Search

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

Aixtreme Racing is reaching a new milestone for the 2025 season by developing their first-ever electric vehicle. Electric Race Car Uses 3D-Printed Components Aixtreme Racing is reaching a new milestone for the 2025 season by developing their first-ever electric vehicle. Terry Persun Sports Jun 17, 2025 Aixtreme Racing is a Formula Student team of 40 passionate engineers from the University of Applied Science Aachen that have been designing and building prototype race cars since 2007. The team is reaching a new milestone by developing their first-ever electric vehicle. This transition has opened the door to new technical challenges and innovative approaches, including the adoption of advanced 3D printing for lightweight custom parts, reliable housings, and rapid prototyping. It’s a pleasure to see how passionate, talented engineers are using 3D printing to push the boundaries of innovation. Also from Entertainment Engineering: According to Luis Do Carmo, Head of Powertrain & LV-Electronics, “We are very happy with our Raise3D printer. Our printed parts are quickly processed and easy to slice. The workflow integration is smooth, and the print quality consistently meets our needs.” Challenges Before 3D Printing Before integrating 3D printing into their workflow, Aixtreme Racing primarily relied on composite structures, as well as aluminum and steel milling, to manufacture their parts. While effective, these traditional methods had notable drawbacks such as long lead times, high production costs per part, and a dependence on machine availability and workshop capacity. Other concerns included the high material waste, especially for parts that didn’t require metal strength. But most of all, the team found very limited agility when iterative changes were required. The transition to an electric vehicle also introduced new demands, such as the need for flame-retardant and electrically insulating components—something that is very difficult to achieve cost-effectively while using conventional methods. Selecting a 3D Printer To meet these challenges, Aixtreme Racing turned to 3D printing for its rapid, flexible, and material-efficient production capabilities. Not only did the technology provide faster development of lightweight custom components but gave the team greater independence from external suppliers and workshop scheduling bottlenecks. This gave the team an improved ability to prototype and test complex geometries quickly and easily while providing reduced material waste compared to milling processes. After researching the alternatives available to them, the team chose to purchase Raise3D products specifically because their faculty advisor had experience with the Raise3D Pro2, and was impressed by the print quality, reliability, and seamless workflow capabilities it offered. Raise3D printed parts had been mounted on previous vehicles, though not as extensively as planned for the upcoming e-car. The Raise3D Pro3 was selected for its generous build volume, more than sufficient for the team’s relatively compact parts, and the option to upgrade to a Hyper Speed Extruder if faster print times were required in the future. Materials and Applications Aixtreme Racing primarily uses Polymaker’s PC-FR filament for their high-voltage tractive system enclosures, which demand flame-retardant, electrically non-conductive properties in compliance with Formula Student regulations. Additionally, the team has been experimenting with a UL94 V-0 rated TPU 95A, which delivers additionally flexible components such as vibration-dampening parts, seals, small molds. Besides producing high-voltage and low-voltage enclosures for PCBs and cell fixations, Aixtreme Racing also uses PETG, PLA, and PC materials to print tools, test fittings, small molds, and prototypes such us the Red Stack Enclosure below. Raise3D’s Open Material Program allowed the team to access pre-configured material templates for PC-FR, minimizing setup time and ensuring consistent print quality. “We really appreciate the consistency of the prints and the seamless integration between the Raise3D cloud platform and the ideaMaker slicer. So far, all our prints have worked out very well — even without deep prior knowledge in 3D printing,” Luis Do Carmo said. The team relies heavily on ideaMaker for slicing and RaiseCloud for managing print jobs remotely. Features they particularly value include pre-configured material profiles for reliable, out-of-the-box performance; centralized job management via RaiseCloud, which allows multiple team members to manage prints independently; and efficient printer queue management, with minimal downtime between jobs. For information: Raise3D: https://www.raise3d.com/ Raise3D Demo Videos: https://www.raise3d.com/demo-video/ University of Applied Sciences Aachen: https://www.fh-aachen.de/en/ Previous Facebook LinkedIn Copy link Next

Archive of Entertainment Engineering Magazine's past newsletters. Video Archive Click on a link below to view past videos One-on-One: Henry O'Bryan of Biomerics on Hobby Engineering and Creativity One-on-One: Chris Porter of igus on Amusement Park Technology Announcing Our Relaunch: Interview with EE Co-Founder Terry Persun Video intro credits: Theme Parks El Charcoal Video of roller coaster Roller Coaster Stock Videos by Vecteezy Sports & Games Yevhen Roshchyn Video of car Vehicle Stock Videos by Vecteezy Stage Events Media Whale Stock Video of stage event Adventure Stock Videos by Vecteezy

Vertical take-off and landing aircraft uses hydrogen-electric technology to complete landmark 523-mile flight. This Electric Air Taxi has Only One Byproduct: Water Vertical take-off and landing aircraft uses hydrogen-electric technology to complete landmark 523-mile flight. Cool Stuff Jul 29, 2025 On June 30, 2025 Joby Aviation, Inc., a company developing electric air taxis for commercial passenger service announced that its electric air taxi has completed a series of piloted, electric Vertical Take-Off and Landing (VTOL) wingborne flights in Dubai, marking the start of its commercial market readiness efforts in the region. These efforts will further develop Joby’s readiness in anticipation of carrying its first passengers in 2026 and marks a major step in the company’s three-pronged commercialization strategy: direct operations, aircraft sales, and regional partnerships. In July of 2024, Joby demonstrated its potential for emissions-free regional journeys. The company’s hydrogen-electric air taxi demonstrator had built on Joby’s successful battery-electric air taxi development program and demonstrated the potential for hydrogen to unlock emissions-free, regional journeys that didn’t require a runway. The hydrogen-electric program built on technology developed by Joby subsidiary H2FLY and was supported through Joby’s partnership with the U.S. Air Force’ Agility Prime program. The landmark test flight, believed to be the first forward flight of a vertical take-off and landing aircraft powered by liquid hydrogen had been completed using a converted Joby pre-production prototype battery-electric aircraft fitted with a liquid hydrogen fuel tank and fuel cell system. It landed with 10% of its hydrogen fuel load remaining. Jacob Wilson, (Acting) Branch Chief, AFWERX Agility Prime, said: "Agility Prime has been very supportive of hydrogen-powered aircraft development and testing as it aligns with the program’s goals to advance transformative vertical lift technologies and broader Department of Defense operational energy goals of energy substitution and diversification, and energy demand reduction.” All photos courtesy of Joby Aviation Joby’s hydrogen-electric demonstrator was part of the Company’s future technology program and was the result of several years of collaboration between a small team at Joby and H2FLY, Joby’s wholly-owned subsidiary based in Stuttgart, Germany. The converted aircraft previously completed more than 25,000 miles of testing as a battery-electric aircraft at Joby’s base in Marina, CA. Using the same airframe and overall architecture as Joby’s core, battery-electric aircraft, this demonstrator featured a liquid hydrogen fuel tank, designed and built by Joby, which stored up to 40 kilograms of liquid hydrogen, alongside a reduced mass of batteries. Hydrogen was fed into a fuel cell system, designed and built by H2FLY, to produce electricity, water, and heat. The electricity produced by the hydrogen fuel cell powered the six electric motors on the Joby aircraft, while the batteries provided additional power primarily during take-off and landing. As part of Joby’s wider commitment to leading the way on the development of new aviation technologies, it recently acquired Xwing Inc., an industry leader in the development of autonomous technology for aviation. Xwing has been flying autonomous aircraft since 2020, with 250 fully autonomous flights and more than 500 auto-landings completed to date, using the Superpilot software it developed in-house. For more information: Joby Aviation H2FLY U.S. Air Force’ Agility Prime program Previous Facebook LinkedIn Copy link Next

Simulating brain-controlled flying at the Institute for Flight System Dynamics Brain-Controlled Flight Simulating brain-controlled flying at the Institute for Flight System Dynamics EE Staff Cool Stuff Jun 4, 2025 Pilots of the future could be able to control their aircraft by merely thinking commands. Scientists of the Technische Universität München and the TU Berlin have now demonstrated the feasibility of flying via brain control – with astonishing accuracy. The pilot wears a white cap with myriad attached cables. His gaze is concentrated on the runway ahead of him. All of a sudden the control stick starts to move. The airplane banks and then approaches straight on toward the runway. The position of the plane is corrected time and again until the landing gear gently touches down. During the entire maneuver the pilot touches neither pedals nor controls. "A long-term vision of the project is to make flying accessible to more people," explains aerospace engineer Tim Fricke, who heads the project at TUM. "With brain control, flying could become easier. This would reduce the workload of pilots and thereby increase safety. In addition, pilots would have more freedom of movement to manage other manual tasks in the cockpit." The scientists have logged their first breakthrough: They succeeded in demonstrating that brain-controlled flight is indeed possible, with amazing precision. Seven subjects took part in the flight simulator tests. They had varying levels of flight experience, including one person without any practical cockpit experience whatsoever. The accuracy with which the test subjects stayed on course by merely thinking commands would have sufficed, in part, to fulfill the requirements of a flying license test. "One of the subjects was able to follow eight out of ten target headings with a deviation of only 10 degrees," reports Fricke. Several of the subjects also managed the landing approach under poor visibility. One test pilot even landed within only few meters of the centerline. The TU München scientists are now focusing in particular on the question of how the requirements for the control system and flight dynamics need to be altered to accommodate the new control method. Normally, pilots feel resistance in steering and must exert significant force when the loads induced on the aircraft become too large. This feedback is missing when using brain control. The researchers are thus looking for alternative methods of feedback to signal when the envelope is pushed too hard, for example. In order for humans and machines to communicate, brain waves of the pilots are measured using electroencephalography (EEG) electrodes connected to a cap. An algorithm developed by scientists from Physiological Parameters for Adaptation of the Technische Universität Berlin allows the program to decipher electrical potentials and convert them into useful control commands. Only the very clearly defined electrical brain impulses required for control are recognized by the brain-computer interface. For more information: Technische Universität Münche Previous Facebook LinkedIn Copy link Next

This VR experience features realistic and intuitive navigation, helpful advice from Mission Control, and compelling and visceral science-related content. Explore the International Space Station with Immersive VR Experience This VR experience features realistic and intuitive navigation, helpful advice from Mission Control, and compelling and visceral science-related content. Edited by EE Staff Cool Stuff Oct 28, 2025 Every person on the planet, young and old alike, has wondered about our place in the universe. The idea of space creates a deep yearning for answers and experiences in all of us, and it serves as a common, unifying thread for humanity. NASA wanted to bring the magic of space travel to everyone and teamed up with Magnopus to bring Mission: I SS into reality and to help promote these common feelings through thrilling immersive technology. Mission: ISS lets users explore the International Space Station in detail to understand what it’s like to be an astronaut in a way that’s never before been possible. Based on NASA models and honed with input from astronauts who have lived in space, Mission: ISS recreates the International Space Station in painstaking detail. Users can experience how to move and work in zero-gravity, use space tools, dock a space capsule, and take a spacewalk. Images courtesy of Magnopus, NASA, and Meta. Real astronauts provide a sense of presence through instructional video clips. With strong STEM-related themes, anyone can take part in experiments and actual missions on the station. Since the experience is fully immersive, users feel a sense of weightlessness that can only be felt in VR, similar to what astronauts feel—a fact that Mission: ISS’s astronaut advisors have confirmed. In fact, more than one astronaut said it was like making a return trip! VR experiences are ideal for taking users to places that are too dangerous or too expensive to go. With that in mind, Mission: ISS was designed to remove those barriers—literally anyone with a VR headset can get a taste of space exploration. Images courtesy of Magnopus, NASA, and Meta. Mission: ISS is a non-profit initiative. It is freely available on Meta’s Quest store and has been demonstrated at science exhibits, international conferences, fairs, and exhibitions across North America and Europe to wide acclaim. The experience has won multiple awards including those from the Television Academy, VR Awards, XR Awards, and was even nominated for an Emmy. For more information: Magnopus NASA Meta Read more about applications in space >>> Previous Facebook LinkedIn Copy link Next

Fluid power components help the wicked witch levitate at the end of Act 1. Wicked Technology Defies Gravity on Broadway Fluid power components help the wicked witch levitate at the end of Act 1. Stage Events Jul 22, 2025 Cool Stuff Although Wicked recently came to the big screen, the Broadway edition of Wicked is still playing at the Gershwin Theatre—since 2003—and is currently the fourth-longest running Broadway show. The play focuses on the friendship between Elphaba and Glinda. At the climax of Act 1, a hydraulics system installed and maintained by Atlantic Hydraulic Systems provides the power and control to raise the witch 20 feet above the stage as she sings “Defying Gravity.” The company built their hydraulic system for the play around two Parker pressure compensated 8 GPM hydraulic gear piston pumps with a maximum flow of 7.9 gallons per minute and at 2600 psi pressures. These pumps are specially designed to use mineral oil, fire-resistant fluids. For additional control, the platform that the witch is raised on also incorporates two 15 horsepower, totally enclosed fan-cooled TEFC electric motors. These motors typically operate from a 230/460V three-phase power source, and typically operate from around 1800 rpm to 3600 rpm. The Wicked Hydraulic Levitator, which raises the actress into the air, does not contain an on-board hydraulic power unit. Instead, a remote hydraulic power unit charges up accumulators on the levitator prior to being detached. Proportional valves and redundant circuitry are employed to assure the actress’ safety throughout the show. For more information: Atlantic Hydraulic Systems Previous Facebook LinkedIn Copy link Next

How large synchronized telescopes utilize industrial devices and PC-based control technology. Discovering Traces of the Big Bang Requires Telescopes with Precise Controls How large synchronized telescopes utilize industrial devices and PC-based control technology. Edited by Terry Persun Cool Stuff Dec 9, 2025 The Instituto de Astrofisica de Canarias (IAC–Institute of Astrophysics of the Canary Islands), a research institute at the University of La Laguna, Spain, operates two astronomical observatories on the Canary Islands: the Roque de los Muchachos Observatory on La Palma and the Teide Observatory on Tenerife. These two locations enable astrophysicists to explore the limits of space. To do this, the IAC partnered with Beckhoff. The partnership between IAC and Beckhoff began with the first telescope for the Q-U-I Joint Tenerife Experiment (QUIJOTE I) over twelve years ago. Its aim was to characterize the polarization of the cosmic microwave background (CMB) and other galactic and extragalactic emission processes in frequency ranges from 10 to 42 GHz, and to discover traces of the Big Bang in this way. All other images ©Beckhoff. The telescope’s enormous dimensions are precisely aligned with stars and galaxies and tracked using a control system based on TwinCAT 2 NC PTP and a C5102 19-inch slide-in Industrial PC, which precisely controls the azimuth and elevation of the telescope. In addition to the digital and analog inputs and outputs required to control the telescope, the EL6688 (IEEE 1588/PTP) communication interface facilitated the programming and implementation of the Precision Time Protocol. This EtherCAT Terminal supports PTPv1 (IEEE 1588-2002) and PTPv2 (IEEE 1588-2008) as a device in the IEEE 1588 synchronization system. “Clock synchronization is crucial for synchronizing telescopes very precisely with the movements of the stars and galaxies being observed,” states Jose Miguel Herreros, Engineering Director of IAC. Another major challenge was moving the axes with exceptional precision at both very slow speeds and higher speeds. The reason for this was the significant moment of inertia on the direct drive of the azimuth axis, which required extensive adjustments to the speed controller in the AX2000 servo drive used at the time, recalls Roberto Iraola, Sales Manager at Beckhoff, who adds: “This was fundamental to the project’s success.” This project was followed by the QUIJOTE II telescope for the TFGI (Thirty and Forty GHz Instrument), which consists of a total of 30 receivers. AX5000 digital compact servo drives were already in use with this telescope. Beckhoff developed both telescopes in close cooperation with Spanish company IDOM, while IAC employees developed the control software. In 2022, both control systems were migrated to TwinCAT 3 and C5240 19-inch slide-in Industrial PCs. “We are currently working with Beckhoff on many projects such as ‘Harmoni’ for the Extremely Large Telescope (ELT), robotic telescopes, and various instruments mounted on these telescopes,” says Jose Miguel Herreros. All other images ©Beckhoff. Extensive Modernization The Carlos Sánchez (TCS) and IAC80 telescopes at the Teide Observatory on Tenerife are manually controlled by astronomers using computer applications that were developed back in the 1990s. Although some modernization measures have been carried out, a large part of the control system is still based on components that are now completely outdated. A project that started in mid-2019 and has not yet been completed aims to migrate the control systems of these telescopes to state-of-the-art, robust software and hardware, and to implement advanced remote control in the process. This future high-level control software will be based on the ROS (Robot Operating System) open-source operating system, while the underlying control architecture will be based on EtherCAT and TwinCAT 3 from Beckhoff. To reduce the possibility of technical risks affecting the project, the team developed a telescope simulator to represent the telescopes’ drive system and data network, and provide a virtual test bed for developing and testing the new system. An ongoing investigation is assessing the suitability of using TwinCAT Vision for automatic star tracking by telescope—an autoguiding system has been selected for testing and can also be used for other telescope tracking systems. All other images ©Beckhoff. Different Site, Same Technology The Roque de los Muchachos Observatory (ORM) on the edge of the Caldera de Taburiente National Park, sitting at an altitude of 2396 meters in the municipality of Garafía (La Palma), boasts one of the most comprehensive telescope technologies in the world. Thanks to the clear atmosphere and its location far away from disruptive light waves, the observatory offers ideal conditions for astronomical research. This is why the location has been home to some of the largest-ever telescope projects as well as the new generation of Cherenkov telescopes for exploring the universe using very high-energy gamma rays. The observatory operates what is currently the world’s largest optical and infrared telescope, the Gran Telescopio de Canarias (GTC), alongside twenty other telescopes and astronomical instruments for applications such as nocturnal, robotic, solar, and astrophysical observations involving high energy. These telescopes have already made significant progress in exploring the universe: for example, identifying the most distant galaxy or confirming the existence of black holes and the accelerated expansion of the universe. Cross-Industry Application With a mirror diameter spanning 10.4 m, the GTC is the largest telescope at this observatory. Its planning phase began in 1994 and the GTC was put into scientific operation around 15 years later in 2009. As the technology of the control system specified at the time eventually became outdated, it has since been replaced by PC-based control. This occasion also enabled subsystems such as building automation and lighting systems to be integrated. “We have been able to implement these subsystems thanks to Beckhoff’s open PC-based technology and its experience in building automation,” explains Roberto Iraola. The close cooperation between Beckhoff and GTC extends not only to modernization, but also to the development of new technologies such as instrument calibration modules (ICMs). In the GTC, this system consists of a series of lamps with defined wavelengths and a mechanism for positioning a parabolic mirror that reflects the light onto the telescope mirror. PC-based control is used to control and dim the ICM’s spectral and incandescent lamps. A CANopen interface (master) for operation with the existing CANopen infrastructure was also implemented. Beckhoff technology has also played a role in other projects, such as monitoring and controlling the helium tank compressors and their refrigerants. *Lead image ©AdobeStock/underworld. For more information: Beckhoff TwinCAT Automation Software Industrial PC Institute of Astrophysics of the Canary Islands Read about the automation of other telescopes >>> Previous Facebook LinkedIn Copy link Next

The fast-moving world of Formula 1 motor racing technology is constantly changing as a result of the desire to gain an advantage in such a highly competitive arena, as well as the need to comply with ever-changing rules and regulations. Formula 1 Wings Use Mini Solenoid Valves The fast-moving world of Formula 1 motor racing technology is constantly changing as a result of the desire to gain an advantage in such a highly competitive arena, as well as the need to comply with ever-changing rules and regulations. Edited by EE Staff Sports Sep 11, 2025 After being banned for 40 years on safety grounds, in 2011 driver-activated rear wings were returned to Formula 1. This decision was made at a meeting of the sports governing body, the FIA World Motor Sport Council, with the objective of allowing more overtaking in F1. One of the beneficiaries of this decision was The Lee Company, which has sold hundreds of miniature solenoid valves to all of the F1 teams for a wide range of applications, including fuel flaps, emergency clutch disengagement, reverse gear selection, power steering, auxiliary lube oil tank top-up applications, and front wing control. In fact, The Lee Company specifically developed its Performance Racing Solenoid Valve at the request of its F1 customers, and this was subsequently homologated by the FIA for use in F1. In the video below, Marc Priestley builds a scale(ish) model to explain exactly how DRS works in F1. Marc 'Elvis' Priestley worked for McLaren Racing as a Formula One mechanic and member of the pitstop crew from 2000-2009. He worked with a distinguished list of drivers including Mika Hakkinen, David Coulthard, Kimi Raikkonen, Jean Alesi, Juan Pablo Montoya, Fernando Alonso and Lewis Hamilton. For the real F1, the active front wings have a trailing edge which can be adjusted by the driver to increase downforce during braking. Active front wings were a feature on Formula 1 cars for the 2010 season but were banned for the 2011 season, to be replaced by the active rear wing. Drivers are now able to control the rear wing once they have been behind another driver for a set amount of time, thereby reducing drag on the straightaway and allowing greater opportunity for overtaking. The high-flow 3-way single-coil solenoid valve. All photos courtesy of The Lee Company. The wings are raised and lowered by a large hydraulic actuator, which must move very quickly and therefore demands a fast-acting, high-flow valve to control it. The Lee Company developed a 12 VDC version of its 3-way high flow solenoid valve specifically for this purpose, and several Formula 1 teams have specified the valve for this function. This modified valve can operate at temperatures of up to 329°F (165°C). Also, the retaining nut has been removed to save space and reduce weight, and the lead wires now exit from the rear of the valve, instead of at the hydraulic end. The Lee Company’s miniature 3-way high flow solenoid valves are a natural evolution of our proven piloting solenoid valves, which set new standards in reducing space, weight, and power consumption. Valve elements are based on the low leakage, highly reliable designs used in Lee check and shuttle valves. Functions and features include two-position, 3-way, 3000 psi, 4.0 GPM minimum flow at 3000 psid (300 Lohms), single-coil, and an integral safety screen with a 0.004 inch hole size. Power consumption is 7.8 W at 18-32 VDC, and the valves can operate within a temperature range of -129°F to 275°F (-54°C to 135°C). These miniature solenoid valves are part of The Lee Company’s extensive range of plugs, restrictors, check valves, relief valves, shuttle valves, filter screens, and flow controls, which are all being used in current Formula 1 cars and engines. Formula 1 and F1 are trademarks of Formula One Licensing BV, a Formula One Group Company. For more information: The Lee Company The Lee Company Performance Racing Solenoid Valve Marc Priestley F1 Elvis 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

When a Vancouver-based boutique animation studio outgrew its consumer-grade storage when it took on bigger projects for film, TV, and commercials, it looked to a more scalable solution. Big Animation Dreams Mean Big Storage Needs When a Vancouver-based boutique animation studio outgrew its consumer-grade storage when it took on bigger projects for film, TV, and commercials, it looked to a more scalable solution. Edited by EE Staff Film and TV Nov 17, 2025 Od Studios (Vancouver, BC) started as a boutique visual effects studio with an aim to produce full length animated feature films using the latest technology and production practices. In the video production industry, great work can lead to more work—which means more generated data, and subsequently, the need for more storage. To reach their goal, they knew that they could no longer get by with their older consumer-grade storage solution. Od Studios generates a significant amount of data during production. Their product is the data they produce. Their efficiency was impacted by the low throughput of their previous consumer grade hardware solution. As they grow, the projects they work on become higher profile and their need to produce high quality work increases. Od Studios required a stable solution to finish projects on time and on budget. They needed a storage solution that would allow them to scale and provide them with the flexibility to resolve their specific problems. As a relatively new company, they had been using a product that only offered mediocre throughput that constrained their ability to produce work quickly. The system was slow, and they constantly questioned how many days remained until they pushed the system to failure. As a newer studio with a limited budget, total cost of ownership (TCO) was very high on their list of requirements. They needed to balance affordability with throughput and stability yet wanted flexibility to allow for scaling and future growth. They began researching hardware vendors for a replacement solution, considering Seagate along with competitors that are traditionally used to provide storage solutions in the animation/visual effects production industry. Od Studios wanted the ability to install whichever vendor’s drives they chose, as well as to use the Lustre file system software they selected. They believed that they could achieve performance that was as good as, if not better than, many of the proprietary systems in the market. All photos courtesy of Seagate and Od Studios. In the early part of their selection process, Od Studios appreciated that Seagate’s storage options were different than competitors that locked customers into a single, one size fits all solution where the hardware appliance, installed drives, and software are provided by one single vendor. That’s why the studio chose Seagate’s Exos™ X 5U84 RAID array that provided them with future flexibility and minimal vendor lock-in—a solution that gives them the flexibility to pivot should they ever need to. The 5U84 provides room to grow through a versatile architecture that opimzes TCO for petabyte-scale storage with industry-leading density. Plus, Od Studios can get its data to applications when and where it’s needed with high-speed, high-performance storage. The secure hard drives provide reduced power consumption and adaptive cooling technology to help Od Studios realize cost and energy savings. All photos courtesy of Seagate and Od Studios. The 5U84 is placed behind a Dell server which serves as the Lustre file system’s object storage service (OSS). A second Dell server is used for the Lustre metadata service (MDS). Due to the Seagate array’s design, Od Studios can scale out their system in different ways as needed—although with its extremely large capacity it may be a while before that happens. Another benefit for Od Studios is how the ADAPT RAID on the array allows for rapid rebuild times in case of drive loss. In addition, the ability to use preferred drives in the array, along with using a scalable software-defined storage solution like Lustre, provides Od Studios with the flexibility, scalability, and performance they need out of their storage system. Today, in addition to films, Od Studios also works on TV series and commercials. Its clients include Netflix, Amazon Prime, Canadian Broadcasting Corporation (CBC), Warner Bros., Marvel, and NBC. According to Od Studios Founder and Visual Effects Supervisor, Marc Horsfield, “The ability to scale out is a big win. With Seagate’s Exos X 5U84, we have options to scale, and that flexibility is paramount in an ever-changing industry.” For more information: Seagate Od Studios Exos X 5U84 RAID System Read more articles about filmmaking >>> Previous Facebook LinkedIn Copy link Next

Stage lighting rigging uses spring cable drums to solve a complex challenge. Creative Rigging Solution for Moveable Nightclub Ceiling Stage lighting rigging uses spring cable drums to solve a complex challenge. Stage Events Jul 28, 2025 Cool Stuff Winner of the bronze vector award in 2024, French company Mecaoctet has created a movable ceiling for a nightclub in the Accor Arena in Paris. For the power supply, the designers rely on slip-ring-free spring cable drums from the igus e-spool series. The vector award jury was highly impressed by the unique technical solution used for the breathtaking light show. All photos courtesy of igus The movable nightclub ceiling consists of a fragmented mirror measuring 16x15 meters, which is divided into 32 triangular elements, 16 of which are movable. Each of these triangles has two mirror surfaces, one at the top and one at the bottom, with the edge consisting of an SRU LED strip. In combination with spotlights, a breathtaking light show with monumental shapes in motion is created above the heads of the guests. The design challenge was to set the triangles in motion and supply the LED strips with power. To solve this complex challenge, the engineering team involved chose to rely on three motorized winches, one at each corner of the triangles. For the power supply, the experts chose slip-ring-free spring cable drums from the igus e-spool series, which are fitted with hybrid cables and connected to the centers of gravity of the triangles. All photos courtesy of igus The stroke for the application is six meters. The speed is 0.5 meters per second. According to Mecaoctet, thanks to the igus solution they were able to avoid using complex coils with rotating collectors—which would have been very expensive and unreliable. Compared to a slider system with cable loops, the solution is also more fail-safe and aesthetically pleasing. The igus e-spool series are able to confine many different cables within a confined space and uniquely combines two different energy supply systems, puts no tensile load on the cables, can supply energy in all directions (horizontal, vertical, and diagonal), and is available for indoor and outdoor applications. Overall, the final design provided accuracy, reliability, and aesthetics. For more information, visit igus and Mecaoctet . Previous Facebook LinkedIn Copy link Next