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A discussion about why one might get into engineering and the many ways to apply continued learning and experience. WATCH: One-on-One with Henry O’Bryan of Biomerics A discussion about why one might get into engineering and the many ways to apply continued learning and experience. EE Staff Videos Oct 7, 2025 DIY/Home Applications In Entertainment Engineering’s second one-on-one discussion, we spent time with Henry O’Bryan, Design Transfer Engineer at Biomerics, a company that provides solutions to the medical device industry from concept review through manufacturing. The company employs multiple engineers with varying expertise to help their customers bring their products to market. Together, Henry and Terry Persun, co-founder of Entertainment Engineering , talked about how Henry ended up becoming an engineer, what his present job entails, and how his hobby working with projects from Bottango add to his capabilities and value on the job. Bottango is an animatronics development tool that encourages creativity in robotics. It’s always interesting to hear how individuals pull together what they do at work and what they do outside of work to create a life that is both interesting and forward thinking. Design engineers are some of the most creative people working today. They often mix several categories of engineering along with creative concepts and ideas at work and at home. For more information: Biomerics Bottango Bambu Lab Previous Facebook LinkedIn Copy link Next

A small but vital component helps protect people, goods, and ships in some of the harshest conditions imaginable. The Special Materials That Make Harsh Ocean Travel Possible A small but vital component helps protect people, goods, and ships in some of the harshest conditions imaginable. Edited by EE Staff Cool Stuff Feb 16, 2026 When a cargo ship crosses the ocean in heavy weather, there’s a lot at stake. Inside multiple containers might be food for a supermarket, medicine for a hospital, or a long-awaited package on its way to someone’s doorstep. And while most people think it’s size or strength of the ship itself that keeps everything steady, the truth is often something much smaller—a spring, hidden deep inside the system of the cargo ship.  The disc spring is a powerful example of Alleima’s innovative capabilities in developing advanced steels built to withstand life at sea. Disc springs absorb shock, reduce vibration, and help prevent cargo from shifting when a ship hits rough seas. They’re not made to stand out. They are hidden deep within the ship’s systems. But when they do their job, everything stays exactly where it should. If that spring doesn’t work, containers can move, and even small shifts can cause serious damage. That’s when a tiny spring suddenly makes a big difference.  Harsh conditions The marine environment is no joke. Pressure, movement, salt, heat, and vibration all work against the materials used on and inside the ship. That’s why what you put into a disc spring really matters. Alleima, as a materials expert, has developed a spring steel designed specifically for extreme demands like cargo ships and other ocean liners. The material is tough, elastic, and resistant to fatigue. In other words, it doesn’t give up when the conditions get hard. It holds.  Creating a steel that performs under constant movement, pressure, and exposure to saltwater isn’t just experience—it’s innovation. Each new material is tested and pushed far beyond typical conditions to make sure it can handle whatever the ocean delivers. “All of our spring steels are rigorously evaluated for fatigue resistance through extensive testing in our advanced R&D facility,” says Mikael Hansson, Product Specialist at Alleima. “Because when you're out in the middle of the ocean, you need to know your materials will perform. No second chances.”  Invisible, But Essential Disc springs don’t get much credit. You won’t find them on a poster or in a campaign. But they are there, behind the scenes and doing what needs to be done. Disc springs keep cargo secure and protect the systems that keep the ship moving. They help the world move, even when the sea says otherwise.  Premium spring steel developed by Alleima can be used for all types of demanding applications. The company offers a range of spring steels in stainless and nickel-based alloys that combine strength, elasticity, and corrosion resistance for use in automotive, electronics, medical, and other applications. They manufacture disc springs, non-magnetic springs, contact springs, brush springs and more in a large variety of sizes. For information: Alleima Spring Steel *Images courtesy of Alleima. Read more about ocean and deep sea technology >>> Previous Facebook LinkedIn Copy link Next

Industrial class robots holding other robots deliver a light show with precision of motion with the grace of a dancer. Giant Laser-Headed Robot Dances at Drake Concert Industrial class robots holding other robots deliver a light show with precision of motion with the grace of a dancer. Terry Persun Stage Events Sep 11, 2025 Cool Stuff A humanoid robot is basically a collection of robots mounted to each other. When designing the entertainment robots for the Drake concert, andyRobot had to be very careful. The robot heads held super powerful lasers that had to be aimed away from the crowd for safety purposes. Yet, they also had to present spectacular choreography for the viewing audience. The application of standard industrial class robots by KUKA is enhanced by using them in an entertainment environment. andyRobot uses the same exact robots you might find in a manufacturing plant in a way that provides smooth, high precision motion night after night, even when the robots are continually moved from one location to the next. At each new arena, a team goes in to chalk out the location of the robots in four corners—often up to 200 feet apart from one another—which are brought in by semi-truck, carefully unloaded, and placed into precise location. The combined components are assembled to create each humanoid robot that rises above the crowd by over eight feet. Each multi-ton humanoid has a laser for a head and arms that hold 16-inch mirrors in each hand. During the Drake concert, the humanoids shoot lasers out of their heads and bounce them off the mirrors held by other robots standing across and diagonally from them, creating a spectacular lightshow over the heads of the audience. The overall show complexity of movement was created through andyRobot’s proprietary software Robot Animator. Robot Animator employs what is called inverse kinematics to control multiple robots. Inverse kinematics comes from computer animation and refers to how that field makes characters move on screen. In the physical world of robotics, this is when the robot follows a trajectory to reach an end point which makes the movement look more natural. Robot Animator is a plug-in that works inside Autodesk Maya. Because robots used in manufacturing move quickly until they are in position then stop abruptly, perform the operation, and move quickly away, there is a jerkiness to the movement. Think of it this way, in a stage production at a concert you want the precision that is required in a manufacturing facility only you don’t want the jerky start and stop motion. The robot movements created by Robot Animator must vary from slow to fast to follow the music being played, producing surgically exact movements at every show. Robot Animator is able to smoothly ramp up and ramp down every motion—and do it with precise accurately. According to Andy Flessas, President of andyRobot, “Grace of movement is created through Robot Animator’s Motion Planning software, which translates industrial robot motion into the language of animation.” All photos courtesy of andyRobot. Basically, to do this, the software must ease in and ease out of every movement. For example, it can take over thirty separate micro moves to provide one second of actual robot motion, all of which allows the humanoid robots at the Drake concert to look like they are dancing. The robots used in the Drake Concert include four KUKA KR210 robots, each with six axes of movement, and eight KUKA KR10 robots, with six axes of movement. All told, each of the four humanoid robots incorporates 18 axes of motion that must be precisely choreographed with one another. That’s 72 axes of motion that had to be programmed for a two-hour concert, second by second. andyRobot provides the key components necessary for all types of entertainment using the same robots you might see in any manufacturing plant. Adjusting them for multiple movements not normally found in industry, andyRobot exploits the precision required in manufacturing into a creative experience for a large audience. For more information: andyRobot Autodesk Maya ABB Robotics KUKA Robotics Previous Facebook LinkedIn Copy link Next

Ensuring the long-term reliability and performance of wearable sensors hinges on robust manufacturing processes. Precision Dispenser Provides Nontoxic Adhesive to Wearable Sensor Technology Ensuring the long-term reliability and performance of wearable sensors hinges on robust manufacturing processes. Anthony Buzzerio, Venkat Nandivada, Rohit Ramnath Cool Stuff Dec 9, 2025 From smart watches to fitness trackers to smart clothing, the growing field of wearable technology relies heavily on miniaturized sensors capable of providing accurate and continuous physiological data. This is especially true in the medical field where all types of demanding conditions including physical stress, thermal fluctuations, and exposure to bodily fluids can create a harsh environment. One of the keys to operational superiority includes biocompatible adhesives for encapsulating these delicate sensor components. Images courtesy of Nordson EFD and Master Bond. Here we’ll examine the selection and implementation of a non-cytotoxic adhesive chosen for its ability to encapsulate sensors from harsh environmental factors such as humidity, dust, and mechanical impact. We’ll also explore the automated dispensing equipment used to achieve the accuracy and consistency required for production. To ensure that the manufacturing process was optimized, Nordson EFD partnered with specialty adhesive manufacturer Master Bond. The product selected for this encapsulation process needed to meet several key requirements to ensure its effectiveness and compatibility with the wearable sensor, including a low-viscosity epoxy with capillary flow characteristics for precise dispensing, the material needed to be curable below 80oC to protect heat-sensitive electronic components from damage, and it needed to be a non-cytotoxic encapsulant to ensure safe use when used against a human body. Finally, the dispensing process had to be automated and capable of dispensing approximately 3cc of the material per sensor consistently. Material Solution Master Bond’s EP21LSCL-2Med, a two-component epoxy adhesive, met the overall application requirements. The product has an ISO 10993-5 non-cytotoxicity rating, which qualifies for wearable sensors. EP21LSCL-2Med was specifically engineered for low-temperature heat curing, which was instrumental in protecting the integrity of the sensitive electronics within the device. Important was the adhesive’s low mixed viscosity—measured at 500–1000 cps at room temperature—making it highly suitable for capillary action, which ensured that intricate spaces were properly filled with no voids. The Master Bond EP21LSCL-2Med has a working life of 6-8 hours. The working life of a fluid is the amount of time before the epoxy becomes too thick to be applied. An additional consideration for fluid dispensing technology selection was that once the Master Bond compound was thawed to room temperature from the -40° C freezer in the manufacturing process, it could not be re-frozen. This fact informed the dispense solution selection for the application. Images courtesy of Nordson EFD and Master Bond. The material was packaged in pre-mixed and frozen syringes (stored at -40oC until use), delivered in 3cc Nordson EFD syringes, making the process highly efficient and reducing waste. Operators could simply thaw and load the syringes into Nordson's dispensing system, streamlining the workflow and minimizing handling errors. Dispensing and Packaging Nordson EFD offers several fluid dispensing solutions for effectively encapsulating wearable electronics. The company’s broad selection of fluid dispense solutions enables manufacturers to choose the right technology for their unique application needs. To meet the requirement for the material to flow easily around the sensor components and fill the intricate spaces without leaving voids in the application, a fluid dispenser, valve, automation, cartridge, and tip technologies were required. To maximize the usage within the Master Bond EP21LSCL-2Med’s working life, Nordson EFD engineers recommended using the Ultimus V high precision dispensers, which provided a benchtop fluid dispensing control for the manual or automated application of fluids. As the viscosity of the epoxy changes, the full electronic press regulation feature keeps the critical fluid dispensing processes consistent from start to finish. The Ultimus V fluid dispensing solution shot size stays consistent regardless of changes in viscosity of the epoxy. This solution also offered electronic control of the dispensing time, air pressure, and vacuum. Once programmed the air pressure automatically adjusts as the fluid gets thicker. If larger volume is required (30cc or more), an xQR41V Series needle valve can be an alternative to avoid full-to-empty variation issues. The design of the xQR41V allows for quick fluid change-over and easy cleaning of wetted parts at the end of the shift. The needle valve features a patented quick release clasp, enabling fast and easy servicing in the field. In addition, the low level of fluids retained in the fluid body reduces fluid waste, and the reduced form factor of the solution increases production capacity. Images courtesy of Nordson EFD and Master Bond. After benchtop testing was successful, in order to meet the longer time requirement for automated dispensing, Nordson EFD advised that the customer use the EV Series of tabletop automated dispensing systems for easy integration into the manufacturing operations. The consistent application of the fluid was maintained by using Nordson EFD for general purpose orange or red stainless-steel tips. The orange tip is 23 gauge and has an inner diameter of 0.33 mm/0.013-in. This tip is most optimal when the material is applied manually. The red tip is 25 gauge and has an inner diameter of 0.25 mm/0.010-in, which is more suited for automated processes. Nordson EFD uses a laboratory-focused approach to recommending fluid dispensing technologies—evaluating fluids, substrates, application goals, and production needs to provide a consultative approach to selecting the right solution. Minimizing Air Bubbles for Pre-mixed and Frozen Packaging One of the most common challenges in dispensing epoxy adhesives is the presence of air bubbles. To address this, Master Bond implemented rigorous degassing protocols during the packaging process. After mixing the two components of the EP21LSCL-2Med, the formulation underwent centrifugation at 2000–3000 rpm for 1–2 minutes. This critical step effectively removed entrapped air and reduced the risk of voids during application. Using a centrifuge system like the ProcessMate 5000 Universal Centrifuge is a proven way to ensure no air pockets exist after thawing the epoxy used in this application. This approach only eliminated the need for on-site mixing, a process prone to variability and contamination, but also dramatically improved production uptime and consistency. The collaborative application of Master Bond’s innovative pre-mixed and frozen epoxy alongside Nordson’s best-in-class dispensing technology proved instrumental in the customer's success in manufacturing their wearable sensor solution. For more information: Nordson EFD Ultimus V Dispenser xQR41V Needle Valves 3-Axis EV Dispensing Robot ProcessMate 5000 Master Bond EP21LSCL-2Med About the authors: Anthony Buzzerio is the Application/Systems Engineer II at Nordson EFD; Venkat Nandivada is the Manager of Technical Support, Master Bond; and Rohit Ramnath is the Senior Product Engineer at Master Bond. Previous Facebook LinkedIn Copy link Next

How Disney Imagineering Research & Development brought a robot into the real world that walks and talks just like the beloved animated character from Frozen. The Groundbreaking Technology Behind Disney's New Robotic Olaf How Disney Imagineering Research & Development brought a robot into the real world that walks and talks just like the beloved animated character from Frozen. Terry Persun Theme Parks Jan 13, 2026 Per a recent press release, Disney Imagineering Research & Development has recently brought Olaf into the physical world as a fully free-walking robotic character. To do this, there were several real-world challenges, such as translating a stylized, animated character with non-physical movement into a believable real-world figure. At the outset, it was obvious that traditional robotics approaches were not going to work simply because Olaf’s proportions, motion style, and expressive requirement differed significantly from typical walking robots. Challenges included creating Olaf’s large, heavy head while supporting it by a very slim neck. Then there were the small snowball feet with no visible legs leading to an animated walk cycle that doesn’t follow realistic physics. Finally, there was the challenge of adjusting to the high sensitivity to noise, jitter, or awkward impacts that could easily break the illusion of life. Even small issues like loud footsteps or stiff motion were found to immediately reduce believability, making this one of the most demanding character robotics projects Disney has attempted. To preserve Olaf's on-screen appearance, the team designed a compact robotic structure that was completely hidden beneath the costume. They used a novel asymmetric six-degree-of-freedom leg system with one leg inverted relative to the other. The legs were totally concealed under the soft polyurethane foam skirt to create the illusion that Olaf’s feed moved freely along his body. The flexibility of the foam snowballs was able to absorb impacts and allow recovery steps. The design allowed Olaf to walk naturally while keeping all of the mechanical elements out of view. Reinforcement Learning Rather than programming Olaf’s movements by hand, the imagineering team relied on reinforcement learning guided by animation references. Artists first created stylized walking and standing animations and then used them to train AI policies in simulation. Separate standing and walking policies user used along with a reward system that focused on matching animation, maintaining balance, and staying within physical limits of the robot. Training also included real-time puppeteering through an animation engine that blends idle motion, triggered gestures, and joystick control. This approach allowed Olaf to move in a way that closely matched his animated personality, rather than simply walking like a typical robot. Solving Noise and Overheating Problems Two practical issues proved especially challenging: footstep noise and overheating. To address sound, researchers introduced a special impact-reduction reward that smooths foot motion during contact with the ground. Testing showed this reduced average stepping noise by 13.5 decibels, without significantly changing Olaf's gait. Overheating, especially in the neck where small actuators support Olaf's heavy head, the team developed a thermal-aware control policy that fed real-time actuator temperature into the AI system. This allowed the system to adjust motion to reduce torque before temperatures reached unsafe levels. This approach slightly relaxes animation accuracy when needed to protect the hardware, enabling Olaf to perform extended movement without damaging internal components. Expressive Face, Mouth, and Arms Beyond walking, Olaf's expressiveness comes from a separate set of "show functions" that control fully articulated eyes and eyelids, moving his mouth to look like he’s talking, and moving his arms—done through hidden spherical linkages. All of these elements are controlled using classical methods rather than reinforcement learning, allowing precise facial and gesture animation layered on top of the walking system. Many costume elements, including the carrot nose and arms, are magnetically attached so they can safely detach during a fall. Olaf represents a new benchmark for non-robotic character believability. While the system was built specifically for Olaf, the techniques developed—including asymmetric leg design, thermal-aware AI policies, and sound-reducing motion control—can be applied to future Disney characters. As Disney continues to preview Olaf's upcoming debut in parks overseas, the research makes it clear that this is only an early step toward a broader lineup of expressive, autonomous characters. The self-walking Olaf will debut at World of Frozen in Hong Kong Disneyland and at Walt Disney Studios Park in Paris in 2026. * Image courtesy of Disney. For more information: Disney Disney Hong Kong-Frozen Disney Paris-Frozen Read more about theme parks >>> Previous Facebook LinkedIn Copy link Next

The Gröna Lund Amusement Park recently inaugurated some new rides, including a refurbished “Blå Tåget” ride. Stockholm, Sweden Amusement Park Features Synchronized AV System The Gröna Lund Amusement Park recently inaugurated some new rides, including a refurbished “Blå Tåget” ride. Kreativ Teknik Theme Parks Jun 4, 2025 The “Blå Tåget” ride went through a total makeover. This ride is a ghost train loaded with new chills, thrills, and effects especially designed for visitors’ enjoyment. The train passes through several chambers, each filled with skeletons, scarecrows, rats, wolves, fire, lightning, ghosts, and more. The setting inside the ride was designed by artist Magnus Sörman and the entrance to the ride was designed by artist Joakim Hansén. For the technical portions of the adventure-ride, Kreativ Teknik was contacted by Gröna Lund. Kreativ Teknik, a Swedish-based company that mainly works with lighting, control systems, and effects, selected Medialon to be part of the project. Kreativ Teknik delivered a total solution including lighting, smoke, video projectors, control system, as well as the programming of the entire ride’s special effects. One Medialon Showmaster Pro embedded show controller controls and synchronizes the entire AV system. Medialon controls everything from light and sound to lightning, smoke-effects, movements of the animatronics, and video, which are continuously timed and trigged by the exact positions of the train’s chariots. “It was surprisingly quick and easy to set the timings of the animatronics together with the effects. I really liked the system and I want to continue to work with it in my future projects” says Marcus Persson, Project Manager and CEO at Kreativ Teknik. “We think that the project has been carried out really well and it’s been done with great interest and commitment,” Peter Osbeck, Ride Manager at Gröna Lund said. For more information: Gröna Lund Amusement Park Home Kreativ Teknik Home Medialon Home 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

Upgrading to professional-grade comms offered better sound quality and interference-free communication, but involved numerous behind-the-scenes considerations. Why This Laser Tag Arena Replaced Walkie-Talkies with Professional-Grade Comms Upgrading to professional-grade comms offered better sound quality and interference-free communication, but involved numerous behind-the-scenes considerations. Edited by EE Team Theme Parks Nov 25, 2025 Games Mission Laser offers interactive laser tag gaming experiences in Richmond, Virginia, and Charlotte, North Carolina, with a third arena opening soon. At one point, the company had an interest in upgrading its communications systems, both inside and outside the arena. Director of Operations and Sales, Trip Roberts explained that when he was looking for ways to help the team become more efficient, he chose to work with Clear-Com® systems. Upgrading its critical communications was certainly a core goal, but so was the ease of use and operation of the devices by the crew, who are often team members unfamiliar with professional-grade communication systems. Images courtesy of Clear-Com and Mission Laser. Roberts had worked with Clear-Com in the past and felt that they were the right company to partner with. He opted for the Clear-Com DX210 Digital Wireless System comprised of a two-channel communication base system and lightweight all-in-one WH220 wireless headsets. This system was an instant “upgrade” over the walkie-talkies the staff previously used, offering exceptional sound clarity and interference-free communications with the option of a single or dual-channel intercom system in Mission Laser’s demanding environment. Images courtesy of Clear-Com and Mission Laser. The DX210 can run in ISO intercom mode, so that communications can be routed directly to the facility’s indoor and outdoor speakers. This feature is perfect for customer announcements and getting the attention of the large and often distracted crowds. DX210 base stations and extender antennas are placed in “mission control” mode and integrated seamlessly with Mission Laser’s house audio system. The WH220 headsets are lightweight and comfortable to wear, yet rugged and reliable—an important feature in a fast-paced and physically active business. Plus, they allow staff to keep their hands free for other on-the-job tasks, and most importantly, provide superior sound quality and word recognition, a critical factor in a loud laser tag environment. Images courtesy of Clear-Com and Mission Laser. “Being able to communicate in a more controlled and coherent way removes a fair amount of stress for our crew, improving overall productivity and fun on the job,” Roberts said. After their shifts, each team member can simply hang up their headsets, set the batteries on chargers, and the equipment is all set for the next shift to start. “If I’m working in front of the house, I can easily troubleshoot any issues with my team without having to physically go to them,” Roberts explained. “Precise communications are an essential component of our day-to-day business running smoothly. The Clear-Com technology gives our busy staff the freedom and flexibility they need to manage the games, gather customer groups, work more efficiently, and ultimately offer better customer service.” For more information: Clear-Com DX210 Digital Wireless System and WH220 Wireless Headset Mission Laser Previous Facebook LinkedIn Copy link Next

Customizations necessary for large-scale stage production rotational applications require the right components to deliver accuracy, repeatability, and safety in any environment. Precision Rotational Stages Enhance Performances at Concerts, Theaters, Theme Parks, and More Customizations necessary for large-scale stage production rotational applications require the right components to deliver accuracy, repeatability, and safety in any environment. Stage Events Sep 5, 2025 Large-scale rotational applications, such as those used in theatre settings, for concerts, and theme park attractions, require precise motion feedback to gain optimal performance, safety, and efficiency. Custom encoder design provides an innovative solution for these applications, similar to other high-demand products such as forklifts, MRI machines, mobile equipment, and a wide variety of specific stagecraft turntables. Reliability and accurate positioning of the rotational element is key. Encoder Products Company has designed a custom encoder design that leverages a spring-loaded gear or wheel system to provide absolute motion feedback. The challenge with such applications is that large diameter rotary motion introduces unique problems because traditional encoders struggle to provide accurate feedback. The reasons for this are many. For example, accurate tracking of large diameters requires specialized designs, which can often involve large, fragile, difficult to install, and very expensive optical sensor rings. Further challenges include environmental durability, space constraints, and safe operational control. In addition, gear ratios that result in irrational numbers can be difficult to work with. Image courtesy of Encoder Products Company. Encoder Products has designed a gear slewing technology that allows their encoders to calculate the correct position of a large ring gear when installed on a smaller drive gear using any gear ratio. The company’s A36R Absolute Encoder is a 22 Bit ST/24 Bit MT single turn/multi-turn absolute encoder that uses BiSS C or SSI communications. The device has a low profile of just 1-inch (25.4mm). The encoder offers flex mount options to eliminate couplings and the option of a battery/backup power interface for data retention in the absence of primary power. Custom Solutions For large-scale rotational projects, Encoder Products Company eliminates the need for engineers to spend time piecing together parts and assembling components themselves. They offer customizable solutions that combine the housing from their TR1 Tru-Trac® wheeled encoder and the stability of the A36 Absolute Encoder with a spring-loaded gear or wheel system tailored to each application's unique requirements. Image courtesy of Encoder Products Company. TheTR1 Tru-Trac is rugged and versatile. Its housing provides robust protection against environmental factors such as dust, moisture, and vibrations, while its modular design allows seamless integration into diverse systems. Known for its compact size and exceptional performance, the A36 encoder delivers precise absolute motion feedback even under harsh environmental conditions. The inclusion of a spring-loaded gear or wheel mechanism enables precise tracking of large-diameter rotary motion, ensuring maximum positioning accuracy. Image courtesy of Encoder Products Company. Particularly valuable in stagecraft where the turntable must rotate smoothly and precisely to create seamless theatrical or production experiences, the company’s spring-loaded gear or wheel system pushes the limits on accuracy for large-diameter motion and position tracking. This ensures flawless operation in a variety of high-pressure settings. The encoder can also be used as secondary feedback for safety, giving position data right at the point of motion itself. Encoder Products Company’s custom encoder solutions are redefining motion feedback technology across industries. By combining the rugged TR1 Tru-Trac encoder housing, high-performance A36 absolute encoder, and a precision gear and wheel system, the company is able to deliver an all-in-one solution that provides engineers with the tools they need—without the hassle of assembly. For more information: Encoder Products Company A36R Creative Conners *Lead photo is a general photo from Depositphotos.com Previous Facebook LinkedIn Copy link Next

Entertainment Engineering talks with the best-known and most highly respected special effects companies in the film business to discuss creativity, freedom, and herding cats. Dave Merritt is Model Shop Supervisor at Legacy Effects, and took time out of a very busy day to speak with us. Here is part of that conversation. Creativity on a Monstrous Scale Entertainment Engineering talks with the best-known and most highly respected special effects companies in the film business to discuss creativity, freedom, and herding cats. Dave Merritt is Model Shop Supervisor at Legacy Effects, and took time out of a very busy day to speak with us. Here is part of that conversation. Derek Wells Film and TV Jun 4, 2025 EE: First of all, how many men and women do you typically employ, and what are their specialties? Dave Merritt: Legacy Effects operates from a core group of about 45 people, and we can quickly ramp up to 150 people as more projects come in. We staff all types of specialists, but we separate them by departments; some departments include more than one specialist. The Departments are broken up into Art, 3D Modeling, Mechanical, Fabrication (which includes hair and fur), Electronics, Molding and Casting, and the Model Shop. EE: Creativity is an important aspect of Legacy’s production. How often do you start with one design and end up with something completely different based on inputs from different departments? Dave: We strive to create exactly what our clients desire, but there are times when our staff collaboration may change our approach to the final project. Typically our timeframes are short so a great deal of collaboration needs to happen during the project. For example, we may use materials and processes from one department to replace a more time consuming method in another department. EE: What percentage of your projects have some sort of motion involved? And do your designers typically use electric, pneumatic, or hydraulic components for the motion? Dave: About 50 percent of our work involves some sort of motion. That motion can incorporate everything from simple rod puppets to large hydraulic systems depending on the individual project. In Real Steel, the robot Atom was built with rod puppet arms and a hydraulic head which allowed for a smoother and more fluid operation. EE: For any single project, how many different designers are involved? Dave: Each department has input on the design of a project. For instance, 5 key designers from various departments were involved with the Iron Man suit. Our Fabrication Dept. dealt with how the materials would work together as a whole; Mechanical worked out hinge points and fasteners, while the Model Shop and Mold Dept. focused on the patterns and casting process. Then, Electronics followed up with the lighting and wiring harness. Now for something like the aliens in Cowboys and Aliens, the same process applied, but the puppet was more organic, so the Digital and Real World Sculptors, Mechanics and Mold Dept. were more predominate in the build. EE: How do you use the computers you have in-house, since you don’t provide CGI to your clients? Dave: We utilize 3D modeling in order to visualize what we are going to build and to identify specific elements that may go through the rapid prototyping process. We use our in-house system to produce maquettes for clients as well as small detail components. EE: How many projects do you work on at any one time? Dave: We typically run four to six television commercials and two to four feature films at one time. EE: If you had only a few words to explain how it is to work with such a diverse and talented group, what would you say? Dave: It's a very rewarding experience to be able to work in a creative environment with such talented people. EE: Thank you for taking the time to answer our questions. Dave: Thank you. For more information: Legacy Effects Home Previous Facebook LinkedIn Copy link Next

As differentiating features of automobiles are increasingly defined by software, OEMs are transforming their development processes from hardware- and component-centric to software-centric approaches. Complete Automotive Design Through Virtual Prototyping As differentiating features of automobiles are increasingly defined by software, OEMs are transforming their development processes from hardware- and component-centric to software-centric approaches. Gunnar Braun, Technical Product Manager, Synopsys and Stewart Williams, Segment Mamagement Director, Synopsys Cool Stuff Jul 29, 2025 In the race to develop software-defined vehicles (SDVs), automotive manufacturers (OEMs) and their suppliers are facing pressure from all angles. With vehicular codebases often exceeding those of commercial aircraft, OEMs must wrangle enormous complexity while shortening developing cycles. In addition, companies must deliver frequent software updates throughout the vehicle’s lifecycle, which continually assures quality, safety, security, and reliability. Further, cost pressures are enormous. These challenges demand faster, more rigorous software development, testing, and validation. While traditional hardware-in-the-loop (HiL) testing rigs are still a mainstay for system validation, their expense, latency, and inflexibility are increasingly at odds with the agility required by today’s automotive software development practices. To enable earlier and more efficient software testing and validation, the industry is adopting cloud-based development practices and the use of virtual prototypes. Cloud-native development Automotive software is simultaneously becoming more expensive and central to a car’s identity. Infotainment, advanced driver-assistance systems (ADAS), traction control, and even powertrain management are all shaped by lines of code. The growing adoption of electric vehicles (EVs) and the push toward fully autonomous transport have further increased the role and importance of automotive software. The shift from hardware-centric to software-centric vehicles means that OEMs and suppliers must rethink their development models. The IT industry pioneered cloud-native development approaches, leading to web applications and Software-as-a-Service (SaaS) solutions that are quickly delivered and continuously updated. These approaches involve incremental development and a strong emphasis on automation. DevOps practices further bridged the gap between the software development process and its operational deployment environment. Thanks to technologies such as containerization, testing cycles are now performed and automated in a production-simulated environment. This is one of the key challenges for OEMs and suppliers adopting cloud-native methods for SDV development: The replication of the operating environment — the vehicle — when developing and testing software. While the cloud provides virtually unlimited compute and collaboration resources, physical hardware—the ultimate destination for automotive software—often lags behind in availability. Teams often wait months for electronic control units (ECUs) to be ready for initial testing and validation. If hardware revisions are required, it extends the waiting period before OEMs and their suppliers can fully test their software at scale. All photos courtesy of Synopsys. Virtual prototypes accelerate automotive software development Virtual prototypes are models of target hardware that are used for software development, testing, and validation — before the hardware is available. Referred to as electronics digital twins (eDTs), these virtual prototypes simulate the behavior of automotive compute platforms; enable continuous software testing, integration, and delivery (CI/CD); and minimize the reliance on hardware and eliminate associated delays. Virtual platforms are used throughout the embedded software industry for starting software development before hardware is available, which results in a significant time-to-market advantage. A notable example is the open-source community’s use of QEMU, an emulator that allows open-source software stacks to leverage cutting-edge Arm CPU features well before the corresponding hardware is available. But traditional emulation-based tools were never designed for the complexity of modern automotive processors, such as Arm’s Cortex-A720AE, or the runtime demands of continuous, cloud-based software development. With Synopsys’s introduction of Virtualizer Native Execution, they are addressing these limitations and enabling Arm embedded software to be executed directly on Arm server CPUs—in the cloud, with no emulation or hardware required. This means developers can run workloads at the speed of the eventual hardware, roughly 100x faster than traditional instruction set simulators, while retaining the benefits of virtual prototypes and full compatibility with the existing ecosystem of models, tools, and workflows. Here are some of the technical and operational impacts: Software teams can validate complex system-level behaviors early and often, reducing the dependency on HiL rigs during the development cycle. With architecture parity between cloud and vehicle CPU (via Arm’s instruction set), developers can use the same development tools to significantly reduce workflow complexity. Native execution on Arm-based cloud instances, such as AWS Graviton servers, enables continuous DevOps and CI/CD pipelines, with virtual prototypes providing the critical link between development and operational environments. Leveraging the SOAFEE reference architecture An essential part of this puzzle is the SOAFEE (Scalable Open Architecture for Embedded Edge) initiative. Led by Arm and other industry stakeholders, SOAFEE provides a standardized framework and reference architecture—based on the principles of modularity and orchestration—for SDV workloads. By adhering to common standards like SOAFEE, the ecosystem of automotive OEMs, suppliers, and technology leaders can increase interoperability and reduce vendor lock-in. All photos courtesy of Synopsys. At Embedded World 2025, while in collaboration with Arm, Synopsys demonstrated how virtual prototypes, SOAFEE reference architecture, and cloud-to-edge software development come together: Leveraging Synopsys Virtualizer Native Execution in an AWS cloud environment, the demonstration featured an open-source autonomous driving workload running on top of the SOAFEE edge reference stack. Executed at real-time speed, the virtual prototype was approximately 100x faster than a comparable QEMU-based simulation. The demonstration showed how virtual prototypes replicate the structure of an edge device with sufficient granularity to validate real-world functionality and software behavior, while remaining scalable and shareable across teams and geographies. While the technical underpinnings are compelling, the business value of virtual prototypes and cloud-native development is just as important. Cloud-based workflows are becoming a prerequisite for meeting time-to-market expectations in a world where vehicle features are continuously updated via over-the-air (OTA) software pushes. Synopsys’s collaboration with Arm and other SOAFEE partners is ongoing, and forthcoming advances to Virtualizer Native Execution will enable more complex scenarios and system-level parity. This includes better support for real-time behavior, safety domains, and full-vehicle E/E system integration. In the meantime, the automotive industry has a powerful foundation on which to build. For more information: Synopsys Home Synopsys Virtualizer Native Execution release Previous Facebook LinkedIn Copy link Next

Country star Megan Moroney’s varied tour environments required a system that was reliable in all conditions, including weather-sensitive locations. From Rodeos to Outdoor Arenas: The LED System That Handles it All Country star Megan Moroney’s varied tour environments required a system that was reliable in all conditions, including weather-sensitive locations. Edited by Terry Persun Stage Events Jun 16, 2026 Megan Moroney steps onto stages across the country with a sound that has quickly become a fixture in modern country music. Gained attention with her single “Tennessee Orange” following her debut EP Pistol Made of Roses , Moroney released her first album, Lucky , in 2023 and followed it with Am I Okay? in 2024—which debuted in the top 10 of the Billboard 200. Moroney’s tour has taken her team across a wide mix of venues, from rodeos and music festivals to arenas and outdoor stages. For OSA International, Inc., the variety demanded an LED system that could withstand shifting environments, tight schedules, and repeated transport. Those requirements were met using Absen’s X5, a legacy product that still performs like new, citing its durability, serviceability, and performance consistency across more than 60 shows. Matt Searle, video director for OSA International, said the X5 tiles performed reliably in all conditions, including weather-sensitive locations such as Red Rocks. “You can put a lot of weight on the tiles, and you can easily swap one without taking the whole videoscope down,” he said. Searle noted that the design cut load-in and load-out time and limited downtime during travel. The system’s stability played a direct role in show execution. “It made it good for me directing the show, knowing everything was safe and performing the way it should.” Because Absen offered a knowledgeable local technical team that responded quickly, “It felt good going across the country and to other countries knowing they were a phone call away.” That rapid response emphasized Absen’s commitment to long-term product reliability through ongoing support, which is a core element of the company’s engineering philosophy. Images courtesy of Absen. Timmy Abercrombie, production manager for Megan Moroney, emphasized the X5 system’s adaptability for both indoor and outdoor use. The heavier tile construction allowed the crew to secure the walls in windy conditions and maintain fast build times. Abercrombie cited a quick technical resolution earlier in the year when an issue arose. “Absen took over one of the tiles and the computer,” he said. “Within 10 minutes, they had it fixed. Everything was up and running, and we were ready for the show that night.” He noted that the collaborative relationship between OSA International and Absen helped keep the tour on schedule, describing the partnership as aligned around shared tour-wide goals. Niel Niu, mechanical design engineer for Absen Inc., said, “We are not only an LED manufacturing company; we are a full solution support partner.” Niu highlighted that the X5’s durability and service-friendly design reflect the same engineering principles Absen applies across its product portfolio, contributing to the product line’s lasting performance in the field. Images courtesy of Absen. For OSA International, the combination of rugged hardware and responsive assistance helped maintain consistent visuals throughout a demanding tour. With the X5 system in place, the team delivered stable performance across diverse venues, weather conditions, and tight travel windows. Absen’s X5 is a 5.2mm LED display designed for outdoor rental applications, including concerts, live shows and festivals. The X5 supports front and rear module access, allowing module replacement in about five seconds to streamline maintenance during fast turnarounds. With brightness levels exceeding 5000 nits and a high refresh rate, the system is built for clear visibility across varied lighting conditions, but more importantly, its lasting durability spotlights Absen’s commitment to engineering products that continue performing long after they leave production. For information: Absen Inc. Absen X Series OSA International, Inc Read more about concert tech >>> Previous Facebook LinkedIn Copy link Next