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

The increase in the number of EVs on the road has also increased the demand for more charging stations, which require high-end components to keep them running cool. Pump Technology Keeps EV Charging Stations Cool The increase in the number of EVs on the road has also increased the demand for more charging stations, which require high-end components to keep them running cool. KNF Cool Stuff Jul 9, 2025 Sports The world has become more environmentally conscious, and emissions regulations are becoming stricter, making electric vehicles (EVs) increasingly popular. As the demand for newer, better EVs increases, so too does the demand for the charging stations that are necessary for keeping EVs powered and operational. These stations will need to be installed both commercially and residentially as more drivers move to EVs. Also from EE: Hydraulic Gimbal Aids Iron Man’s Motion Control Because charging stations output so much electricity, they also generate substantial amounts of heat. There are three different levels of chargers, with levels one and two available for both public and private use and level three available for public use only. The level three DC Fast Chargers (DCFCs) can output up to 500 A and 350 kW. Even more powerful chargers are on the horizon, which could be capable of outputting more than 400 kW and charging a vehicle to 200-mile range in less than eight minutes. How Cooling Systems Work Liquid cooling works by pumping a fluid, called coolant, through pipes or tubes, absorbing heat and dissipating it away from critical components. This reduces the temperature of those critical components, including capacitors, inductors, and control circuits, leading to more efficient charging and longer product life. The coolant is typically water mixed with glycol to prevent freezing or boiling. High quality liquid pumps are essential for effective liquid cooling operations. Constant and consistent flow is required for these systems to function properly. This ensures heat is being adequately transferred away from the element while also keeping the coolant at an appropriate temperature. Reliability is also key, as leaked coolant could result in catastrophic equipment damage. Photo from Depositphotos.com Liquid Pump Experts KNF has extensive experience creating state-of-the-art diaphragm liquid pumps for a variety of OEM and process industry applications. These pumps are self-priming and dry run safe, with flow rates ranging from 0.018 to 12.4 l/min and pressures up to 16 bar (rel.). KNF pumps are suitable for use with a variety of liquids, including abrasive and corrosive media and offer clean and reliable operation. Because of this, KNF pumps are trusted in some of the most demanding applications. In addition to offering a wide range of liquid pump series, KNF also provides custom options for all liquid diaphragm pumps. Pump heads, valves, and diaphragms are all available in various materials, while hydraulic and electrical connections can also be customized. Several motor options are available. KNF’s modular design approach allows pumps to be tailored to specific applications and ensures customer needs will be met. Cooling is Critical More power is required for EV chargers to provide faster charging. However, more power also leads to more heat generated. This makes cooling, specifically liquid cooling, an essential part of their operations. This is especially true in the larger, publicly available fast chargers, which need to output huge amounts of power to charge vehicles quickly and effectively. Faster charging is important for increased adoption of EVs, but it is also directly correlated to excess heat generation. Many readily available cooling systems are unable to adequately cool EV chargers quickly or efficiently enough, leading to slower charging speeds, performance issues, and increased maintenance costs. Cooling is also important in EV charging station cables, which are required to transport large amounts of energy very quickly. Reaching adequate charging speeds requires cables that are capable of doing so, often resulting in large, bulky cables that can be difficult to maintain. Liquid cooled cables allow for faster charging and better performance while also being easier to handle. A New Era for EVs The latest data from the International Energy Agency estimates there are more than 40 million EVs on the road worldwide, an increase from about 26 million in 2022. Sales of electric vehicles are climbing worldwide, increasing substantially in North America, Europe, Asia and other parts of the world. Estimates vary, but predictions for percentage of global vehicle sales for EVs by 2030 are as high 86 percent. With this relatively new technology rapidly gaining in popularity, efficient and safe charging stations will be a necessity. For more information: KNF's Website 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

To reach the consumer market, automated robotics systems must be accessible, reliable, and economical. Robot Bartender? How This Company Fine-Tuned Beer Serving Technology To reach the consumer market, automated robotics systems must be accessible, reliable, and economical. Grayson Dawson Cool Stuff Sep 22, 2026 Food Bringing technology to the consumer, especially robotics, has been a challenge. Yet, after working for more than a decade on industrial and automation projects, Grayson Dawson founded Hop Robotics to do just that. His goal was to bring high-technology robotic serving systems to the food and beverage and hospitality sectors. Making devices that can be used in a wide variety of operations from bars and restaurants, to hotels and spas, to trade shows and conferences. Images courtesy of Hop Robotics. While there is a common understanding that automated robotics improve the speed and accuracy of industrial operations, the technology is only moving slowly into the consumer arena due to cost, reliability, and safety concerns. Many solutions are complex and difficult to program or operate. To reach the consumer market, automated robotics systems must be accessible by a wide range of people with varying degrees of technological understanding. Hop Robotics considered all of this information and examined all these factors as they researched market needs for an automated beer dispensing platform suitable for all types of hospitality venues. The solution had to be easy-to-use, highly efficient, and cost-effective, requiring the use of commercial off-the-shelf components and software. Automation would be an integral part of the design, but in a limited capacity — just enough to make the system functional and supportable without driving up costs. Images courtesy of Hop Robotics. Many functions would require coordination, including the robotic arm control, cup handling devices, point-of-sale systems, messaging to external systems, and visualization of menus, branding, and queuing. Creating a compact form factor using components designed to withstand the rigors of transport was also a key concern. The beer dispensing system has multiple order modes, monitors and sends keg alerts, automatically purges after keg changes, and has an extensive database of bands so that it can update ordering screens and menu boards accurately. Images courtesy of Hop Robotics. The Hop Robotics team already had previous experience with the performance, quality, availability, and value of AutomationDirect products, so they selected circuit breakers, relays, terminal blocks, power supplies, and more from the company’s portfolio of products. Hop Robotics could easily access CAD files for product so that their team could take advantage of 3D modelling tools. This allowed them to focus on specifications such as slim relays and double-level color-coded terminal blocks to optimize their control panel space and usability. Hop Robotics found that AutomationDirect—with a depth of brands along with their own line of products—provided a wide range of options, simplifying the search for components. This availability allowed the company to design through two iterations to present a valuable and impressive end product. Users are delighted at how the mobile system pours beer accurately and rapidly. In the end, Hop Robotics has used just the right amount of technology to create a design that will outlast novelty concepts. Note: This article was adapted from an article published in ISA’s Automation.com here . For information: Hop Robotics AutomationDirect Circuit Breakers Relays Terminal Blocks Power Supplies Previous Facebook LinkedIn Copy link Next

Welcome to our series on how companies solve customer challenges through creative innovation. We spoke with Nordson EFD about how they lead a customer through the design process while meeting all of their needs, wants, and specifications. When Challenges Lead to Innovation: How Nordson EFD Delivers Custom Flexibility While Using Off-the-Shelf Products Welcome to our series on how companies solve customer challenges through creative innovation. We spoke with Nordson EFD about how they lead a customer through the design process while meeting all of their needs, wants, and specifications. EE in Conversation with Anthony Buzzerio from Nordson EFD Innovation Apr 28, 2026 Cool Stuff Welcome to Entertainment Engineering magazine’s series where we ask companies to explain their approach to solving customer problems. We recognize the value of transferring technology and design innovations from one industry to another and believe that it all starts with those initial conversations. Here’s how Nordson EFD works with its customers. About Nordson EFD: Nordson EFD designs and manufactures precision fluid dispensing systems for benchtop and automated assembly lines. By enabling manufacturers to accurately apply the same amount of assembly fluid to every part, every time, EFD helps customers improve process control and throughput. In addition to producing high-quality fluid packaging syringe and cartridge systems, the company is also a leading formulator of specialty solder pastes for dispensing and printing applications. Nordson EFD is at the forefront of introducing Industry 4.0 efficiencies to the marketplace, adding a new level of control and connectivity to its micro-dispensing solutions. Serving a wide variety of industries for more than 60 years, Nordson EFD has worldwide offices, application laboratories and technical support staff. Manufacturers partner with Nordson EFD because we offer consistent precision fluid dispensing plus laboratory rigor to ensure that assembly challenges are resolved before production starts. From R&D to prototyping to production, the Nordson advantage enables you to focus on what really matters: creating impactful technologies for the people who need them. For this series, we spoke with Anthony Buzzerio, an Application/Systems Engineer II at Nordson EFD. He has 4.5 years in the fluid dispensing industry. Buzzerio holds a Bachelor of Science in Engineering from Roger Williams University of Bristol, RI. Nordson EFD vision-guided GV Series automated fluid dispensing gantry robots equipped with PICO Nexµs ™ jetting systems at the forefront of introducing Industry 4.0 efficiencies to the marketplace. Ideas: Understanding the challenge How do customers typically approach you with a challenge, and what information do they provide? At Nordson EFD, when our customers approach us with a challenge, they can be sorted into three broad categories: PRODUCTION: The customer is experiencing an assembly problem that has a negative impact on their production line. PROCESS: The customer is starting up a new production or assembly process and is exploring options. CONTINUOUS IMPROVEMENT: The customer is tasked with improving an existing assembly or application process, such as applying accurate, consistent amounts of adhesives, sealants, lubricants, and other assembly fluids to a substrate. Generally, in our initial conversations, the customer provides their specifications and the Nordson team asks questions that go deeper into the details of the project. A material data sheet, information about the substrate the customer plans to use, and fluid specifications are typically part of that conversation. High level production goals are also part of this dialogue, where we can get very specific about the application and list of requirements. What information would make the process smoother or more effective? The process goes much smoother and more effectively once we are provided a complete set of fluid dispensing data, assuming the data has already been collected. Since fluid dispensing is something of a specialty, specific data points are critical for us to maximize the required outcomes. We need fluid specifics from the fluid formulator. If this is an instance where a customer is looking to optimize an existing process, good photos or videos of the process are also a great way to clarify and improve effectiveness at this point in the project. Lastly, projects go more smoothly when we can arrive at realistic expectations early in the relationship. As the adage goes, not letting the perfect be the enemy of progress is a smart philosophy to adopt at the beginning of a project. As we move forward, our mission becomes iterating for improvement. At what point do you decide an application requires a unique and innovative approach? At Nordson EFD, we have a deep experience pool to draw from. We’ve been delivering precision dispense systems since the inception of modern fluid dispensing solutions in the mid to late 1960s. Thus, it is rare but not unheard of for us to encounter an application or circumstance that is unique and requires an innovative approach. That said, there are examples of a situation where a customer offers an idea and we listen to them, mull it over, and add value to the concept they have proposed. Using that 60+ years of know-how, we evaluate the application to deliver the most efficient process for the project. The laboratory rigor we apply to each new project gives us hard data to assess whether a new or innovative approach is truly required. Understanding exactly what is going on and what is needed for an application is a great tool for determining if a unique approach is needed; the customer has peace of mind knowing that Nordson EFD is part of the larger Nordson organization, and that we can leverage the combined strength of the divisions to drive a new process or combination of skill sets and technology. . . . a customer offers an idea, and we listen to them, mull it over, and add value to the concept they have proposed. Does your company have a response policy or procedure when this situation occurs? If yes, briefly explain. Using the data gleaned from this work, we test and iterate until we have determined that this application is going to require an innovative approach. Though EFD typically proposes turn-key solutions using a combination of existing off-the-shelf products, we do not hesitate to explore and innovate. We have on-going discussions with our internal market innovation and design teams to share market trends, application challenges, and bottlenecks, and bounce off ideas on how to solve them. We employ a rigorous new product development (NPD) process to identify technology and product gaps, explore and experiment engineered solutions, and launch new products covering those gaps. What determines whether a challenging project receives a “go” or “no-go” decision? At Nordson EFD, lab tests are what drive technology and process decisions. It’s purely a data-driven approach to the “go” or “no go” question. Economic constraints from a customer can sometimes halt or interrupt a project. If the budget isn’t there, it can be very difficult to optimize the manufacturing process. This is true for every organization. A “go” scenario is indicated from favorable test data and having a proof of concept to show the customer. When the testing proves out that an overall application will work, that is also a strong positive indicator that the dispense process will work as intended. The throughline across all decisions is collecting data and analyzing those results to drive the best decisions possible. Innovation: Working as Partners How do you and the customer align expectations, priorities, and desired outcomes early in the process? At Nordson EFD, we start each project with a call and conversation with the key stakeholders. At that time, we review all of the project specifications. We ask a lot of questions and perform application tests to gather information. In addition to this call, part of this process is the questionnaire the customer completes as part of the intake phase of a project. This clarifies anything that is unclear or not understood, and the conversation enables Nordson EFD engineers to expand upon the information shared in the questionnaire. The intent at this point is to minimize the time required to communicate and minimize the need to retest applications. We conduct these meetings before the customer ships the application, or directly after we receive the application and start testing it. As a matter of course, we schedule a call with our customer before every application test. We double check each of the desired goals and outcomes. During this process, we work diligently to communicate with the customer about what they need from the testing process. In a case where we are working with an automation house or machine builder, we have conversations with both these organizations and their customer to ensure that we are aligning the expectations, priorities, and desired outcomes. We double check each of the desired goals and outcomes. Which internal team disciplines (engineering, design, manufacturing, software, etc.) are usually involved, and how do they collaborate on these types of challenges? The internal team disciplines collaborating at Nordson EFD include application engineering and design engineering teams. Internally, the combined engineering team collaborates to map out and implement the best fluid dispensing solution/process for the customer. Nordson EFD does not provide custom products to customers. All the solutions are off the shelf, but the configurations are unique to the customer’s application needs. That work takes place at the East Providence laboratory and continues throughout the implementation phase at the customer’s manufacturing facility. At that time, an application engineer ensures that the dispense system is operating as intended. The application engineer also provides education and training about the dispense system. How do you turn project constraints (timeline, cost, materials, regulations) into opportunities? We address all of these concerns from the outset of the project. If the challenge is cost-based, our usual methodology is to scale the solution to the budget. Similarly, we will scale the project to expectations as well. . . . restrictions force our team to flex our minds and push through to a solution. When the hurdle is a material, timeline, or a regulation challenge, Nordson EFD is able to put our unique skill set as a fluid engineering resource to work for our customers. Sometimes that means a stopgap solution; oftentimes mining our experience yields an answer. To answer the question regarding regulation constraints, typically during the phase of the project where the customer is investigating and sourcing a fluid dispensing solution for manufacturing, the regulatory requirements are fully managed already. To clarify, the regulatory requirements are usually managed by material handling sheets, and the documentation is provided as part of the project initiation process. What typically pushes your team to think more creatively during these projects? Being blocked — that is, struggling to determine why things aren’t working as expected — is what pushes the team at Nordson EFD to think creatively. There’s a saying that “restrictions breed creativity.” Working in the Nordson EFD applications lab, those restrictions force our team to flex our minds and push through to a solution. Creativity comes as a result of needing to push past a problem. The challenge could be a system’s integration, or a problem with a part. We identify the blocker and work to push past it. Fortunately for us, these situations are rare because we have a deep set of experience to draw from learned from our 60+ years of solving difficult engineering challenges. Thus, it is rare but not unheard of for us to encounter an application or circumstance that is unique and requires creativity to resolve. What part does AI play in your team’s approach or decision-making during challenging projects? AI tools, at this point, seldom result in a creative approach because they have been trained on projects that already have a solution. Therefore, AI tools are not widely used by the Nordson EFD organization. Execution: Mindset and Lessons Learned How do you and the customer maintain strong communications and alignment as the project evolves? In order to ensure that we are aligned and communicating, once a project is in motion we sign a non-disclosure agreement (NDA) with our customer. This protects both parties and fosters an atmosphere of clear communication and trust. Every project has a schedule of calls and virtual meetings. As part of the agreed deliverables, we update our clients with photos and videos of progress being made on their system. In addition, reports and data sets are shared with the customer. Oftentimes a customer wants to visit our laboratories in person. This might be to witness the testing, or to review the dispense system and process for their application. Additionally, we frequently offer in-house demonstrations of a process for our customers. By establishing the key deliverables and working in a professional manner to achieve them, Nordson EFD’s customers are assured of a highly responsive team of experts focused on providing clear communication from start to installation. What aspect of challenging projects requires the most resilience from your team, and how do you maintain momentum when things stall or become difficult? Momentum can be lost whenever a project encounters a challenge — or worse, multiple challenges that grind the effort to a halt. At Nordson EFD there are three kinds of challenges that require resilience to persevere: Scope change Expectations change Budget change Patience must be exercised on any purchase order that suddenly develops a long timeline. Maintaining communication with the customer during the difficulties isn’t easy in these cases but is essential for moving forward, and something we take seriously by facing it head-on. The focus shifts to adapting to a solution based on the project changes. The team’s resilience comes into play when the work becomes about staying on target and leaning in when the situation doesn’t look great. Specifically, at Nordson EFD we leverage our team and use our fluid process expertise to push through when things stall or become difficult. From your perspective, what makes a customer an effective innovation partner when it comes to project execution? Making a customer an effective innovation partner comes down to two things: clearly communicated expectations and clear project process documentation. Our best outcomes begin with customers that start with Nordson EFD early in the development phase. This is the optimal time to work together because this is a point when we are most open to change, and before a process or equipment has been purchased or implemented. Flexibility is important early in a project. Trusting each other’s mutual expertise — you know your process and we know our fluid dispensing equipment — is important for an effective assembly project. Clients that train and upskill their staff and are proactive about training their operators get the most benefit from their investment. When an organization is ready to educate their workforce about using the dispense equipment, we are confident that this is a strong partnership. Clients that train and upskill their staff and are proactive about training their operators get the most benefit from their investment. Thoughtful investments in training and maintenance drives good outcomes; last, but certainly not least, budgeting for replacing high wear parts to prevent downtime is a hallmark of our most effective partners. What is the most important mindset your team brings to ensure a successful project outcome? Nordson EFD is always customer focused. A successful project is inevitably the result of keeping our customers at the front of our mind. And, as we’ve been saying throughout this piece, the best outcomes are the result of communication, communication, communication. *Images courtesy of Nordson EFD. Lead image: Nordson EFD designs and manufactures precision fluid dispensing systems for benchtop and automated assembly lines. For information: Nordson EFD Assembly Challenges LinkedIn Read more about Nordson EFD >>> Previous Facebook LinkedIn Copy link Next

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

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

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 3D scanning specialists digitally captured multiple buildings in one of the busiest areas of the Grand Duchy of Luxembourg with sufficient detail for VR/AR applications. Capturing an Entire Palace Complex with 3D Scanning How 3D scanning specialists digitally captured multiple buildings in one of the busiest areas of the Grand Duchy of Luxembourg with sufficient detail for VR/AR applications. Paul Hanaphy Cool Stuff Apr 27, 2026 Architecture When Artec 3D’s support team got the call to digitize Luxembourg for the World Expo, they were delighted. Push 3D scanning to its limits and put your country on the map? What an opportunity! But as they sought out the fastest, most straightforward method, there were a few hiccups. Initially, they tried digitizing a sugar model of the palace with the high-resolution Artec Spider II. While it featured a very realistic appearance (and Spider II captured its nuances brilliantly) the replica didn’t have the geometric accuracy necessary to create a true one-to-one 3D model. Artec Spider II capturing a sugar model of the Grand Ducal Palace in Luxembourg. When this shortcut didn’t work, the Artec team were left with no choice: they’d have to scan the Grand Duke’s Palace itself. This came with its own challenges. Artec Ray II is fantastic at capturing large objects and areas. However, its tripod-mounting limits what it can “see” from above. Fortunately, Artec Studio features drone-compatible photogrammetry. The next problem was how to get a drone in the air around a busy heritage site. This meant visiting the Palace’s Premier Conseiller , who managed to get permission for the flight. Lastly, there’s the issue of pedestrians. The popular tourist attraction is often swarmed with people. In 3D data capture, this is bad news as it can lead to obstructed details and motion blur. But thanks to a bit of cautious double-scanning, Ray II’s built-in Visual Inertial System (VIS), and advanced algorithms inside Artec Studio, the team was ultimately able to capture an incredibly large yet detailed 3D model—with a realistic appearance for immersive VR applications. Scanning Results According to Keynan Tenenboim, one of the 3D scanning specialists behind the project, Ray II data capture wasn’t actually that difficult. Its VIS system allowed it to track its location in a 3D space, meaning users only needed to position the device for capture from all angles. The real challenge was scanning from a sufficient distance to capture at scale. Ray II can achieve an accuracy of up to 1.9 mm from a range of ten meters. But if Tenenboim got too close, some parts of the palace’s architecture would obscure others. This meant taking a step back—to a range of around 20 meters, so the whole structure was in view, and making a loop around the complex. The final 3D model of the Grand Duke’s Palace. While Tenenboim was scanning with Ray II, his colleague Jerry Klein was piloting a drone over the area. Though he had permission to fly, this would be no easy feat. The palace is surrounded by a complex network of roads, and any navigational error would’ve been hugely expensive. Yet, despite not being an experienced pilot, Klein managed to capture the scene in its entirety. “The advantage of capturing pictures is that you get higher-fidelity imagery and less noise. In Artec Studio, you can also create 3D models from videos—I captured both just to be safe,” Klein said. Merging Datasets Artec Studio is now an all-in-one toolbox for capturing, processing, and combining 3D datasets picked up with structured-light, laser, and LiDAR scanners, as well as photogrammetry. To merge 3D scans and photos/videos, users first need to generate 3D meshes. “Ray II’s VIS system basically aligns all the scans automatically, so when data is uploaded to Artec Studio, all of the objects are already pre-aligned,” said Tenenboim. “Instead of seeing 100 disparate scans, you would actually see one object on screen.” Generating a 3D mesh with AI Photogrammetry is a little different but still yields excellent results. Artec Studio’s algorithms turn photos or video into a “model preview” with an adjustable bounding box. Once told which captured data to use, the software generates lifelike 3D models in real time, which can be merged with those created from 3D scans for high detail at scale. Inside Artec Studio, it’s also possible to fill holes, remove moving objects, map textures, and decimate models to reduce the number of polygons. All of this allows users to add polish—and in the case of Artec’s 3D scanning experts, it was critical to creating lightweight models for VR use cases. Embracing Next-Gen Heritage Preservation Combining Ray II, AI Photogrammetry, and handhelds like the wireless Artec Leo, the team were eventually able to digitize other landmarks for the Luxembourg Pavilion. This includes “Hollow Tooth,” a UNESCO heritage site with a cliff on one side, requiring the use of a drone where data was again merged with Ray II scans—for a model captured from every angle. Alongside all the other beautifully captured models, Hollow Tooth is now available to view via the Osaka Expo app, in a way that brings the country’s history to new audiences. In fact, visitors to the expo itself can join those tuning in remotely to “tour” popular heritage sites in VR. A 3D model of Hollow Tooth, also captured with Ray II & AI Photogrammetry. Klein sees significant potential for this approach, not just in heritage preservation, but other large-scale applications, where different 3D scanners and photogrammetry can bring users incredibly high accuracy and capture scale: the best of both worlds. “I can see this approach being applied everywhere from the Hollywood film industry to video gaming—anywhere you traditionally care more about texture than about geometry.” Images courtesy of Artec 3D. For more information: Artec 3D Ray II Artec Studio Grand Ducal Palace Read more about 3D scanning and printing >>> Previous Facebook LinkedIn Copy link Next

Closed-loop feedback system allows programmers to choreograph four-axes of eagle motion in sync with a musical soundtrack. Rose Parade Float Uses High-End Animatronics Closed-loop feedback system allows programmers to choreograph four-axes of eagle motion in sync with a musical soundtrack. Terry Persun Cool Stuff Jan 19, 2026 Fiesta Productions produced America250’s “Soaring Onward Together” float for the 137 th Rose Parade hailing in the 2026 new year. The design features three larger-than-life majestic eagles soaring above breathtaking landscapes, symbolizing the enduring strength, beauty, and spirit of America. With cascading waterfalls, intricate natural details, and extraordinary animated artistry, the eagles take flight with a complexity and creativity that reflects the grandeur of this historic milestone. Images courtesy of Rando Productions. To complete the project Fiesta Productions required animation for the three eagles and turned to Rando Productions for their technological expertise. The float, which measures 30’x18’x55’ features a cutting-edge, sophisticated electro-servo hydraulic system to animate each of the three soaring eagles, bringing them to life in front of adoring crowds. Each eagle has an 18-foot wingspan and incorporates four distinct axes of motion: head turning, neck lifting, body rolling, and wing flapping. A custom, computer-controlled Rando system precisely adjusts the speed and position of every movement, resulting in smooth, natural movements. The eagles are powered by a 6-cylinder industrial gasoline engine driving a 32-gallon-per-minute hydraulic pump. Images courtesy of Rando Productions. All mechanisms were assembled and tested off-float before the sculpted pencil-steel rod work was split and carefully attached and integrated into the moving components. A specially designed, closed-loop feedback system allows programmers to choreograph the eagles’ motion in sync with Aaron Copeland’s Fanfare for the Common Man soundtrack. The control system was built around Weigl Controls’ ProCommander hardware, combining proven commercial control electronics with fully custom motion programming and tuning developed in-house at Rando Productions. This state-of-the-art animation controller uses timeline-based animation programming to precisely manage the velocity and position of each movement. Motion smoothing and synchronization was used across multiple axes. Special care went into the design and engineering of the system to achieve the most natural, realistic, and majestic motion possible. Joe Rando and David Stark rode inside the float to manage the hydraulics and show controls. Images courtesy of Rando Productions. Rando Productions was involved from the beginning of the project and helped with concept design, which included hand sketches and napkin concepts, motion intent studies, and creative collaboration with the float design teams. Using SolidWorks 3D CAD modeling software, they were able to create multiple iterations for the internal mechanisms and structural and motion feasibility analysis for the float components. Once the design was determined, the team produced pre-visualization 3D-printed models to validate motion paths and proportions prior to fabrication. Besides providing the motion systems for the animatronics, Rando Productions was on-site for the installation and mechanical integration of the system. They provided testing and final motion tuning for the float as well as provide show readiness support. Rando Productions is known for their advanced custom fabrication, mechanical effects, show action equipment, and automation solutions for themed entertainment, film, broadcast, and live event industries. The “Soaring Onward Together” float commemorates America’s 250 th birthday and the signing of the Declaration of Independence. Fiesta Productions is the production company behind the float. For more information: Rando Productions Fiesta Productions Weigl Controls America 250 Previous Facebook LinkedIn Copy link Next

The six-foot Grumpy statue now greeting golfers at hole No. 14 on Disney's Magnolia Golf Course didn't come from a mold or a foundry. It was carved from a solid block of natural Carrara marble using a new process developed by Disney Imagineering. Marble Grumpy Statue Sculpted with Robotic Precision and Traditional Stone Craftsmanship The six-foot Grumpy statue now greeting golfers at hole No. 14 on Disney's Magnolia Golf Course didn't come from a mold or a foundry. It was carved from a solid block of natural Carrara marble using a new process developed by Disney Imagineering. Edited by EE Staff Theme Parks, Sports Jul 7, 2026 Disney's go-to materials for large sculptures are typically fiberglass-reinforced plastic or bronze. But when building the Grumpy's Gauntlet statue, the team took a different direction entirely. “Instead of making them out of one of the materials we normally go to—which might be something like fiberglass-reinforced plastic or bronze—we're actually made them out of natural marble stone,” explains Imagineer Xavier Molina from the Research and Development team. This particular project sits within a broader R&D effort at Imagineering that focuses on advanced fabrication techniques, such as using emerging technologies to shape how Disney builds its parks going forward. Images courtesy of Disney. The process combines digital artistry, robotic precision, and traditional stone craftsmanship. Imagineering artists are tasked with digitally sculpting Grumpy in 3D, researching period-accurate details including what golf clubs and golf balls looked like in the 1920s. The digital file is then handed over to an AI-driven robotic arm, which carves the form from marble a little at a time over several days. Expert stone artisans then take over the operation, refining the surface and adding the fine details that bring the sculpture to life. A KUKA robotic arm, seen in the footage below, handles the bulk material removal with precision that would be difficult and time-consuming to achieve by hand. Molina notes the timeline for the entire process was remarkably fast for a project of this size. “In essentially a year we were able to test something out, produce it out of marble, and then actually get it in front of guests,” he says. The R&D team sees the technology as something genuinely new for Disney as well as the wider world of stone carving. One of the more interesting points Molina makes is about what this technology has done for the stone carving profession itself. Rather than replacing artisans, the process integrates with the artist, which has created new demand. “More people have actually been going into stone carving as an art form than would have been before if this wasn't there,” he said. Images courtesy of Disney. For Imagineering, the Grumpy statue is less a standalone project and more a proof of concept that could shape how Disney approaches large-scale fabrication for future parks and experiences. The statue is now on display at the tee box for hole No. 14 at Disney's Magnolia Golf Course at Walt Disney World. For information: Disney Read more about robotics >>> Previous Facebook LinkedIn Copy link Next