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

Masque Sound provides audio for touring production of Joseph and the Amazing Technicolor Dreamcoat. Custom Audio Packages for Musical Masque Sound provides audio for touring production of Joseph and the Amazing Technicolor Dreamcoat. Masque Sound Home Stage Events Jun 4, 2025 When Andrew Lloyd Webber and Tim Rice’s enduringly popular musical Joseph and the Amazing Technicolor Dreamcoat embarked on its 2014 U.S. tour Masque Sound supported Co-Sound Designers David Patridge and John Shivers in their quest to bring the contemporary production to the stage. Since Joseph and the Amazing Technicolor Dreamcoat is scheduled to tour through spring of 2015, Patridge and Shivers wanted to make sure that in designing the sound system it would be capable of easily moving and fitting into a small footprint on the truck. “We wanted to provide the best audio experience that we could, in working within the confines of a traveling production’s space limitations,” says Patridge. With space at a premium, the designers opted to utilize the smaller-footprint Yamaha CL5 Mixing Console, along with a Yamaha CL3 for monitoring, both of which worked quite well for the show. The Yamaha Console was ideal for the production not only for its compactness, as it could be picked up and lifted into position by two people, but also because its comprehensive feature set addressed all of the production crew’s needs. In addition, connecting the console together is a fairly straightforward process and can be done with Cat 5 cabling, which is ideal on a show that needs to move quickly and efficiently. For the PA, Masque Sound provided an L-Acoustics dV-DOSC array, a tried and true speaker design that sounds great. The dV-DOSC line array was integrated into existing speaker towers from Masque Sound’s inventory, which gives the show a PA that is quite spectacular. The flexible system that Masque Sound provided is ample enough to fit, but also compact enough for smaller venues, which was particularly ideal for this production tour, as it features various venues of different sizes. “Fortunately Masque Sound has a very deep shelf of available gear, and we were able to put together an excellent audio package with its equipment that stayed within our budget and did not compromise on the quality of the sound at all,” adds Patridge. “In addition, Masque Sound’s modification of existing inventory speaker towers to fit with the L-Acoustics PA was a large cost savings to us. Joseph and the Amazing Technicolor Dreamcoat is a family musical about the trials and triumphs of Joseph, Israel’s favorite son. Retelling the Biblical story of Joseph, his eleven brothers and the coat of many colors, this musical is full of unforgettable songs including "Those Canaan Days," "Any Dream Will Do," and "Close Every Door." Directed and choreographed by Tony® Award-winner Andy Blankenbuehler, this new production features Broadway stars Diana DeGarmo ( Hairspray, Hair ) as the Narrator and Ace Young ( Grease, Hair ) as Joseph. For more information: Masque Sound Home Previous Facebook LinkedIn Copy link Next

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

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

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

Space flight is challenging enough without having to worry about the operational limitations of the components used in the devices going to space. Stepper Motor Design Challenges for Space Flight Applications Space flight is challenging enough without having to worry about the operational limitations of the components used in the devices going to space. Terry Persun Cool Stuff Jul 9, 2025 The harsh environment of vacuum and microgravity applications pose many issues with component capabilities that don’t commonly have to be dealt with here on Earth (Figure 1). That is especially true when it comes to components where movement is their primary function—such as motion control systems. Motors specifically introduce many inherent problems to the environment mainly due to the fact that they require considerable amounts of power to operate, can generate excessive heat, can introduce unwanted vibrations into the system, and can become a source of contaminants. Also from EE: Robots Used in Food Preparation, Serving, and Delivery Figure 1: Specifically designed to be used in satellites and space craft, vacuum rated motors can be used for communications antennas as well as vehicle controls. (Photo courtesy of NASA.) Dealing with these issues comes at a substantial cost. Higher power requirements necessitate larger power generation systems, more heat generated requires bigger cooling systems, dealing with unwanted vibrations requires more robust damping systems, and contaminations can cause havoc on instruments and other on-board components. Lin Engineering has designed their space hybrid stepper motors to work in these harsh environments. Their motors are assembled in accordance with Aerospace AS9100 standards in a fully compliant facility in California, where each component origin is traceable to maintain strict control over the manufacturing process as well as the final product specifications. In space applications, every watt that is wasted by a system that has not been fully optimized for space costs precious resources. Optimizing for power consumption includes customizing motor windings (Figure 2) so that they are able to deliver a peak amount of dynamic torque at the desired operating speed—which takes the proper integration of high-precision components, such as low inertia rotors operating at their highest efficiency. Using proprietary, and proven, algorithms, Lin Engineering is able to optimize torque and speed, noise reduction, heat generation or loss, and/or power optimization. Figure 2: Windings can be customized for high and low speeds, torque output tailored to a specific application requirement, and for high and low temperatures. Temperature Management Two critical concerns related to temperature affecting the performance of hybrid stepper motors in space include the temperature range in which the motor operates and the amount of heat the motor generates. Satellites and other spacecraft operate in extreme temperature ranges. Externally mounted systems expected to function in these extreme temperature variations can cause operational issues if not designed properly. For example, heat affects the magnetic strength of permanent magnets embedded in the rotor. As heat increases, motor performance decreases. The solution to this challenge is to incorporate permanent magnets that are constructed from an alloy that provides greater magnetic power at higher and lower temperatures. For example, either rare-earth samarium-cobalt or neodymium are both used for this purpose. Heat also affects the life of the bearings used in the motor and therefore shortens the lifespan of the entire system. To alleviate this problem, it is necessary to use bearings with oil or grease that can withstand high dynamic temperature ranges—from -80C to +200C. High-temperature, non-outgassing bearings can be designed in as well. Although all motors generate some heat, in a vacuum environment, this can become a major problem because there is no atmospheric medium through which heat can dissipate—from the motor or the vehicle. On Earth, air acts as a conductor, which dissipates the generated heat, while in space, heat needs to be dissipated by other means. By optimizing the winding of the stepper motor, the amount of heat generated can be reduced considerably. In addition, the incorporation of conductive pathways in the motor design also assist in temperature management. These pathways include thermally conductive materials that allow for heat dissipation between the insulator (glue) and motor end bells. Vibration Management Getting a spacecraft into orbit is a violent ordeal. Components are exposed to high amplitude vibration, low amplitude vibration, and shock from several different directions during the launch. Then there are the vibrations generated by the stepper motor during its normal operations. The optimization of the motor windings is a practical way to minimize the resonance frequency that develops at specific operating speeds. By using high quality components, which are specifically machined to high concentricity and dimensional accuracy, it is possible to ensure that components such as rotors or shafts do not introduce unwanted vibrations into the system. In space, however, vibrations need to be avoided at every turn. Low-level oscillations can affect measurement sensors as well as the quality of imaging devices. Dampening vibrations in a microgravity environment is challenging since the craft or satellite is suspended in space where there is nothing to transfer the energy to. Every component has to withstand these challenges, which is why every stepper motor designed for space must use the proper materials to create the structural integrity to handle any and all expected forces it may encounter—without altering dimensional accuracy or mechanical integrity. Lin Engineering has incorporated such materials in their standard motors, which makes them sufficiently robust for space applications. Figure 3: Lin Engineering designs and manufactures a complete line of vacuum motors capable of operating in space. Overall, the longevity of components that go into space is a factor of the time and effort put into the proper design of the components and their final assembly using the latest materials while manufactured in a clean room facility (Figure 3). Space flight and satellite applications require a keen sense of the challenges associated with their operating environment. For more information: Lin Engineering Previous Facebook LinkedIn Copy link Next

Touch screen displays with an optical bond are designed to offer an improved viewing angle. Unique Optically Bonded Touch Display Improves Viewing Experience Touch screen displays with an optical bond are designed to offer an improved viewing angle. By Jim Spadaccini, Founder & Creative Director, Ideum Museums Aug 26, 2025 Cool Stuff Ideum has recently been integrating optically bonded 55-inch touch displays into our products. This includes optically bonded versions of the our popular Platform II and Drafting II touch tables, as well as their Presenter and Inline models—and their Tasting Table. Touch screen displays are comprised of a monitor and a touch sensor. In large-format displays, these components are usually separated by a small air gap. This is fine for many (even most) displays and configurations, but there are some instances where optical bonding improves the quality of the touch display. In this process, a clear adhesive is used between the touch sensor and the monitor, bonding the two components together. But what does this mean to the user? All photos courtesy of Ideum. Removing the air gap and replacing it with a transparent adhesive has several advantages. The first is that the display appears to be visibly brighter; this is due to removing any reflection that might occur from the surface glass. In addition, the viewing angle of the display is greatly improved since the display and sensor glass are effectively one, bonded unit. There is no reflected light off the back of the sensor glass, making the integrated touch display brighter and clearer. All photos courtesy of Ideum. Bonded units don’t have issues with parallax, which is the perceived gap between the touch sensor and the display, again because they are bonded together. We have focused on the 55-inch model (and soon the 65-inch model) because they are the most popular, but also because this gap can be noticeable, and closing it improves the viewing quality of the display. Optical Bonding Benefits We’ve always taken pride in creating touch screen tables and displays that are practically indestructible. Our all-aluminum frames and chassis, and tempered glass, provide exceptional security and durability. Optically bonded displays are even stronger than their air-gapped counterparts! This makes sense as the clear adhesive bonds the display and sensor together. Optical bonding also makes it impossible to introduce dust or other particulate matter between the layers, making it perfect for challenging environments. The bonded touch display is also more resistant to spills (that’s why we use it for the Tasting Table). All in all, it is a superior product; the only downsides are that the manufacturing method is more involved and expensive, and the process inherently means that any flaws in the display or the sensor compromise the entire assembly. Air-gapped touch displays allow you to replace damaged components more easily, since those parts remain separate. Bonding is forever. Display Case Design Changes We’ve also improved the display’s case by creating a design that appears slimmer. Our patented manufacturing process for displays uses extruded aluminum as the frame making it appear sleeker and smoother. To create corners that don’t have fasteners, we designed 3D-printed metal corners that can be fastened to the extruded aluminum frames from the inside. The new design provides a better-looking profile and differentiates this new model from its predecessors. All photos courtesy of Ideum. This Fall, we will be announcing all of the available optically bonded models. They will be referred to as the Plus Series, since they appear across all of our offerings, from displays to various touch table formats. We will continue to offer all of our models, so the Plus Series will simply expand our offerings for our customers. For more information: Ideum Platform II Display Touch Screen Displays Previous Facebook LinkedIn Copy link Next

This education center required lighting that could adjust vertically and rotate with precision, while also blending in with the aesthetics of the space. Specialized Lighting Illuminates Environmental Education Center This education center required lighting that could adjust vertically and rotate with precision, while also blending in with the aesthetics of the space. Cool Stuff Aug 18, 2025 Museums Located in an Illinois forest preserve near the convergence of three rivers that form the Illinois River, Four Rivers Environmental Education Center’s visitor center needed a variety of interior and exterior spaces, including a 2,000-gallon fish tank, to immerse visitors in the region’s natural habitat. Wight and Company, partnering for lighting and design with Bluestone and Associates, worked on the overall design and engineering for the project, led by architect Ania Szulc. Szulc was uniquely suited for the large-scale master planning and detailed work on such pedestrian-scaled spaces because of prior planning and design for parks and recreation projects, public and educational projects, and private commercial client applications. All photos courtesy of Alcon Lighting. A two-phase approach was selected for the Four Rivers Environmental Education Center, which is part of the Forest Preserve District in Will County. IL. The initial phase involved converting an underutilized classroom into office space. Phase two involved the architectural, mechanical, electrical, plumbing, and structural infrastructure desig, which was carried out to support the exhibit scope of work designed by Bluestone Associates. The main exhibit is located in the confluence wing of the interpretive center, featuring a 2,000-gallon fish tank and mussels and bird exhibits. Additionally, there is an outside bird bath with a heated pad, providing water for birds year-round. To find the best lighting option to enhance the exhibits, Wight and Company’s challenge was to find the right museum-like lighting they could that also blended with the existing architecture and aesthetics of the education center. All photos courtesy of Alcon Lighting. Overall, the project used 89 of Alcon Lighting’s multi-sized LED track light. This LED track light is stylish and durable, with an aluminum body and clear glass lens. The track head adjusts 180° vertically and rotates 358° for precise lighting control, with a color temperature switch that transitions between 3000K, 3500K and 4000K. The track light met the flexibility required for beam spread and color temperature. The track light’s simple design also blended perfectly with the aesthetics of the space. For more information: Alcon Lighting Wight and Company Bluestone and Associates Previous Facebook LinkedIn Copy link Next

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

Innovative tools help to make NASCAR manufacturing of parts faster, more efficient, and of higher quality. How NASCAR's R&D Group Optimized Its Machining Processes with Next-Level Components Innovative tools help to make NASCAR manufacturing of parts faster, more efficient, and of higher quality. Edited by Terry Persun Sports Dec 1, 2025 Lead image courtesy of Depositphoto.com . NASCAR’s Research and Development (R&D) facility relies on premium innovation to create the right solutions to manufacture next-level components ensuring speed, precision and above all, safety at all stages of development. According to Bob Duvall, Managing Director of NASCAR’s Competition Partner Program, “NASCAR teams are always looking for the best in class, and Kennametal aligns perfectly with that standard.” Behind every racecar, there's a team of dedicated professionals ensuring that each component is machined to perfection. This involves using reliable tooling solutions in a prototyping environment where parts need to be designed, programmed, and manufactured within tight tolerances—and tight deadlines. Increasing Material Removal Rates Recently, NASCAR upgraded its CNC machinery to enhance its manufacturing capabilities. To fully leverage this new technology, Hank Fowler, NASCAR’s Manager of Manufacturing turned to Kennametal which has been instrumental in optimizing NASCAR’s machining processes. “Upgrading our machines has significantly sped up my cutting processes,” said Fowler. “With the addition of flood coolant and Kennametal tools, I’ve been able to increase my material removal rates as well as improve surface finishes and reduce the need for post-processing operations like deburring.” Image courtesy of Kennametal. Fowler also mentions that once he has a part number, he speaks with his rep for additional insight as to whether or not a better option may be available. Shipping tools on time is also critical for success on timely projects. For example, when Fowler was working on a manual turning job that had a .094” groove in chromoly steel, he made a simple phone call and was able to get the tool holder and inserts on time to deliver parts. This reliability is essential for NASCAR’s fast-paced manufacturing needs, where even a slight delay can impact testing and development schedules. As part of NASCAR’s R&D group, Fowler and his team handle a wide variety of tasks. Their most common machining projects include creating inspection tools for their competition group and fixturing for various types of testing within the R&D team. Recently, the team worked on an inspection tool made with 303 stainless steel which featured a tight tolerance slot. In the past, they would have been nervous about this job, but after ordering a 3/16” HARVI™ I TE, they completed the task effortlessly. Kennametal's HARVI I TE high-performance solid end mills are designed with an innovative twisted end face that allows for ultra-aggressive cutting capabilities while also promoting stability in any type of cut. It also offers a number of proprietary features such as a precision faceted eccentric relief reducing vibrations and friction for excellent cutting conditions in multiple materials, and an innovative flute design with chip gashes within the flutes to reduce cutting forces, promote tool cooling and support efficient chip evacuation. The HARVI I TE design also features asymmetrical divided flutes and a variable helix, which enables vibration dampening even at the highest feed rates. Image courtesy of Kennametal. The partnership between NASCAR and Kennametal is a perfect example of how precision tooling can be successful in high-stakes environments. With Kennametal’s reliable and versatile tools, the R&D team can meet the demanding requirements of NASCAR’s manufacturing processes. For more information: Kennametal HARVI I TE NASCAR Read more about racing >>> Previous Facebook LinkedIn Copy link Next

Walt Disney himself is "brought to life," leaving spectators astonished. How Did Imagineers Make This Animatronic Walt Disney So Lifelike? Walt Disney himself is "brought to life," leaving spectators astonished. Joe Gillard Theme Parks Jul 22, 2025 Disneyland Park on July 17, 1955, and Disney is celebrating the 70 th anniversary with some show-stopping technology from the engineers at Walt Disney Imagineering. A new park attraction based on Walt Disney, the man himself, called “Walt Disney – A Magical Life,” recently debuted at the Main Street Opera House in Disneyland last week. Disney says “guests will first experience a cinematic journey (approximately 15 minutes) through the film, “One Man’s Dream,” culminating in a visit with Walt in his office, made possible through the magic of Audio-Animatronics ® storytelling.” Also from EE: Wicked Technology Defies Gravity on Broadway Animatronic Walt Disney leaves commentators stunned Perhaps the main draw of this new attraction is a lifelike, animatronic Walt Disney that moves, talks, and walks. The park says “guests will hear heartfelt stories, anecdotes and words of wisdom shared by Walt using historical recordings.” Walt Disney Imagineering has been working on this project for seven years, and Disney says the idea for doing something like this goes back even further. The dedication shows, apparently. ”Seated in the audience, I couldn’t figure out exactly how it works.” writes Jacob Krol of TechRadar. “There’s no visible harness or backing, not even leads from the desk. This is the first entirely electric figure to complete that lean-to-stand motion fully.” He reports that the Imagineering team did deep research on the human facial features and movements, right down to the cornea bulge of the eye. The level of detail and care that went into the research and the project left many feeling that Disney had done right by the man and his family. “The expertise and care that Walt Disney Imagineering has devoted to this project is nothing short of remarkable,” said Kirsten Komoroske, Executive Director, The Walt Disney Family Museum. “I think that Walt would be thrilled with the blend of cutting-edge technology and artistry. And I think that he would be touched by the tribute.” Technology So, how exactly did the Imagineering team achieve what they’re calling “the most lifelike figure that Walt Disney Imagineering has ever created?” It’s hard to find anything about specifics, only that the team referred to their innovations as “moonshots.” Audio-Animatronics is the trademarked name of the mechatronic animatronic technology familiar to anyone who has been to Disneyland. They generally feature movement synchronized with external audio (think Pirates of the Caribbean). This Walt Disney attraction is the latest iteration of that, and one Disney seems particularly proud of. The puppeteering works through a combination of motors, fluid power, solenoids, and cables. These mechanics are combined with programming to make sure everything works harmoniously. “Many of Disney’s Audio-Animatronics figures are designed to move in concert,” says Disney, “with choreographed movements timed by complex audio cues and digital signals. These movements require extensive engineering — courtesy of Disney Imagineers — and programming to create a seamless display of characters in action.” The system of the animatronics relies on a combination of electric motors, solenoids, hydraulic systems , pneumatic systems, and cables to produce repeatable puppet movements that syncs to sound.[5] The animatronic Walt is “the first ‘lean to stand’ motion for an all-electric figure,” according to Disney, and press material points to a ‘twinkle in the eye,’ a focus on “muscle structure and the nuances of speaking and gesturing such as how the mouth falls when the figure is speaking, as well as the very Walt mannerisms and movements including the way Walt used his hands.” Typical of Disney, there was a commitment to detail. “We worked closely with the Walt Disney Archives and The Walt Disney Family Museum to depict the details of Walt and his office accurately in this theatrical presentation,” said Jeff Shaver-Moskowitz, Portfolio Executive Creative Producer, Walt Disney Imagineering. “Most importantly, we were passionate about creating an Audio-Animatronics figure designed specifically for this attraction, delivering a portrayal that has his nuances, hand gestures, facial expressions, and more- all of the attributes that make this figure’s performance feel uniquely Walt and not simply creating a figure to look like Walt.” See below for a review from a former Imagineer: For more information, visit Walt Disney: A Magical Life . 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