted cabins is larger than two double-decker buses. Another feature of this record-breaking observation wheel — which itself towers over observation wheels in Las Vegas, London, and Singapore — is its special loading conveyor belt, which can move up to 30 percent faster and can thus increase capacity by 30 percent. Furthermore, the loading conveyor belt is also designed as part of the emergency evacuation route. First U-shaped Loading Conveyor Belt Bruckschlögl GmbH, which is headquartered in Bad Goisern in Upper Austria, developed and produced both the belt and the access gate. The company is the main innovation and design location of the Sunkid family of companies. Conveyors from Sunkid (Sunkid Moving Carpet), which were originally developed as ski conveyors are also now used in the amusement park industry and a variety of other applications worldwide. All photos courtesy of Yaskawa. The loading conveyor belt created for “Ain Dubai” is one of the highlights of the company’s solutions to date: it is the first to have a concave U-shape that follows the specific design of the platform. Meanwhile, the design of the antistatic link chains ensures the highest safety standards, silent operation and slip resistance. The chain tensioning eliminates vibrations. Last but not least, a special cleaning feature effectively counters the local climatic conditions in Dubai, including heat, dust, wind, and salty sea air. The overall system conforms to the conveyor belt standard EN 15700. Drive Engineering Challenges Since the Observation wheel turns continuously, the loading conveyor belt optimally adapts the difference in speed between the rotating gondolas and the static platform to achieve the necessary level of safety and the maximum achievable capacity. To do so, the standalone control unit for the loading conveyor belt communicates with the control unit for the Observation wheel and access gate. The normal speed is 0.2 meters per second. Three inverter drives from the Yaskawa GA700 series provide the drive control. Through an internal Modbus bus system, the inverter drives were able to be tightly synchronized with each other. This ensured perfect synchronization between the movements of the while and the belt. The GA700 series offers a high level of connectivity by providing interfaces for all common fieldbuses which enables integration is a wide variety of system environments. This connectivity includes Ethernet/IP, Profibus, Profinet, EtherCAT, Powerlink, CANopen, DeviceNet, CC-Link, and the Yaskawa bus MECHATROLINK. All photos courtesy of Yaskawa. The inverters also feature an integrated RS-485 interface, allowing them to be networked with one another. Up to five inverters can be controlled with a single option card, meaning that fewer cards are required and thus lowering installation costs. These robust and reliable devices meet the high requirements for availability even under particularly challenging climatic conditions. They are able to tolerate operating temperatures up to at least 50° C (122 o F) with no derating. In addition, Yaskawa provides an on-site service, and stocks spare parts in Dubai—as it does in many other markets worldwide. Industrial Drive Versatility The GA700 is the versatile Yaskawa drive for industrial applications in a wide variety of industries. The GA700 inverter series is available in a power range of up to 355 kW and features an outstanding level of user-friendliness along with worldwide standards and maximum reliability. High flexibility, small dimensions and built-in functions make it easy to integrate into practically any application. Intelligent tools such as the startup wizard, data logging, the DriveWizard mobile app, and many more help with setup, startup, and troubleshooting. All photos courtesy of Yaskawa. Functional safety features such as SIL3-compliant STO inputs (Safe Torque Off) and an integrated EMC filter complete the basic equipment of the GA700 inverters. The STO function enables emergency stops to be applied easily and safely. All model variants are designed in protection type IP20 and are correspondingly robust. They are designed for ten years of maintenance-free, continuous operation. For more information: Yaskawa GA70C-GA7000 Series Bruckschlögl GmbH Read more about theme parks and rides >>> Previous Facebook LinkedIn Copy link Next

An interview with Entertainment Engineering co-founder Terry Persun about the magazine's relaunch WATCH: Why Now is the Best Time for Entertainment Engineering's Relaunch An interview with Entertainment Engineering co-founder Terry Persun about the magazine's relaunch Videos Aug 7, 2025 Cool Stuff Terry Persun and Joe Gillard discuss Entertainment Engineering Magazine's digital relaunch and why engineers should care. Entertainment Engineering focuses on the engineering behind entertainment, including films TV, sports, stage, and more. Previous Facebook LinkedIn Copy link Next

McCune Audio, full-service technical event specialists, rely on classic 4088s and discreet 4060s to mic guests and props for the renowned conference. TED2014 Uses DPA Microphones McCune Audio, full-service technical event specialists, rely on classic 4088s and discreet 4060s to mic guests and props for the renowned conference. McCune Audio Stage Events Jun 4, 2025 Heard by thousands of people through live audiences, simulcasts, webcasts, and recordings, and millions more through online video engines, the annual TED Conference requires gear that matches its prestige. With discussions that address a wide range of topics within the research and practice of science and culture, microphones are vital to all TED audiences. To provide the ultimate in sound quality for presenters and performers at TED2014, technical team from McCune Audio/Video, the symposium’s sound services company, relies on DPA Microphones’ classic 4088 Directional Headset Microphones and d:screet 4060 Omnidirectional Microphone. TED2014 marks the second time that DPA Microphones is part of the audio setup for the conference. The McCune Audio team used the same selection of mics at last year’s event because of the high-quality audio of both mics and comfortable fit and feel of the 4088, each requests from production crew workers and presenters, respectively. “For years, the post-production crew was trying to get us to reduce the amount of room acoustics we were hearing in the recordings,” says Nick Malgieri, McCune’s Head of Audio for the TED Conference. “Because of the live PA system in the room, there was a slap-back echo always happening in the voice. We really used some pretty extreme processing paths with our previous mics just to try to help us get ahead of the issues. Once we switched to DPA 4088s, the added isolation let us really scale back on the processing. The sound was so much better that the post-production crew asked us to deploy ambient mics to capture the energy of the venue. That led us to the d:screet 4060s, which we use to pick up a lot of the stage noise from the props and scenery on set, such as chalkboards during presentations, a fire organ for a pyrophone performance or a target being hit by an archer.” The versatility of the DPA mics also plays an important role in the audio support at the TED Conference, which hosts 12 90-minute shows over the course of five days. Throughout each of these individual productions, Malgieri and his crew need to mic as many as 10 separate presenters speaking for up to 18-minute segments each. In these instances, the audio team uses the 4088s. The shows also incorporate other types of presentations, such as musical, theatrical or dance performances, or magical acts, which require the 4060s. “The technology setup for this show is very important because of the high turnover and the way the show is actually produced,” explains Malgieri. “We are doing three shows a day, with only an hour or so to reset between them, so we need high-end gear that can keep up with the constant demand and rigorous use.” As one of DPA’s most popular products, the 4088 is ideal for a variety of performing and vocal presentations. It is designed for acoustically demanding live performance environments, where background noise and feedback is a concern, and boasts the same open and natural sound qualities of the company’s other legendary microphones. Originally designed for use with wireless systems in theater, television and close-miked instrument applications, the d:screet 4060 capsule is highly unobtrusive. Because of its small size, this tiny condenser mic exhibits an exceedingly accurate omnidirectional pattern, and therefore does not need to be aimed directly at the sound source to achieve quality pickup. For more information, visit DPA Microphones . Previous Facebook LinkedIn Copy link Next

Along with comparative analysis tools, Trek Bicycle was able to fine-tune prototypes, investigate potential issues, and adjust their manufacturing process. How Industrial CT Scanning Allows Engineers to Examine Parts Non-Destructively Along with comparative analysis tools, Trek Bicycle was able to fine-tune prototypes, investigate potential issues, and adjust their manufacturing process. Edited by EE Staff Sports Feb 24, 2026 Trek Bicycle is on a mission to make the world a better place to live and ride. Despite humble beginnings in a Wisconsin barn, Trek has been on the cutting edge from day one. Starting with its visionary early entry into carbon fiber bike frames, Trek’s engineering teams continue to embrace new technologies that will benefit their riders. According to Chad Manuell, Global Director of Engineering, Trek, “Our goal is to make only products we love. To do that, we need to have access to the best tools. Over the years, our products have become more complicated, and the tools we use have gotten more sophisticated.” CT scanning had been on Trek’s wish list for a long time, but the complexity and cost of legacy systems kept this vital inspection tool out of reach. Easy to use and significantly less expensive than competitors, the Lumafield Neptune scanner and Voyager analysis software made it possible for Trek to add CT to its core engineering toolkit. “When we got the opportunity to bring a Neptune in-house, we jumped on it,” Manuell said. The Neptune scanner and Voyager analysis software have delivered actionable insights to help Trek create products that both they and their customers love. Examining parts non-destructively with industrial CT allows Trek to understand the implementation of their designs. Larry Lardieri, Product Design Engineer, notes that “The Neptune scanner has given us the ability to look at our prototypes even more closely. It helps us investigate potential issues like adhesion, porosity, and plastic part design shrinkage.” Using Voyager’s suite of comparative analysis tools, including CAD Comparisons, Trek can tune design and production parameters to adapt to a manufacturing process. By overlaying a CAD file on a scan of a finished physical product, Voyager computes deviation from the design and visualizes it using color maps. Images courtesy of Lumafield and Trek. Legacy CT systems process and store data locally, usually requiring a dedicated operator and hardware system. Interacting with this invaluable data has traditionally been restricted to technicians. Lumafield's cloud-based software, however, gives engineers direct access to their scan data, and lets them share it with colleagues. Lumafield’s Voyager analysis software allows Trek engineers to easily access and share scan data, collaborate on analysis workflows, and visualize both external and internal features — all within their own web browser. Anyone using Voyager can author bookmarks, leave comments, and collaborate on analysis in real-time using Voyager’s user-friendly interface. Trek engineers also use Voyager’s high-resolution images of both 2D slice planes and 3D volumetric reconstructions for internal presentations, enabling them to solicit feedback from across teams and chart the progress of product development. Advancing e-Bike Battery Technology The electronics of the future are powered by lithium-ion batteries, which must be carefully integrated into products. This is especially true of products that push the limits of size, weight, and ergonomics. Trek has emerged as an industry leader in electric bikes, and its engineers are constantly innovating on battery integration. For Trek’s eSystems team, CT scanning has emerged as a safe and effective way to inspect the details of these critical components. For batteries, destructive testing not only deprives engineers of insight but can also be dangerous. With industrial CT, Trek engineers gain deep insights into battery enclosure design, latching mechanisms, and overall performance. Voyager’s advanced dimensioning tools allow for automated measurements that can help elucidate the integrity and performance of lithium-ion batteries. Enhancing Safety by Quantifying Impact Rider safety is a top priority at Trek, and CT scanning provides important insights for both bike frame and helmet design by illuminating how they respond to impacts. With Neptune and Voyager, Trek engineers can comprehensively study the way impacts affect a wide variety of materials used in bike parts and helmets. Images courtesy of Lumafield and Trek. To understand which materials and frame designs are less susceptible to everyday impacts from rock strikes and collisions, Trek engineers intentionally impact sections of bike frames and then analyze them with Lumafield’s CT scanning platform. Voyager enables engineers “to be able to do some real exact measurements of the impact site after the first hit, second hit, third hit, which allows us much more information than was previously available,”Manuell said. Megan Bland-Rothgeb, a Helmet Research Engineer at Trek, is able to use CT to quantify helmet impacts. This allows Trek to analyze designs to create high-performance helmets. Lumafield’s Expanded Scan Volume feature broadens the field of view on the Neptune scanner, enabling the inspection of parts that are up to 80% larger than before. Many bike helmets fall into this range and can now be fully scanned at high resolution. Trek’s meticulous, data-driven approach to understanding bike frame and helmet impact dynamics fuels the development of longer-lasting and more reliable products. Trek harnesses the power of Lumafield’s Neptune CT scanner and Voyager analysis software to fortify their product development process. From non-destructive testing of bike frames and parts to advancing e-bike battery integration and enhancing safety through quantifying impact, Trek is poised to advance its mission of getting more people on bikes by guiding the next phase of cycling innovation. For more information: Lumafield CAD Comparison Expanded Scan Volume Trek Previous Facebook LinkedIn Copy link Next

A team of students from a broad mix of engineering disciplines designed, built, and raced a solar-powered car across 3,000 kilometers of Australian wilderness. Here's how they did it. Race Car Crosses Continent With Nothing But Solar Power A team of students from a broad mix of engineering disciplines designed, built, and raced a solar-powered car across 3,000 kilometers of Australian wilderness. Here's how they did it. Alex Edwards, Protolabs Sports Aug 28, 2025 Cool Stuff What does it take to build a car capable of crossing a continent on nothing but solar power? For the Brunel Solar Team, it’s a combination of deep engineering talent, relentless motivation, and an ability to adapt under pressure. As the world’s most decorated solar racing team prepares for the 2025 Bridgestone World Solar Challenge, I sat down with two of its members, Merijn Kroon, Partnerships, and Lucas de Jong, Mechanical Engineer, to explore the innovation behind their latest vehicle, their collaboration with Protolabs, and what it really takes to chase the sun across the Australian outback. Each year, a fresh team of students from TU Delft in the Netherlands puts their degrees on hold to focus full-time on one ambitious goal: designing, building, and racing a solar-powered car across 3,000 kilometers of Australian wilderness. The team draws from a broad mix of disciplines—mechanical engineering, electrical engineering, architecture, aerospace, industrial design, and more. As Merijn explains, “There’s no course at university on building solar cars. What really matters is motivation and the willingness to learn fast.” All photos courtesy of Protolabs and Brunel. Each team is carefully selected by the outgoing group, with a focus on complementary skills. “It’s not just about technical know-how,” adds Lucas. “It’s about creating a team that communicates well, adapts quickly, and supports each other.” A Race Against Time and Nature This year’s race (2025) introduces fresh engineering challenges. It is scheduled two months earlier than usual, in August rather than October—right in the middle of the Australian winter. That means fewer daylight hours and lower solar intensity, directly impacting the energy available to the car. Compounding the challenge is a major rules shake-up. “We’re now allowed to use six square meters of solar panels—up from four,” says Merijn. “But that doesn’t mean we can just scale everything up. A bigger solar array introduces aerodynamic and structural complications, and all of this with two months fewer development time.” To make matters more interesting, the allowable battery capacity has been slashed to one-third of previous years. That makes smart energy management not just useful, but essential. “We can’t just rely on speed,” Lucas says. “Strategy becomes everything. From wind and weather to incline and sunlight patterns, the winning team will be the one that adapts fastest.” All photos courtesy of Protolabs and Brunel. To build a car this innovative on such a tight timeline, reliable manufacturing support is critical. “We’re always looking for partners who share our values around sustainable innovation,” Merijn says. “With Protolabs, the enthusiasm and willingness to collaborate stood out from the start. Their speed and precision made them a natural fit.” Protolabs supplied key CNC-machined components including the brake pedal bracket—crucial for safety—and the front suspension damper brackets. “These are high-load, safety-critical parts that must be lightweight but durable,” explains Lucas. “We used aerospace-grade aluminum and relied on finite element analysis (FEA) to validate designs before manufacture.” Thanks to tight coordination, complex, high-tolerance parts were delivered and mounted on the car in time for early testing. Once complete, the team focused on less time-sensitive parts, which included spares. Additional components were later 3D printed via Protolabs Network, at longer, more cost-effective lead times, adding valuable flexibility to the manufacturing process. By partnering with Protolabs, the team could accelerate the manufacturing process when the pace demanded it, and cruise when efficiency was in the pole position. Engineering a Safer Solar Future While the car is designed for maximum efficiency and lightness, safety remains paramount. “We’ve got an impact-resistant occupant cell, a balance-bar braking system, and new this year—a roll bar similar to Formula One’s Halo structure,” says Merijn. “The entire system is built to comply with strict safety checks during scrutineering in Australia.” Even with the lightweight design, the car remains incredibly stable. “The aerodynamic drag increases massively as you go faster, so our cruise speed is around 90 km/h. It’s all about efficiency—not max speed,” says Lucas. In fact, the team’s 2005 car still holds the solar racing speed record, clocking an average of 131 km/h over 3,000 km. The race itself takes place on public roads, with speed limits and real-world weather to contend with. “You only have one shot,” says Merijn. “Anything can go wrong—weather, mechanical, even wildlife. We heard stories of teams waking up with snakes in their tents.” More Than a Race While solar racing isn’t (yet) the future of commercial transportation, it has a vital role to play. “We don’t expect everyone to drive a solar-powered car tomorrow,” Lucas admits. “But solar as a range-extending technology? Absolutely. Some manufacturers are already exploring that.” View: NUNA 12S 3D Experience Ultimately, the race is a showcase—a proof of what’s possible. “If 18 students can build a car that crosses a continent using nothing but sunlight, what’s stopping the rest of the world from embracing renewable energy?” Merijn asks. Beyond the engineering challenge, both Merijn and Lucas agree that the experience has shaped them personally. “The biggest lesson is how to be part of a high-performing team,” says Lucas. “You learn how to work under pressure, communicate effectively, and put trust in each other.” The team is even coached by a former Olympic champion from the Dutch national hockey team—underscoring the importance they place on performance culture as much as technical expertise. For more information: Protolabs Brunel Solar Team Previous Facebook LinkedIn Copy link Next

Lifting a Bed-of-Nails in a museum display demanded reliable performance, long product life, and simple integration. Bed of Nails Museum Exhibit Lifts with Ease Lifting a Bed-of-Nails in a museum display demanded reliable performance, long product life, and simple integration. Museums Aug 12, 2025 On a Bed-of-Nails lift table application, the question facing engineers was, “How much do you trust your linear bearing technology?” CW Shaw Inc, a designer and fabrication firm that specializes in bringing interactive, fun and educational museum exhibits to life was posed with this question. For linear ball-bearings, any slight contamination of the bearing cages can lead to breakage, stalling, or total machine failure, which results in a low rate of confidence when lying on a spiky table. After considering the design, load, environment, and necessary long-term operation, CW Shaw opted for Simplicity pillow block housings to guide the support rails on the Bed-of-Nails lift table for a museum exhibit. To demonstrate the full effect of the exhibit, the lift table needed to be raised and lowered by 3-inches, handle loads up to 1,000 lb (for safety), and move at a moderate speed of 5-feet per minute. Potential contamination was a major factor CW Shaw considered. Any trace of dust or particulate posed a risk of system failure, raising safety concerns. Therefore, CW Shaw sought a linear motion system that would not fail under contamination (dust and carpet fibers). Since most museums operate on fixed budgets, CW Shaw also held maintenance-free operation as a crucial design prerequisite, which is why the company designers turned to Simplicity linear plain bearings and pillow block assemblies. The Linear Pillow Block Solution Simplicity products from PBC Linear became a proven solution when requiring maintenance-free, worry-free linear motion. Designed and refined for over 25 years, Simplicity technology has been successfully applied in some of the most extreme environments: temperature extremes, high contamination, and shock and vibration. The bearings travel using a proprietary Frelon liner which transfers the load and glides over dust and other particulate without damaging the shaft. Also, since the pillow blocks are precision designed with no rolling elements, Simplicity pillow block housings will never catastrophically fail, allowing for reliable and safe linear guidance of the support rails. Two Simplicity pillow block assemblies were installed at each end of the lift table to support the load and guide the lift rails. CW Shaw noted no problems in performance and, over time, has implemented the design for several nail bed exhibits throughout the country. For more information: PBC Linear Plain Pillow Block Free Product Sample CW Shaw Previous Facebook LinkedIn Copy link Next

Filmmakers and businesses get a creative refuge where they can plan, shoot, edit, score, and finalize projects. Virtual Production Stage for Film Filmmakers and businesses get a creative refuge where they can plan, shoot, edit, score, and finalize projects. Edited by Terry Persun Film and TV Jun 24, 2025 35North Studios is a state-of-the-art production studio that allows creators a peaceful space to focus on their craft and enjoy the process. The company’s full-service approach provides their clients with a well-equipped studio situated in Clear Lake, Iowa. At its 12-acre campus, 35North Studios operates out of a 225,000-square-foot-facility that includes soundstages and editing suites, in addition to a recording studio, equipment rental house and production office space. With an eye on the trends shaping entertainment and production, 35North Studios’ executive leadership began paying close attention during the pandemic lockdowns when virtual production projects started to accelerate. They conducted extensive research and evaluations into virtual production methodologies and the technologies that enable them. Soon after, they committed to building their own virtual production stage. Also from Entertainment Engineering: Photo courtesy of 35North Studios. “It’s just ingrained in us to always be looking forward and to stay ahead of the curve with the latest industry tools,” said Justin Fairfax, Director of 35North Studios. “We also saw the opportunity to be an early adopter in the Midwest.” Technically Advanced 35North Studios’ virtual production workflow features an OptiTrack camera tracking system—a 3D optical tracking technology with sub-millimeter accuracy for virtual production stages and other industry applications. OptiTrack is a 3D precision tracking systems that provides low latency output, easy to use workflows, and a host of developer tools. The system’s primary markets include drone and ground robot tracking, movement sciences, virtual production and character animation for film and games, and mixed reality tracking. The specific OptiTrack system used by 35North Studios is comprised of 12 SlimX13 cameras—a lightweight, high frame-rate capture product that includes a discreet profile and is designed with simplicity and usability in mind. The system also includes CinePuck, a camera tracking tool for virtual production studios that can be seamlessly integrated into any production workflow. The studio’s stage is also equipped with fine pitch LED video walls and ceiling from OptiTrack’s sister company, Planar, a leading provider of LED display solutions, and ARRI cinema cameras. Additionally, 35North Studios custom built all of its rendering nodes and computer hardware systems. Flexibility and Stability 35North Studios selected an OptiTrack system after evaluating the different types of motion capture technologies including how each one would support their vision for the new virtual production stage, both immediately, and long term. “We wanted our LED ceiling to be a reflective surface at all times, which automatically ruled out inside out camera tracking ,” Fairfax said. “If we had to place a bunch of trackers on the ceiling for positional tracking, then that would mean they would be visible in the reflections. We wanted to avoid that.” Because of their need for more creative latitude, their search eventually landed on optical camera tracking and the OptiTrack system. “For us, it’s all about flexibility and stability,” Fairfax said. “With an OptiTrack system, we are not tied solely to virtual production. For example, if we decide at a later stage to invest in an animated feature that needs motion capture, we can do that.” The flexibility of OptiTrack proved beneficial when 35North Studios wanted to expand its tracking volume. “We decided to also track our side walls to Unreal, which allows us to avoid having to remap everything every time we move one of those mobile walls,” Fairfax said. “That wouldn’t be possible using different tools.” The decision to integrate an OptiTrack system was also based on 35North Studios’ set up to use two ARRI cameras in their virtual volume and to be able to track both at once. OptiTrack provided the ability to track props, which the company can build into an active tracker and send to Unreal in real-time. “It’s such a multipurpose tool,” Fairfax said. According to Fairfax, OptiTrack provides several other advantages—the system is user-friendly, the equipment is dependable, and the software is easy to learn and understand. But what stands out the most is that the technology is virtually unnoticeable. “I haven’t had to worry about it being visible once on set,” Fairfax said. “It’s never a thought in my mind.” For information: OptiTrack Planar Epic Games ARRI Brompton Technology Previous Facebook LinkedIn Copy link Next

Reducing maintenance requirements and overall manufacturing costs helped to put book printing machines in libraries, schools, and bookstores. Book-Printing Machines Are Getting Faster, Simpler, and Easier to Maintain — Here's How Reducing maintenance requirements and overall manufacturing costs helped to put book printing machines in libraries, schools, and bookstores. Edited by Terry Persun Cool Stuff Dec 16, 2025 We are all familiar with how eBooks have changed the face of publishing. With lower cost digital books on the market, more books were sold and read. But there were still many readers who wanted to hold the book in their hands, to feel the pages as they turned, and to smell the paper and ink. During the time when eBooks were becoming widespread, print book manufacturers were already working on machines that could print books quickly and for lower costs. The aim was to put book printing machines into the hands of bookstores and libraries. This was where the concept for Print On Demand (POD) books started, and is now used by bookstores and libraries but also by small publishers and large publishers alike. This article is about one of the ways this technology progressed and is now even more important that eBook prices are on the rise. On Demand Books originally came up with the POD solution they called the Espresso Book Machine®. This machine was a collaborative design effort, first conceptualized by Jeff Marsh and On Demand Chairman Jason Epstein. The Espresso Book Machine was further refined for manufacturability by DT Engineering to reduce the overall assembly part count, improve performance, and reduce the total cost of printing. DT Engineering is a specialty engineering firm that focuses on machine design, build, and replication (build to print) of custom machinery. The first working prototype from On Demand Books was presented to DT Engineering, whose task was to bring in a more refined design that increased manufacturability, decreased machine complexity, and operated reliably. One issue with the original design was the numerous linear motion components that made up the system. Rails, mounting components, fasteners, and pillow blocks combined to take up a considerable amount of space resulting in a complex assembly. DT Engineering developed a modular approach for the internal sub-assemblies and sought out maintenance-free components for longer-lasting performance. DT Engineering began by working closely with PBC Linear to simplify the linear motion system, and finally decided on their Uni-Guide linear slide for the three critical tasks of the book printer. The simple, two-piece rail and carriage assembly of Uni-Guide provided a more streamlined design without bulky mounting pieces or painstaking assembly work. In addition, the carriage’s internal Simplicity® plain linear bearings glide smoothly and reliably without the need for additional lubrication or preventative maintenance. Images courtesy of PBC Linear. The rails have dual shafts that are precision machined along the edge to ensure perfect alignment and parallelism. All of these Uni-Guide advantages were essential to improving the performance of the Espresso machine’s smooth cutting of the book pages, gluing of the pages to the cover and spine, and collating the pages for binding. All in all, the Uni-guide provided long-lasting transfer and adjustment for some of the Espresso’s most important operating tasks. Uni-Guide linear slides are available in carriage widths of 75mm, 100mm, and 125mm, and feature a ceramic coated aluminum rail and anodized carriage with an underliner of self-lubricating maintenance-free FrelonGOLD®. This Gliding Surface Technology™ eliminates tolerance stack-up and dampens vibrations and shock loads. The guides are designed to be easily incorporated into existing applications, facilitated by their two-piece assembly. The fact that the device has no rolling elements eliminates the possibility of catastrophic failure. By implementing Uni-Guide technology from PBC Linear, DT Engineering was able to reduce each linear motion assembly from roughly ten pieces down to two, creating a simpler, cost-effective printing machine. Today, the on-demand Espresso Book Machine is used by a wide number of publisher and is also available in college libraries and bookstores worldwide. For readers who want a print book that they can hold in their hands and put on their bookshelves, the machine automatically prints, binds, and trims perfect bound, bookstore-quality paperbacks at the point of sale, eliminating the need for overstocked inventory. What’s better is that the Espresso Book Machine boasts the added value of offering rare, hard to find titles just as easily. Books are first selected using EspressNet® software developed by On Demand, and then printed within minutes. The final book is complete with front/back covers and is ready for immediate purchase. For more information: PBC Linear Uni-Guide DT Engineering Read more about motion >>> Previous Facebook LinkedIn Copy link Next

Systems Interface helps a major South Korean University explore the depths of space by designing precise motion control for a 21-meter telescope. Demystifying the Universe with Precise Motion Control Systems Interface helps a major South Korean University explore the depths of space by designing precise motion control for a 21-meter telescope. Curtis Plett, VP of Engineering, Systems Interface Cool Stuff Jan 13, 2026 Lead photo: NASA's James Webb Space Telescope took a look at the Sagittarius B2 molecular cloud. Image Credit: NASA, ESA, CSA, STScI, Adam Ginsburg (University of Florida), Nazar Budaiev (University of Florida), Taehwa Yoo (University of Florida); Image Processing: Alyssa Pagan (STScI) How often do you think about black holes? Stars? The mysteries of deep space? If you’re a researcher at a major research University in South Korea, it’s a lot. Researching celestial bodies requires high-performing instruments. When the university needed to construct their deep space antenna system they chose to work with Systems Interface. The company is a Gold-level System Integrator member of the Rockwell Automation PartnerNetwork™. Following the success of three previous installations, the project involved the construction of a fourth deep space antenna that could help researchers further explore space. Artist concept of satellite in orbit above the earth. Credit: NASA. This project was unique from the start. The university wanted the fourth antenna to perform as well as the first three. Given that the previous antennas were commissioned years ago, Systems Interface had to match the previous systems, but still use updated technologies, such as current servo drives, while keeping the overriding motion control interface the same. An OEM might refuse to deviate from their standard offering whereas a systems integrator like Systems Interface can bring tremendous value by being able to develop a custom solution. The existing deep space antennas utilized outdated Kinetix 7000 drives and legacy servo motion technology, both of which were becoming obsolete. Precise Control Operating at very slow velocities, the antenna required precise tracking of celestial targets such as stars and black holes. This meant that a motion control system had to be developed that was capable of tracking these targets accurately while maintaining responsiveness to slow signals from outer space. According to Curits Plett, VP of Engineering at Systems Interface, “It wasn’t just simple motion control. It was motion control to a highly calculated and precise position. A higher-level motion control system takes 29-bit encoders off the structure and closes position loops based on those encoders. Then it has to perform celestial calculations of where it thinks an object in the sky should be, pointing the antenna at the object, using the frequency of the antenna to fine tune the position, and then tracking it across the sky overnight.” Systems Interface leveraged a combination of cutting-edge hardware, their own domain expertise, and the Rockwell Automation PartnerNetwork. The solution included state-of-the-art technology, featuring the ControlLogix® 5580 controller and Kinetix® 5700 Servo Drive control system, which orchestrated precise movements with its four Kinetix MPL low-inertia motors. The solution also used the Allen Bradley® PanelView™ operator interface to enable visualization and control, as well as various Rockwell Automation components. In total, the antenna was built with a single manufacturer solution that enables optimal performance and support rather than a control system cobbled together from many manufacturers. The Kinetix MPL Low-inertia Servo Motor is a high-output brushless motor providing high torque with a reduced footprint. Procurement, tech support, and supply chain issues The successful completion of the deep space antenna would not have been possible without the rich ecosystem of the Rockwell Automation PartnerNetwork. Strategic partnerships with distributors like North Coast and Rockwell Automation technology consultants expedited the selection and procurement of essential bill of materials components and accelerated on site tech support. Additionally, the profound domain expertise of the Systems Interface team enabled them to devise innovative solutions, such as working with technology partner Profibus to transition from ControlNet to Profibus communication for enhanced reliability and supportability. The construction of the 21-meter antenna was successfully concluded, bolstered by Rockwell Automation technology, including four servo motors capable of reaching an impressive maximum speed of 3 degrees per second. This milestone allowed the antenna to capture its inaugural astrological images, commonly referred to as “First Light.” With the completion of this project, the University achieved its critical objective of deploying a fully operational antenna within their specified timeline. The antenna's performance not only met but exceeded expectations, showcasing seamless functionality without requiring any additional support during startup. For more information: Systems Interface Inc. Rockwell Automation Allen Bradley ControlLogix 5580 Controllers Kinetix MPL Low-inertia Servo Motors PanelView HMI General images of satellites and space courtesy of NASA. Kinetix MPL image courtesy of Rockwell Automation. More about space >>> Previous Facebook LinkedIn Copy link Next

An innovative approach to teaching music brings music education and technology together.  Violins Too Expensive? School Superintendent Turns to 3D Printing An innovative approach to teaching music brings music education and technology together. Joe Gillard Cool Stuff Sep 23, 2025 Here’s a story at the intersection of entertainment and engineering that will tug on your heart strings, so to speak. A school superintendent in Pennsylvania, Laura Jacob, noticed that students from low-income families had difficulty purchasing violins for music, and came up with a solution inspired by something she had heard of an orchestra doing: 3D-printing instruments. In the past five years, Jacob has 3D-printed 200 violins that are free for students in a school where 70% of them are low income. Violins can be very expensive, even relative to other instruments. It can cost hundreds in rental fees for the families of students, if they want their child to have the opportunity to learn violin in school. Jacob started out with two 3D printers. She now says she has 34 of them, and students can learn to use the machines, too. “I’m not a computer scientist or an engineer by any means, but after a variety of failures, I found one that actually printed and it sounded good,” Jacob told CBS News. The violins are made from a template created by a company called Hova Labs. Beyond that, Jacob used real violin strings, a few additional wooden parts, and then added modified guitar pegs. Hova Labs violin template for 3D printers The whole process takes about three days to finish a violin. If the instrument breaks (probably a strong possibility with schoolchildren), they can easily be fixed. As a fun added benefit, the 3D-printed violins can be made in different colors, which might make the instrument more interesting for kids. Prusa 3D Printers The Prusa XL 3D printers are designed for precision. According the company website, “the precision tolerance of a well-assembled Original Prusa printer is 0,1 mm on the Z-axis and 0,3 mm on X and Y.” And the company says that calibrations can be done to further improve the result. “It can be as little as 0,05 mm on all axes, after making additional calibrations such as the Extrusion multiplier calibration and Extruder linearity correction.” Prusa XL 3D printer The magnetic heatbed can hold a two-sided flexible spring-steel sheet, for removal of printed objects from the print surface, according to the product page for the Prusa XL. There are six varieties of sheets for the Prusa XL: smooth, powder-coated textured, PA Nylon, PP, and HighTemp, all of which serve a specific type of 3D-print job. For information: Hova Labs: https://www.hovalabs.com/ Prusa Research https://www.prusa3d.com/ CBS Interview with Laura Jacob: https://www.cbsnews.com/news/pennsylvania-school-3d-printers-violins/ Cover photo: u_l5sf233ead , Pixabay Previous Facebook LinkedIn Copy link Next

A specially-made through-hole slip ring delivers all the right measurements. Testing Dirt Bikes is a Tricky Application, Requiring Specialized Components A specially-made through-hole slip ring delivers all the right measurements. Edited by EE Staff Sports Jan 6, 2026 Rotary Systems is often tasked with improving upon existing slip ring designs. In one such case the company facilitated the design and production of a slip ring encoder made specifically for dirt bike testing. Images and gifs courtesy of Rotary Systems. Testing dirt bikes can be a tricky application, so when a leading producer of measurement and testing equipment requested that Rotary Systems, Inc. (RSI) engineer and manufacture a specialized slip ring they took on the challenge. The testing customer needed a product that allowed a dirt bike motor to measure temperature and calculate drivetrain efficiency. This application required a compact slip ring needed to fit around the shaft of an axle. One of RSI’s specialties include through-hole slip rings which meant that their engineers had the experience and expertise to design the product in-house. How a slip ring encoder works In a basic sense, the slip ring encoder receives power directly from the motor and in exchange transmits data to the customer’s computers onsite. The testing customer is then able to detect extreme changes in temperature and, if the shocks are overloaded, the company can remedy the situation quickly. Working with other engineering teams to develop the best solutions is what keeps RSI at the top of their game. In this particular application the company’s engineering team worked hard to develop a product that withstood extreme environments like the rugged terrain of the motorcross trail, in order to ensure data was transferred as efficiently and safely as possible. For more information: Rotary Systems Slip Rings Other cool sports and racing articles >>> Previous Facebook LinkedIn Copy link Next