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Inspired by the automation used in Halloween props, this engineer used creativity and technology to pull together a Halloween Box specifically designed to scare trick-or-treaters. How an Engineer Used Spare Automation Components for Spooky Halloween Fun Inspired by the automation used in Halloween props, this engineer used creativity and technology to pull together a Halloween Box specifically designed to scare trick-or-treaters. By Jay Rees, PE, “The Independent Integrator”, Rees Engineering Corp. Cool Stuff Oct 6, 2025 DIY/Home Applications In every haunted house, you’ll find automated props: chairs that rock on their own, slamming doors, rattling chains, drawers opening and closing as if by some supernatural force. These “tricks” enhance the “treat” of getting the life scared out of you. The process behind making a Halloween prop can be quite simple. Here is just one example of how a system integrator put used and spare parts to good use to frighten any trick-or-treater. This article is a perfect example of how creative design engineers are. As soon as Jay got his hands on a wooden crate, he knew it could be something much more than it was. —the EE staff. Trick or Treat I purchased a DURApulse 60HP variable frequency drive (VFD) from AutomationDirect as a replacement for a customer’s damaged VFD. When the shipping container was delivered to my shop, I immediately knew what the wooden crate would become. This crate was just the right size for building a Halloween Box. You may have seen similar Halloween props covered with labels, such as “Danger” or “Wild Animal”. I didn’t know at the time what the final result would be, but I could see “The Box” had potential. I wanted The Box to give the impression that some type of wild creature was inside and was desperate to escape. Because this was a hobby project, keeping down costs was a primary objective. As the owner of a system integration business serving multiple industries, I have accumulated spare components and hardware from retrofitting and upgrading applications. Case in point, the VFD shipping container came courtesy of a wastewater pumping station application. All photos courtesy of Jay Rees. The Box’s controller uses a CLICK programmable logic controller that was removed from a metal alloy chiller system. A C-more EA7 HMI, pulled from a fracking fluid control system, is used to provide displays and audio; I used pneumatic cylinders from previous applications and purchased a couple of new Nitra solenoid valves to assemble “the creature.” Finally, a Rhino power supply was borrowed from stock. Due to my odd assortment of pneumatic cylinders, the next challenge was to figure out what I could do with what I had. A couple of squat cylinders would fit on the bottom of the box, placed between the legs at opposite corners to rock the box and make it look like there was something moving around inside. All photos courtesy of Jay Rees. To give the impression that the ‘thing’ or ‘creature’ inside the box is trying to escape, a cylinder is used to push the lid open. With a padlock hasp connected to the lid, the staple and lock appear to hold the lid closed. What the observer doesn’t know is that the staple is installed in a slot, concealed by the hasp, and a small cylinder is used to hold it down so the lid only moves up and down a little bit. After a few ‘locked’ lid bounces, the cylinder retracts and the lid opens another couple of inches, giving the impression that the creature had broken the lock and is getting ready to escape. To add to the experience, when the lid pops up, a claw (from a Freddy Krueger costume) emerges from the gap in the open lid. All photos courtesy of Jay Rees. If that’s not enough excitement, the C-more HMI, displaying pictures of creepy eyes with simple animation to look like they are moving towards the audience, is mounted near the front of the box behind a small cage providing audio of growling, howling, and snarling animals. While the PLC controls the pneumatic actions, the audio is triggered to play through a set of old PC speakers. To provide a way to save energy when no one is around, and give a more realistic experience, retroreflective photoelectric sensors are used to bring the creature to life when someone approaches The Box. Putting together this project was a lot of fun. The challenge was figuring out what could be put together with stuff that was sitting on shelves and in bins. I still wonder what I would have been doing for fun if that DURApulse VFD ‘Box’ hadn’t arrived at my shop. All components mentioned in this article can be found at AutomationDirect . Learn more about Rees Engineering Corp. Previous Facebook LinkedIn Copy link Next

When you combine 2,700 LED panels, 42 processors, and 120 distribution units together for one event, you had better do it right. Massive Event Incorporates Over 2700 LED Panels When you combine 2,700 LED panels, 42 processors, and 120 distribution units together for one event, you had better do it right. Edited by EE Staff Stage Events Apr 20, 2026 Microsoft Ignite Keynote Event at the Chase Center in San Francisco delivered a high-profile experience to over 14,600 in-person attendees and over 200,000 live viewers. MeyerPro, a Pacific Northwest event production partner with experience supporting complex live events, is known for dependable execution and a collaborative approach when executing end-to-end services across LED, audio, video, broadcast, and show crew support. The keynote event used 2700 LED panels across multiple ROE Visual platforms including Vanish Solid Touring, Carbon, Topaz, and Graphite, which provided MeyerPro the ability to translate creative intent into flexible, broadcast-ready environments that support complex presentations and workflows at scale. Images courtesy of ROE Visual. For the Microsoft Ignite 2025 event, they were able to deliver a high-profile keynote experience across multiple platforms requiring a visual system capable of supporting live presentation, broadcast workflows, and rapid content transitions across a broad range of stage areas. Microsoft’s expectation was to deliver a stage that felt monumental while remaining highly readable. For the live audience, the displays needed presence, brightness, and a physical quality that felt architectural. For the broadcast audience, the priority shifted to detail, consistent exposure, and color fidelity that remained accurate across camera cuts. This combination was no easy task to complete. Images courtesy of ROE Visual. MeyerPro collaborated across both the design and execution phases, aligning LED and video systems within a broadcast-forward workflow. This approach ensured keynote moments maintained visual consistency regardless of where the content was displayed. The Visual Ecosystem Rather than relying on a single display solution, the design used multiple ROE platforms to support different spatial and storytelling requirements across the venue. Varied panels were used to balance large-scale presence, layout flexibility, and on-camera performance. Each screen served a distinct role within the keynote environment, allowing presentation zones to shift naturally between speaker moments, product demonstrations, and supporting visual content. Images courtesy of ROE Visual. In total, the setup featured more than 20 LED walls spanning a range of sizes, configurations, and curved applications. ROE V4ST and CB3 formed the backbone of the environment, with eight screens built from V4ST (684 panels) and another eight using CB3 (900 panels). Three additional screens used Topaz TP-C2.6 for curved elements (714 panels), while a large Graphite GP2.6 sidewall made up of 420 panels handled the primary wide-format display. All together, the system supported multiple keynote presentation zones while maintaining clarity for both in-room audiences and broadcast viewers—delivering nearly 130 million pixels overall. Processing was built around 42 Brompton 4K Tessera SX-40 LED processors and 120 Brompton Tessera XD data distribution units. The wider show system was centralized around a flypack that included a Ross FR12 and Ultra 60. In addition, the show included a pair of Analog Way RS4s as well as a number of Christie Spyder X80s. The large scale system had many recording options and playback routes via three EVS XT-VIA servers in addition to many PIXERA servers for high-resolution playback. Images courtesy of ROE Visual. The success of Microsoft Ignite continues to highlight an evolution across corporate events. LED is being selected over projection or traditional scenic more frequently when environments require brightness under ambient lighting, rapid content updates, hybrid broadcast workflows, or multi-day flexibility. Production teams can adapt layouts through content and configuration rather than physical rebuilds, maintaining visual impact while reducing disruption. For information: MeyerPro ROE Visual Brompton Technology Read more about events technology >>> Previous Facebook LinkedIn Copy link Next

A Swiss startup — known for its process that makes glass permeable to telecommunication frequencies — requires the right components to create their revolutionary technology. Window Glass on Public Transportation Hinders Cell Service — Until Now A Swiss startup — known for its process that makes glass permeable to telecommunication frequencies — requires the right components to create their revolutionary technology. Edited by EE Staff Cool Stuff Apr 27, 2026 As the world becomes increasingly more reliant on wireless technology in both professional and personal applications, wireless users continue to face certain unique challenges. Making calls or using data indoors can still be a hassle in many locations. This is especially true for those using public transportation like trains, where window glass greatly impacts wireless signals. While wireless signals have become stronger and more efficient in recent years, they still struggle to penetrate building materials, including insulated glass. This makes it difficult, and in some cases impossible, to get service. Everyday clear glass can reduce wireless signals by up to 4 decibels (dB), while coated glass can reduce signals by as many as 30 dB (x1000). This is especially a problem in public transportation vehicles like trains, where passengers may struggle to receive wireless signals at all. It is an issue faced by commuters worldwide, for which Swiss startup nu glass has developed a cutting-edge solution. nu glass’s revolutionary glass cutting pattern allows wireless signals to better penetrate windows. The engraving can be completed on-site without having to remove windows. Unique Glass Cutting Pattern Most glass is insulated with a thin metal layer invisible to the naked eye. nu glass uses a patented laser technology to engrave a pattern on this layer, allowing for wireless frequencies to penetrate the glass. This treatment can increase indoor signal by up to 1000 times. The etching is nearly invisible, and it has no detrimental impact on the glass, which keeps its original protective properties. nu glass uses a portable system to complete the engraving process, allowing them to visit customers on site. The system can engrave glass while it’s in place, preventing the costly and time-consuming process of removing and reinstalling individual panes of glass. The process is fast and efficient and can be applied parallel to standard maintenance, allowing for trains to keep on their schedule and return to service on time with enhanced connectivity. nu glass’s system is currently used exclusively on trains but could potentially be used on glass installed in buildings or other structures. KNF diaphragm pumps play an integral role in nu glass’s cutting process. Multiple N 838 pumps are used in suction plates, which help adhere the system to the window during the engraving process. The pumps allow for the precision process to take place with minimal vibration. The N 838 is an outstanding gas transfer pump option. It offers a maximum flow rate of 34 l/min with an ultimate vacuum down to 100 mbar (abs.). Also available are a variety of motor options, including brushless DC motors for energy efficiency. The N 838 has excellent reliability and operates oil free, preventing media contamination. KNF’s N 838 diaphragm gas pump plays a vital role in nu glass’ engraving system, holding it in place during the precision etching process. While finding the ideal pump for their system was important, nu glass wanted to make sure they were working with a partner that shared their values. A focus on quality and sustainability were key components of those values. It was also important for nu glass, which began its life at the EPFL Lausanne, to work with a local company. This made working with KNF, with multiple facilities in nearby cities and a strong presence in the community, a natural choice. KNF has locations in 24 countries and a commitment to collaborative pump design, which allows each location to serve their communities directly. * Images courtesy of KNF. For more information: KNF nu Glass N838 Order a Sample Pump Previous Facebook LinkedIn Copy link Next

Students at California State University, Chico, gained hands-on experience and technical expertise that will empower them to excel in real-world engineering and innovation roles. Students Design Versatile and Scalable Vehicle Students at California State University, Chico, gained hands-on experience and technical expertise that will empower them to excel in real-world engineering and innovation roles. Shannon William Vlaming Cool Stuff May 4, 2026 Design The vehicle platform was all about simplicity and precision. Designed for easy scalability, it used a skid-steer configuration, controlling the left and right wheels independently for unmatched off-road maneuverability. A compact single-board computer handled the drives with analog velocity commands, while a separate computer processed high-level commands, seamlessly controlling the vehicle's actuators over a wireless network. Engineering an initial design was about laying a solid foundation for success by combining creativity, precision, and problem-solving in order to deliver a streamlined, responsive system ready to tackle any terrain with ease. The student engineering team consisted of Laine Wood, Lars Bartels, William Kettle, and Adam Garza. Joshua Mirand was the Capstone Design Program Coordinator who oversaw the project. Images courtesy of California State University, Chico. Handling Multiple Drives As in any engineering endeavor, challenges and obstacles arose throughout each process. The main challenge was expanding control of the drives from discrete signals on the vehicle controller to network-based control over the drives. The existing setup relied on individual signals for each drive, which limited the flexibility and scalability of the system. To achieve a more efficient and dynamic control mechanism, the team aimed to transition to a network-controlled system that handled multiple drives simultaneously with more precision. Every challenge encountered along the way became an opportunity to refine the team’s ideas, strengthen the overall design, and build resilience. By embracing obstacles as part of the journey, engineers set the stage for innovative solutions and lasting impact. ADVANCED Motion Controls played a critical role in the vehicle's design. To ensure the platform could scale easily, Digiflex® Performance DPCANTE-060B080 and DPRALTE-060B080 servo drives were chosen for their versatility. These drives come in a wide range of amperage ratings and form factors, which allowed the team to use the same motion and control system whether they scaled the platform up or down. Images courtesy of California State University, Chico. Working with the Digiflex amplifiers informed AMC was a great experience. The software and documentation were straightforward, which made the integration process smooth. The team was able to get each of the drives controlling the motors within a few hours of unboxing them, which led to an efficient and seamless integration. According to Joshua Miranda, Senior Capstone Design Program CoordinatorCollege of Engineering, Computer Science, and Construction Management, “The performance of these drives met our expectations, expanding our control capabilities and opened up a wide range of possibilities for future developments. We are excited about the potential these new platforms bring and look forward to further advancements.” Images courtesy of California State University, Chico. Moving forward, the California State University Chico Engineering team made significant progress by getting two more vehicles up and running. The first platform is now ready for testing and is better suited for indoor navigation, incorporating 4 Digiflex® Performance DPRALTE-020B080 servo drives that are also used in the Motion and Machine Automation Course at Chico State. The second platform is a smaller vehicle utilizing RC components. The team is currently looking at implementing AMC drives for traction control. For more information: Advanced Motion Controls California State University Chico Read more about vehicle projects >>> Previous Facebook LinkedIn Copy link Next

Acoustic echosounder simultaneously collects bathymetric, seafloor backscatter, and water column backscatter data to identify seafloor and water column features. Mapping the Seafloor for Underwater Explorations Acoustic echosounder simultaneously collects bathymetric, seafloor backscatter, and water column backscatter data to identify seafloor and water column features. Edited by EE Staff Cool Stuff Sep 9, 2025 Header image caption: High-resolution seafloor mapping revealed unusual pancake-like features of a seamount in the Moonless Mountains chain in the Eastern Pacific. To plan efficient and safe operations, Nautilus (sea exploration ship) often creates its own seafloor maps—particularly when exploring little-known regions of the ocean. To facilitate this operation, the ship incorporates various equipment that provides high-quality seafloor maps at depths to 7,000 meters (23,000 feet). Whether focused on a canyon, seamount, or shipwreck, creating a map allows the crew to identify potential targets, cutting down exploration time and boosting mission efficiency. Before ROVs are deployed, the team must first map the area to understand the characteristics of the region and identify potential benthic habitats, seeps, and other environments and resources worthy of exploration. In addition to informing dive objectives, Nautilus transit routes cover unmapped areas of the ocean and contribute to the Seabed 2030 initiative, an international collaborative project to combine all bathymetric data in order to create a comprehensive map of the ocean floor. Nautilus. All images courtesy of Ocean Exploration Trust. Multibeam Echosounder Mounted on the hull of the vessel is a Kongsberg EM302 multibeam echosounder capable of accurately producing state-of-the-art maps covering large areas of the seafloor. The echosounder maps the seafloor at depths between 50 and 7,000 meters (300 to 23,000 feet) while cruising at ship speeds up to 12 knots (14 mph). The transmit array emits acoustic pulses that ensonify the seafloor with a wide fan-shaped swath of sound, while a second transducer receives the return signal echoes. Each pulse sends many beams of sound in a fan shape toward the seafloor. When these pulses strike the seafloor and return to the transducer/receiver combination mounted on the hull of the ship, the system computes a “sounding” associated with each returning pulse via the time it took to travel down and up through the water column. Because the ship is moving between the transmit and receive functions, a motion sensor connected to the system allows the echosounder to “steer” the sound pulses to correct for the ship’s rolling and swaying motions. This allows the ship to collect an even distribution of data from the seafloor. Received soundings are combined with the ship’s Global Navigation Satellite System (GNSS) information, to produce a grid or “digital elevation model” of ocean bathymetry—essentially a topographic map of the seafloor. Images such as those from Google Earth and other satellites offer very little modern depth observations and only provide general highs and lows of deep-sea topography. A depiction of the seafloor using satellite data (left) and after a Nautilus pass (right) with multibeam sonar data processed in QPS Qimera. All images courtesy of Ocean Exploration Trust. The multibeam echosounder acoustically “sees” different scales and resolutions at different depths. When Nautilus is mapping, the multibeam sonar fan covers a different width (scale) on the seafloor depending on the depth, however the number of measurements across the swath of the fan remains the same. In shallow water, the soundings are closer together delivering many details of the seafloor in a small area (higher resolution data). In deeper water, fewer details are available (lower resolution) but the multibeam fan of soundings covers a much wider area. In addition to the depth, the signal strength that the sonar receives back from the seafloor (“backscatter”) will be different depending on the type of seafloor that reflects the ping. By making corrections to this signal to account for the changes as it went through the seawater from the ship and back, the processing can extract information to indicate variations in the seafloor type. Reflections from rocky seafloor will generally provide a stronger signal than a muddy area. Backscatter measurements are then combined in another grid called a backscatter mosaic, which can be combined with the bathymetry grid to provide a better understanding of the shape and seafloor type. The multibeam echosounder can also detect phenomena in the water column, such as plumes of bubbles emanating from the seafloor that indicate gas seeps. To date, the Nautilus has documented thousands of methane seeps along the Cascadia Margin off the Oregon and Washington coast. Sound waves reflect strongly off gas bubbles emanating from the seafloor. All images courtesy of Ocean Exploration Trust. Exploring Sub-surface Faults Revealing structures below the seabed is just as important as discovering the seascape and habitats above. To complement the multibeam mapping work, the team uses a Knudsen 3260 sub-bottom profiler and echosounder. Mounted inside the hull of Nautilus , the echosounder operates at low frequencies to penetrate and reflect off of the layers of sediment, revealing a cross-section of the seafloor structure. The dual-frequency profiler operates at 3.5Khz or 15Khz (two discrete channels with separate transducers) and is capable of full ocean depth soundings. An acoustic pulse is directed through the water column to the seafloor and then captured by the system as it bounces back from each layer. Scientists use this data to identify subsurface geological structures such as faults, ancient channels, and buried levees. In early 2023, Ocean Exploration Trust installed a Kongsberg Simrad EC150-3C 150 kHz transducer on E/V Nautilus . Mounted within the ship's hull, the EC150-3C is the first of its kind to combine an acoustic Doppler current profiler (ADCP) and an EK80 split-beam fisheries sonar into one instrument. The ADCP, which measures the speed and direction of currents at various depths underneath the ship supports safe remotely-operated vehicle (ROV) operations and provides data for improving oceanographic current models. The integrated split-beam echosounder maps and characterize features found within the water column, such as biology, scattering layers, and potentially bubble plumes. The EC150 will equip E/V Nautilus with the capability to better serve as an operations hub for multi-vehicle operations, increase OET’s capacity to explore and map the water column, and to collaborate with partners from the Ocean Exploration Cooperative Institute to advance combined robotics and new technologies to increase and advance the pace of ocean exploration. For more information: Ocean Exploration Trust & Nautilus Live Kongsberg Simrad EC150-C Seabed 2030 Qimera Previous Facebook LinkedIn Copy link Next

Truss systems used for public events require the right fastener and interface components to withstand shock, vibration, and the high shear values needed for public safety. Coiled Pins Prove More Reliable for Stage Event Truss Systems Truss systems used for public events require the right fastener and interface components to withstand shock, vibration, and the high shear values needed for public safety. Stage Events Aug 13, 2025 Frames for truss systems designed to support stadium lighting, sound equipment, and even bleacher seating systems are often composed of extruded aluminum tubing and solid or tubular couplers. Considerable liability surrounds the use of these systems for public events, and the interface between these components becomes crucial to the integrity of the system. The fastener and its interface with the truss system becomes extremely critical as they are often subjected to shock, vibration, and high shear values when equipment is mounted to the trusses, or while audience members are seated during an event. A top manufacturer of truss systems consulted SPIROL about their needs for an existing design that was comprised of one tubular structural member and one solid male member that slid inside the tubular extrusion and was cross-pinned with two high carbon steel Slotted Pins to hold the coupler to the frame. During installation, the Slotted Pin was difficult to install and would often damage the expensive, yet relatively soft, aluminum frame. Once the hole was deformed, the manufacturer noted instances where the pin would begin to walk out of the hole over time, particularly in permanent installations. This was also noted in mobile systems if subjected to extreme loading. In some instances, the company noticed that the Slotted Pin had stress cracks located 180 degrees from the slot. In extreme weather conditions, the high carbon steel pin was also prone to corrosion. With a lack of options, the manufacturer had investigated implementation of an expensive machined Solid Pin with a secondary retention feature of a Cotter Pin. SPIROL was asked to evaluate the application and ultimately recommend the most robust and cost-effective solution for this incredibly demanding application. SPIROL’s Coiled Spring Pin; photo courtesy of SPIROL. SPIROL’s engineering team determined that 420 stainless steel coiled pins could act as a high-performance alternative to the Slotted Pins being used. Since the Coiled Pin does not need to be aligned in the shear plane like a Slotted Pin, this eliminates the potential of failure due to pin orientation in the hole. Since Coiled Pins remain flexible in the application after installation, they are able to absorb dynamic loading rather than transferring it into the host—which can cause deformation. This reduction in deformation increased the life of the structure, and reduced the potential of the holes opening up to the extent that the pin would eventually fall out. Since a 420 stainless steel Coiled Pin is heat treated, its shear value exceeds that of a machined low carbon steel Solid Pin. Complexity of the assembly was kept to one component rather than two, as proposed with the Solid Pin and Cotter Pin solution; thus saving time during set-up and tear down as well as the task of managing multiple components. By using 420 series stainless steel, the manufacturer would also achieve the necessary corrosion resistance, which would ultimately yield more reliable performance over the life of the structure. An added bonus to the Coiled Pin solution was that no adjustment to the hole size would be required to transition from the Slotted Pin to the Coiled Pin. This benefit extended beyond the manufacturer to their customers that already had truss systems in service throughout the country. Implementation of the Coiled Pin ultimately met all of the manufacturer’s performance and commercial requirements and significantly increased the integrity of the assembly. For more information: SPIROL SPIROL Coiled Spring Pins Previous Facebook LinkedIn Copy link Next

The pyrotechnic effects on the Disturbed “Take Back Your Life” tour was precisely controlled for safety as well as a spectacular presentation. Rock Band Uses Musically-Synced Pyrotechnic "Fire Snake" on Tour The pyrotechnic effects on the Disturbed “Take Back Your Life” tour was precisely controlled for safety as well as a spectacular presentation. Terry Persun Stage Events Jan 6, 2026 Image Engineering, based in Curtis Bay, Maryland, designs spectacular pyrotechnic effects for top bands. Music, lighting, lasers, and fire combine to fully immerse the audience in the concert experience. The fully integrated system must synchronize the special effects in real time and stop at the touch of a button for band and audience safety. Image Engineering has been behind some of the most outrageous concert productions of the past few years. The most notable of which were Disturbed’s “Take Back Your Life” rock concert tour of 2023 and Trans-Siberian Orchestra’s 2024 winter tour, "The Lost Christmas Eve." The Image Engineering team often pushes the boundaries of special effects technology by integrating advanced automation and controls into their projects. “The company’s owners are all engineers, and since the beginning, engineering has been central to who we are,” says Ian Bottiglieri, Vice President of Operations, Image Engineering. “That sets us apart from our competitors in the live event space.” Image courtesy of Beckhoff. The Fire Snake concept developed from the need for never-before-seen, jaw-dropping pyrotechnic effects by top-billed band Disturbed. Where most other bands installed video screens, Disturbed decided to have fire as the only visuals for the entire show. Image Engineering worked with the Disturbed production team to ensure that the Fire Snake operated safely and reliably in numerous environments, temperatures, and orientations – within a deadline of less than four months. A trial by fire for engineers The Fire Snake required a lot of R&D work that included how to safely feed the appropriate amount of propane at a pressure of up to 22 psi and maintain a steady pilot light no matter what orientation the Fire Snake is in. The design required replacing traditional burn bars with advanced, responsive burners that could provide more dynamic fire effects. The resulting linear burn system is capable of creating a 3.35 meter (11-foot) wall of fire with proportional control for variable height and shape up to 1.20 to 1.80 meters (4- to 6-foot). In addition, two large burst valves can produce rolling fireballs. The Fire Snake had to be compact and modular to make it easy to transport, assemble, and integrate with existing stage structures from show to show. It was crucial for the automation and safety systems to manage complex fire effects and provide safety assurances to local officials. After various meetings with the Beckhoff entertainment industry team, Image Engineering decided to work with the automation experts to bring the Fire Snake to life. They idea was to leverage advanced PC-based control technology with the integrated safety technology TwinSAFE backed by the EtherCAT industrial Ethernet system. Image courtesy of Beckhoff. Fire Snake comes to life On the Disturbed tour, the Fire Snake had to actively move and change shape according to routines that synced up with the flow of the setlist. When the band first started playing, the Fire Snake rig would slowly come to life and build into more dynamic movement. For that purpose, five segmented Fire Snake units are bolted to a custom truss structure with five winches to change the degree of angle for each unit. A little bit more than a centimeter of clearance between each unit allows free movement yet maintains a continuous, unbroken look to the linear fire effects. Image Engineering’s Touring Accumulator System (TAS) manages the propane from liquid to vapor and feeds it to the effect heads. When adjusting Fire Snake units by 45 or 50 degrees, fuel and fire behave differently and the control system has to maintain the effects and safety. “The Beckhoff system provides the flexibility to not only meet the baseline standards for flame effect systems such as those outlined in the NFPA 160 standard for fire effects but exceed them in many local jurisdictions across the U.S.,” says Nick Hock, Director of R&D and Installation/Integrations, Image Engineering. The Fire Snake features numerous safety measures to ensure trouble-free performances, which are integrated into the control platform via TwinSAFE I/O terminals. One e-stop can halt the entire rig, and the operator can see all safety-relevant status information with a glance at the control console. “It was extremely reassuring to local fire marshals to see a safety system demo and witness the entire Fire Snake shut down to a controlled stop at the push of a button,” Hock says. Installed in the Fire Snake’s shippable case control boxes are CX5140 and CX8190 Embedded PCs with directly attached EtherCAT I/O as primary and backup controllers respectively. EtherCAT and Safety over EtherCAT (FSoE) establish real-time communication and synchronization throughout the entire system including safety devices, and equipment used for lighting and other stage effects. “We have to keep perfect time with the band’s music and lighting,” Hock says. “If we were out of sync even a couple milliseconds, audiences would notice.” The various EtherCAT I/O modules are supported by TwinCAT software to connect flexibly with devices from other networks such as DMX and OSC. For example, Image Engineering uses the EL6851 single channel DMX interface to trigger the Fire Snake’s flame effects. Image courtesy of Beckhoff. Since its completion, the Fire Snake met the requirements for rapid setup and dismantle during multiple tours for Disturbed and Trans-Siberian Orchestra. For example, Image Engineering was responsible for bringing multiple Fire Snakes on the road to 56 Trans-Siberian Orchestra concerts in just 40 days on both the East and West Coasts of the U.S. – at the same time. The Beckhoff system's ability to operate reliably in extremely high ambient temperatures became another critical benefit on the road, especially for concerts in the summertime. “The heat resiliency of the embedded PC hardware is impressive,” Claire Bowman, Associate Director of Engineering, Image Engineering, says. “We've used other embedded systems before that had performance issues on rooftops in Las Vegas when the temperatures reach as high as 49° C (120°F). However, the Beckhoff system always performs without fail.” *Lead image courtesy of Steve Jennings. For more information: Beckhoff TwinSAFE I/O Terminals CX5140 CX8190 Image Engineering Read other articles about concerts >>> Previous Facebook LinkedIn Copy link Next

An insightful dialogue about what goes into designing something new and how it relates to other projects. WATCH: One-on-One with Chris Porter of igus An insightful dialogue about what goes into designing something new and how it relates to other projects. Videos Aug 11, 2025 Theme Parks In a casual conversation with the Industry Manager for Stage & Amusement in Central Florida for igus, Inc., Entertainment Engineering explores how closely designers get to their projects, how they start the process of designing something new, and how they are always working on several projects in several different industries at the same time. In this video, we show how creativity and inspiration can come from anywhere and how easily it can reshape a solution to fit a specific application. Whether working with off-the-shelf components or thinking up a completely off-the-charts custom approach, it’s all about brining your experience as well as an open mind to the table. Note to our audience: Technology Transfer DIY Stories Entertainment Engineering Magazine is looking for stories about your home projects where you take the technological experience you have at work and apply it to your home projects. I know engineers in aerospace who have rebuilt their lawn mowers, engineers in medical devices who built their own toy rocket. The spark of inspiration can come from anywhere. And once that spark is enflamed the design can morph and adapt along the way. We’re interested in your non-work-related projects. What are you designing at home, for yourself or a neighbor or relative? Is it a Halloween project? A Christmas project? Or just a backyard thing you’re working on? Here’s what we’d like to see: 1) What got you thinking about the project in the first place? 2) What is your background and why you thought you could tackle the project? 3) What technologies did you use (electrical, electronics, mechanical, fluid power, materials, etc.)? 4) How does the end product work and how did it do what you needed it to? 5) Answer those four questions in less than 800 words (and focus on the tech), then send us your story, some photos, and even a video if you have one. We can’t publish every story, but we can choose a few a month to publish. If you want to read an example, check this out: You can reach us at: Contact@EntertainmentEngineeringMagazine.com Previous Facebook LinkedIn Copy link Next

Creating new designs includes a wide view of the possibilities long before nailing down the details. These Robot Bugs Inspired by Nature Mimic the Real Thing Creating new designs includes a wide view of the possibilities long before nailing down the details. Terry Persun Museums Sep 23, 2025 Cool Stuff Entertainment Engineering Magazine is based on the concept of technology transfer where an engineer reading an article about one industry will instantly transfer that information to whatever project or projects they might be involved with in other industries. We’ve also heard this called cross-industry innovation. Well, Festo has been doing something similar only using nature as the crossover point and then cross-industry innovation. It’s pretty cool and we thought we’d bring some of their thinking to you. In a talk given by Dr. Elias Knubben, Head of corporate bionic projects at Festo, we learn some important elements about how creativity is being used to advance automation. EE pulled some of the key points from a video produced by Wired UK. Here’s what we got from the talk: Festo has a small team that explores technology through the window of nature. They’ve created butterflies and dragonflies, but also ants that work together as a team, and have recreated what resembles the tongue of a lizard. Many of the capabilities designed using nature as a model have seen their way into industrial products including control systems and robot end effectors. To create innovative products, the small team that works with Dr. Knubben goes for concept first. They look for something innovative, fascinating, educational, and inspiring. These elements are necessary so that the project gets everyone’s attention, gets everyone involved. Each member must bring confidence and the courage to fail to the project even as early prototypes are created, even when they are requesting funding. Ultimately, though, the risk is shared. From this point, the whole team can come together. By working in interdisciplinary teams that literally work side by side, each person can come at a possible solution from a different angle. Using biological role models for inspiration, the team gets started as quickly and easily as possible. Once started they are able to incubate their ideas and then put several methods into place at the same time. During the project phase, Dr. Knubben’s team constantly zooms in and out to come up with iterations and variants on a particular project. To do this, Festo incorporates generalists to keep an eye on the big picture and specialists to dive deeply into the technical details such as creating the circuit boards, writing code etc. Together, the team has the freedom and the playground to work on any project. In the end, the results are not simply to mimic nature, like an ant or kangaroo but the algorithms used to get there, the principles of operation that are now available for other industrial automation devices. Because Festo is involved with a wide variety of industries such as electronics, automotive, life sciences, process control, food processing, and others, the company is continually employing cross-industry innovation to move their products into the future. Much of the innovation for this forward motion comes from nature. Something Fun A fun display created by Festo for a recent tradeshow uses a Rube Goldberg approach to take viewers through the history of automation. Rube Goldberg takes a simple process and represents it using a complex and convoluted series of chain reactions. Called the Incredible Machine, the Festo display starts with moving the wings of a butterfly as a metaphor for the butterfly effect: the concept in chaos theory where a small change in conditions leads to vastly different outcomes in a complex system. Watch the video below and see just how significant one small event can become by moving through a variety of technologies in various industries only to end similar to how it began. *All photos courtesy of Festo. For information: Festo: https://www.festo.com/us/en/ Adaptive Shape Gripper: https://www.festo.com/us/en/p/adaptive-shape-gripper-id_DHEF/?q=robotic%20grippers~:festoSortOrderScored Previous Facebook LinkedIn Copy link Next

Entirely 3D printed auto-follow device for GoPro cameras begins US tour Auto-Follow Sports Drone Set for Take-Off Entirely 3D printed auto-follow device for GoPro cameras begins US tour EE Staff Sports Jun 4, 2025 Aimed primarily at the consumer market, AirDog is an innovative, yet simple-to-use, ‘quad-copter’ that operates via a wrist-worn tracking device and accommodates a standard GoPro sports camera. Users can automatically capture exciting live aerial video footage and still photography of themselves, having set distance, speed and height levels for AirDog to follow. Helico is specifically targeting the outdoor ‘extreme’ sports market and expects AirDog to be of particular interest to recreational participants of freestyle BMX, motocross and skateboarding, as well as water-sports such as surfing, kite-surfing and wake-boarding. AirDog might literally have not got off the ground, had it not been for the instrumental role 3D printing played during the prototyping phase. The company sought the expertise of Stratasys’ Latvian partner, Baltic3D, who also worked with Polish reseller Bibus Menos to meet the requirements outlined by Helico’s team. In order to produce fully-functional parts that could perform in the real environment, both Stratasys’ FDM and PolyJet 3D printing technologies were employed for AirDog and its AirLeash tracking device, respectively. The final AirDog drone was fully 3D printed using Stratasys’ FDM-based ULTEM material, chosen thanks to its ability to provide parts of extreme strength and durability, with the lightweight characteristics vital for take-off and in-flight maneuverability. For more information: Stratasys Home AirDog Quadcopter Drone Previous Facebook LinkedIn Copy link Next

Multiple industries including broadcasting, medical, military, consumer, and others require heating and cooling depending on their application. Thermal Management for Concert Lighting Multiple industries including broadcasting, medical, military, consumer, and others require heating and cooling depending on their application. Terry Persun Stage Events Jun 11, 2025 Cooling fans are a staple product in many industries, such as large data centers, broadcasting, medical, commercial products, military and defense, and multiple large-scale operations whether in lighting or temperature management in office buildings. As a design and manufacturing company, Pelonis provides a wide array of products that deliver the necessary thermal management required by users. When the right product isn’t available off-the-shelf, they provide custom and semi-custom solutions. Here are a few examples: A high-end concert lighting company required exceptionally good airflow blowers to maintain temperatures on a series of high-temperature emitting lights. Pelonis was able to meet the challenge by first evaluating the environment and calculating the overall needs of the system. For motorcycle rider comfort, one motorcycle manufacturer called on Pelonis to supply off-the-shelf cooling fans. In a similar operation, the company supplied fans for delivery vans to cool the driver. Each application required the company to understand the needs of the system to select the most affordable and reliable product for the customer. A consumer electronics company who required ultra-thin flexible heaters for their latest line of portable devices selected Pelonis to help them solve the challenge. Pelonis engineered low-profile heating elements that not only maintained optimal device temperatures but did so without compromising design aesthetics. A robotics manufacturer needed a compact, yet highly efficient cooling system for their automated machinery. Overcoming multiple proprietary design challenges, Pelonis was able to provide customized axial fans that improved thermal management, ensured longer operational life of the equipment, and reduced overheating risks. A commercial HVAC company sought an energy-efficient blower solution to enhance airflow in a large-scale ventilation system. To provide the right system for the project, Pelonis had to design and develop a cross-flow system of fans that could deliver consistent air distribution while reducing power consumption to help save energy. For more information: Pelonis Technologies, Inc. Previous Facebook LinkedIn Copy link Next

Software enabled a popular swimwear company to reduce prototyping cycles, increase quality, automate workflows, and streamline collaboration. Reimagining Sports Swimwear Software enabled a popular swimwear company to reduce prototyping cycles, increase quality, automate workflows, and streamline collaboration. Terry Persun Sports Jun 16, 2025 Horst Dassler, the founder of Arena and son of Adidas founder, was on the pool deck at the 1972 Munich Olympics to witness Mark Spitz win his historic seven gold medals while setting seven new world records. Dassler immediately started forming plans for a swimwear company dedicated to aquatic sports and performance swimwear. Just one year after the Games, Arena launched Skinfit® as its first competition swimwear line. The new ultra-light fabric only weighed 18 grams and was designed to cling to a swimmer’s body like a second skin.Today , Arena is headquartered in Tolentino, in central Italy, and is still fully dedicated to producing premium swimwear, equipment, and accessories for swimmers. Also from Entertainment Engineering Fast forward to the present. Arena Chief Information Officer, Andrea Mazzanti, understood that the company needed to reduce the time spent preparing prototypes of new swimwear and related products. At the same time, he wanted to reduce the company’s carbon emissions. By moving to a 3D printing model, the company was able to shorten the life cycle for producing new product prototypes. Plus, by adding 3D EXPERIENCE® Works, Arena was able to ensure all its designers had up-to-date feedback to create, test, and optimize models in real time. According to Mazzanti, “Before 3D EXPERIENCE, the company’s workflow was messier—less predictable and more manual, and they often transferred data via Excel spreadsheets. With 3DEXPERIENCE, we have a single environment where designers can work together and quickly exchange information, which also greatly helps them collaborate with our partners.” Mazzanti said, “ 3D EXPERIENCE is helping us create an ecosystem, connecting all the necessary people with our designers.” Arena mainly uses 3D EXPERIENCE with Solidworks® and 3D Sculptor, along with Simulation. With 3DEXPERIENCE Works, the company has reduced its prototyping cycle by 70 percent while decreasing time to market and enhancing quality by reducing the number of product defects. Photo: Screenshot of a swim goggle lens in design software. Simulation helps Arena reduce their CO2 emissions. Leveraging Simulation to Preserve Resources Another welcome benefit of decreasing the prototype cycle is the increase in sustainability from reduced carbon emissions. Mazzanti continues, “By simulating everything in our design office, we don’t have to create multiple product samples or use third-party product samples, which reduces our CO2 emissions.” He predicts that digital technologies will continue to help Arena improve products for swimmers, particularly in capturing images and measuring and tracking data regarding the performance of fabrics on swimmers in the water. Technology can also help designers develop and test smart fibers. 3D EXPERIENCE® Works collaboration tools ensure that Arena designers have up-to-date feedback to create, test, and optimize models in real time. Besides reducing their prototyping cycle, Arena experienced a decrease in time to market, and enhanced quality by reducing the number of product defects. For more information: SolidWorks Arena Previous Facebook LinkedIn Copy link Next