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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

A behind-the-scenes look at the drive systems, automation, and comms that keep America’s #1 Broadway musical running smoothly. The Technology Behind The Lion King Musical’s North American Rafiki Tour A behind-the-scenes look at the drive systems, automation, and comms that keep America’s #1 Broadway musical running smoothly. Nicole Persun Stage Events Dec 16, 2025 Lead photo: Cheetah and Giraffes with the sun in the background | Photo by Joan Marcus and courtesy of Disney Since its debut in 1997, more than 114 million people have experienced the awe-inspiring artistry of Disney’s The Lion King on Broadway. The musical has won six Tony Awards, is Broadway’s third-longest running show in history, and is the highest-grossing Broadway production of all time. From the iconic first notes of “Circle of Life,” to the song’s reprise at the end of the final act, every element of the show — moving sets, puppets, dancers, actors, and the crew behind the scenes — must work together with precision. To celebrate The Lion King’s latest North American Tour, Entertainment Engineering spoke with Head Carpenter Kyle Techentin at Seattle’s Paramount Theatre about what goes into running this iconic and beloved show, and the technology that helps make it happen. Managing 23 Axes of Motion As the Head Carpenter, Kyle Techentin manages the setup, takedown, and ongoing maintenance of the show. “We start with a blank canvas,” he said. “The stage, lighting, hardware — all of it is ours.” The show never stops, so the production owns duplicate sets: one for the current city, and one that travels to the next location on the tour. “If something breaks,” Techentin explained, “we send it to the upcoming city to be maintenanced, so that it’s ready for the next stop.” This strategy helps keep the tour running continuously without unforeseen breaks. The Lion King musical has gone on multiple tours since its inception, with slightly different set configurations evolving over time to suit the needs of the locations it visits. The show is currently touring North America on their Rafiki Tour; the tour is open-ended, with cities currently announced through the end of September 2026. “There was actually more automation in the Gazelle Tour,” Techentin said, referring to the previous tour. “We cut the set down by about four feet to be able to fit it into smaller theaters.” This resulted in more manual set pieces and fewer electronically-operated elements — but there are still plenty of ways that technology fits into the show. The production itself has 23 axes of motion. “Anything that moves is considered its own axis,” Techentin explained. Pride Rock — a motorized staircase that travels across the stage on a track circuit system — is considered one axis of motion. The grasses — props with wooden bases that also move across the stage on the track — are another. The diaphanous fabric sun is its own axis, too. Company of The Lion King on Broadway during “Circle of Life” | Photo by Matthew Murphy and courtesy of Disney “There can be up to thirty-six actors onstage at a time, and many of the costumes greatly hinder the actor’s ability to see,” Techentin said, emphasizing the importance that everything runs according to plan. All axes must move with precision and reliability to ensure a safe environment for the actors and crew — and an unforgettable experience for the audience. Motion Control Pride Rock is perhaps the most iconic and recognizable part of the set, traveling out from the wings and turning in slow circles while the actors move through a scene. Its path is operated by a circuit track system in the stage that incorporates pneumatic switching units and eleven magnetic sensors. Inside Pride Rock, there’s a battery powered friction drive that controls its speed and timing as it moves along the track. A top-down camera allows a stage manager to monitor its progress in relation to the actors onstage. Peter Hargrave as Scar atop Pride Rock | Photo by Matthew Murphy and courtesy of Disney Entertainment Engineering also got an inside look at the mechanical wildebeest “herd” that is used to indicate the fateful stampede scene toward the end of Act I. As Simba runs from the stampede of wildebeest, there are three visual elements used to create a sense of depth onstage. First, in the background, a piece of fabric painted with tiny wildebeest rotates on a wheel to give the illusion of the herd running toward the audience from a distance. Then, in the middle ground, is a motor driven “herd,” which consists of multiple wooden wildebeests mounted on rotating arms. If there’s an error, the crew can flip a switch to “kill the beast” and operate it manually. Finally, in the foreground, actors in large wildebeest masks crowd the stage. It’s an intense moment in Simba’s journey — but it’s also an intense part of the musical for the crew due to the various set axes happening simultaneously. Closeup photo of the mechanical, motor-driven wildebeest “herd” taken by EE Staff with permission. This combination of set design, motorized components, and actors all add to the grand scope of one of the most pivotal and emotional scenes in the musical. How it All Comes Together It takes about 120 people — including actors and behind-the-scenes crew — with a minimum of three stage managers (there are five on staff) to run the show on any given night. Techentin manages many of the moving parts at his onsite automation desk that incorporates a Blackmagic Design control system and software used to monitor all of the set axes. The backstage support crew stays in touch using a professional-grade, multi-channel intercom system from Clear-Com, known for their complete connectivity and effortless scaleability. Techentin relies primarily on Hudson Scenic for much of the motion control and automation components, including custom jobs when required. “They get us whatever we need,” Techentin said. When watching Disney’s The Lion King Musical, it’s easy to get swept away in the incredible set designs, puppets, costumes, and superb acting. The technology might be subtle, but the seamlessness is intentional. From friction drive motors, to all-LED lighting, to CO2 “geysers,” and more, all the components — and the crewmembers who operate those components — are an essential part of the magic. The result? A truly unforgettable experience. For more information: Disney’s The Lion King Musical Seattle Theatre Group / Broadway at the Paramount Theatre Blackmagic Clear-Com Hudson Scenic Studio Previous Facebook LinkedIn Copy link Next

Coco Robotics partners with Prime Video and Omnicom to promote Eddie Murphy film Delivery Robots Used to Market New Film in LA Coco Robotics partners with Prime Video and Omnicom to promote Eddie Murphy film Film and TV Sep 1, 2025 Coco Robotics, an urban robot delivery company, partnered with Prime Video and Omnicom to promote The Pickup , a heist comedy film starring Eddie Murphy, Pete Davidson, and Keke Palmer. Coco Robotics was founded in 2020 and brings zero-emission deliveries in the U.S. and Europe through robot delivery. In a new campaign, the robots will be doing double duty, serving as marketing devices for the new film. Marketing with robot delivery The campaign launched July 21 and repurposed Coco's Los Angeles fleet of “robocouriers,” which are urban delivery robots, into marketing bots on the streets of LA, or as they call them, “immersive mobile brand activations” that blend entertainment and technology. As part of the campaign, Coco wrapped its LA-based mobile robots in Prime Video and film branding, designed “to evoke the film's iconic armored money trucks,” according to a press release. The campaign is intended to play on the film's central theme while it turns the robots into an extension of the film's story. The robots play voice lines from the film when deliveries are picked up, “turning each vehicle into an in-world character that expands the cinematic universe from screen to sidewalk.” So, Coco's robots deliver food, but also generate “broad exposure” that the company says rival traditional marketing methods, such as billboards. “Unlike static ads, Coco's robots draw eyes wherever they go - making them an attention-grabbing ad surface in any city that naturally sparks filming and sharing,” said the company in a press release. See Coco robot in action The visibility is powered by a combination of proprietary impression-tracking technology and OOH measurement tools. "This campaign shows how our robots can amplify brand storytelling in real time," said Josh Dubin, Head of Ads at Coco Robotics. "It transforms routine deliveries into personal, one-to-one brand experiences that connect with consumers in a natural, memorable way." This type of out-of-home advertising is something that some believe will be more common in the future. "We're always looking for ways to push boundaries and create media moments that people haven't seen before," said Elizabeth Boone, Senior Associate in Emerging Platforms and Partnerships at Omnicom Media Group. "This campaign is a glimpse into the future of media. It's a perfect example of a unique integration of robotics, storytelling, and neighborhood-scale visibility that can come together to bring a movie to life in the real world." The campaign also includes a custom commercial using Coco's delivery robots in a heist scene from The Pickup . Source: Coco Robotics Previous Facebook LinkedIn Copy link Next

Building a large interactive exhibit took insight, innovation, and the perfect systems to get it right. Volcanoes Explode on Interactive Table Exhibit Building a large interactive exhibit took insight, innovation, and the perfect systems to get it right. Edited by EE Staff Museums Sep 12, 2025 Ideum recently completed an interactive exhibit for the Volcano Discovery Center located inside the Valles Caldera National Preserve. For 1.25 million years, Valles Caldera has been shaped by dramatic geological events, thriving ecosystems, and a rich tapestry of human history. These stories unfold across the 89,000-acre landscape and span vast stretches of time. To represent this significant landscape, Ideum, in collaboration with the National Park Service, created a 12-foot topographic relief map as a canvas for this rich history to be projected upon. Immersive Technologies Suspended above the map, a 4K projector brings the table to life with projection-mapped sequences that engage multiple visitors at once. Synchronized RGB lighting washes over the walls in colors, while a 6.1 surround sound system with a 15-inch subwoofer creates a dynamic audioscape that can be felt. The show control system ties into motorized roller shades that darken the room every hour for the signature volcanic eruption sequence, transforming the exhibit hall into a fully immersive, cinematic environment. All photos courtesy of Ideum. Interactive Touch Screen Displays While the large map table captivates groups, the experience is designed for multiuser interaction. Four Ideum-built 34-inch 5K UltraWide Presenter touch screen displays surround the perimeter of the table, giving multiple visitors simultaneous control of the projected animations. Each station offers games and activities tied to one of four themes: Cultural History: Traces human activity from archaic-period settlers to the present day, developed in collaboration with 38 tribes and pueblos to honor their enduring cultural connections to the Caldera. Geology: Features a scrubbable geologic timeline where guests can witness the Caldera’s primary eruption 1.2 million years ago, along with the formation of lakes, lava domes, and other dramatic landscape changes. Ecology: The exhibit’s most extensive library of animations allows users to visualize wildlife migration patterns, plant communities, watersheds, and wildfire impacts across the preserve. Scientific Discovery: Explores the scientific research that has occurred in the region, including paleomagnetics, geothermal research, and seismic monitoring efforts. Exhibit Design and Fabrication The Ideum team starts work on a project with an exhibit design phase where they collaborate closely with the customer to design an immersive digital experience that will be engaging for visitors of all ages. Using Geographic Information System (GIS) data provided by the National Park Service, the Ideum exhibit fabrication team created the true-to-life scaled model of the Valles Caldera landscape. The CNC topographic relief map model, exhibit base, and screen mounts were created entirely in-house. The floating screen mounts were a particularly fun engineering challenge—the end result being a low-profile hidden mount meant to fade away into the table. The mount is tied off to the center ring of the exhibit, allowing for structural rigidity and strength even under the weight of visitors leaning or hanging on the screen. All photos courtesy of Ideum. The topographic relief map, spanning 12-feet in diameter, was fabricated in sections using 3D milling operations on a CNC machine. The map surface was machine-milled from high-density foam, then coated with epoxy for durability and finished with projection-enhancing paint. This hard-wearing surface is easy to clean and resistant to damage. The pieces were trimmed to the outer diameter of the circle and glued together. The map was then cut apart into five organic shapes that follow the natural landscapes of the Valles Caldera. Once on site, the map was seamed together with silicone and repainted. The table’s substructure, built from steel and wooden joists, is clad in Staron and Nevamar Armored Protection, creating an ultra-durable piece designed to endure the heavy use of public spaces while maintaining a refined appearance. Beyond the Exhibit Hall Since the newly branded Volcano Discovery Center sits more than a mile from the park’s main entrance, Ideum and the NPS created a way to draw visitors into the new interactive exhibit hall. At the Welcome Station, a 65-inch Ideum Presenter is programmed to be a Digital Docent providing maps, FAQs, and other day planning tools. Most notably, it includes a countdown clock inviting guests to witness the “volcanic eruption” of the table every hour, a feature drawn from the visitor anticipation that surrounds Yellowstone’s Old Faithful geyser. For more information: Ideum Ideum Presenter Displays Innovative Design Valles Caldera National Park Previous Facebook LinkedIn Copy link Next

An innovative approach to teaching music brings music education and technology together.  Violins Too Expensive? School Superintendent Turns to 3D Printing An innovative approach to teaching music brings music education and technology together. Joe Gillard Cool Stuff Sep 23, 2025 Here’s a story at the intersection of entertainment and engineering that will tug on your heart strings, so to speak. A school superintendent in Pennsylvania, Laura Jacob, noticed that students from low-income families had difficulty purchasing violins for music, and came up with a solution inspired by something she had heard of an orchestra doing: 3D-printing instruments. In the past five years, Jacob has 3D-printed 200 violins that are free for students in a school where 70% of them are low income. Violins can be very expensive, even relative to other instruments. It can cost hundreds in rental fees for the families of students, if they want their child to have the opportunity to learn violin in school. Jacob started out with two 3D printers. She now says she has 34 of them, and students can learn to use the machines, too. “I’m not a computer scientist or an engineer by any means, but after a variety of failures, I found one that actually printed and it sounded good,” Jacob told CBS News. The violins are made from a template created by a company called Hova Labs. Beyond that, Jacob used real violin strings, a few additional wooden parts, and then added modified guitar pegs. Hova Labs violin template for 3D printers The whole process takes about three days to finish a violin. If the instrument breaks (probably a strong possibility with schoolchildren), they can easily be fixed. As a fun added benefit, the 3D-printed violins can be made in different colors, which might make the instrument more interesting for kids. Prusa 3D Printers The Prusa XL 3D printers are designed for precision. According the company website, “the precision tolerance of a well-assembled Original Prusa printer is 0,1 mm on the Z-axis and 0,3 mm on X and Y.” And the company says that calibrations can be done to further improve the result. “It can be as little as 0,05 mm on all axes, after making additional calibrations such as the Extrusion multiplier calibration and Extruder linearity correction.” Prusa XL 3D printer The magnetic heatbed can hold a two-sided flexible spring-steel sheet, for removal of printed objects from the print surface, according to the product page for the Prusa XL. There are six varieties of sheets for the Prusa XL: smooth, powder-coated textured, PA Nylon, PP, and HighTemp, all of which serve a specific type of 3D-print job. For information: Hova Labs: https://www.hovalabs.com/ Prusa Research https://www.prusa3d.com/ CBS Interview with Laura Jacob: https://www.cbsnews.com/news/pennsylvania-school-3d-printers-violins/ Cover photo: u_l5sf233ead , Pixabay Previous Facebook LinkedIn Copy link Next

Designed to operate in various environments where human-machine interaction is essential, this humanoid robot provides versatility, intelligence, and is fully modular. Reachy the Open-Source Robot is Designed for Research and Industry Designed to operate in various environments where human-machine interaction is essential, this humanoid robot provides versatility, intelligence, and is fully modular. Edited by EE Staff Cool Stuff Jan 6, 2026 Reachy 2, from Pollen Robotics, was designed to adapt to a wide variety of uses and allows users to choose from several configurations. Its natural expressions and gestures make it an intuitive and engaging robot, capable of integrating into social environments. The robot’s fluidity is based on the company’s key innovation, Orbita, the bio-inspired joint system. The Orbita 3D is mounted to the robot as the wrists and neck, allowing harmonious and smooth movements with a wide range thanks to its three degrees of freedom. Similarly, the Orbita 2D, integrated into the elbows and shoulders, articulates via two degrees of freedom. The Orbita 2D is design to support loads of up to 3 kg. Image courtesy of Pollen Robotics. Reachy 2 is equipped with a Python SDK and is based on ROS2, offering researchers and developers an open and flexible programming environment. According to Elsa Kervella, Sales and Marketing Director at Pollen Robotics, “We designed Reachy as a platform: researchers can integrate their own algorithms, and developers can enrich the software.” Reachy even includes a teleoperation feature—remote control—opening up additional prospects for difficult-to-access environments or those requiring great precision. With a virtual reality headset, an operator can control the robot's movements in real-time as well as teach it new movements. This learning capability allows Reachy to reproduce learned gestures autonomously. Image courtesy of Pollen Robotics. The open-source approach is a central pillar of Pollen Robotics' identity. By making Reachy's plans and resources public, the company offers the global community an opportunity to customize and enrich the platform. This choice promotes collective innovation, aligned with the goal of democratizing access to useful robotics. "This not only allows our customers to adapt Reachy to their needs but also a global community to advance the technology, " said Kervella. Reachy was designed to appeal to both the academic world and industrial world. In prestigious institutions like EPFL or Cornell University, it is used to explore human-robot interaction and machine learning, pushing the limits of artificial intelligence in real conditions. In industry, its modularity allows it to adapt to complex environments, whether for cobotic tasks or specific simulations. When Pollen Robotics sought to push Reachy's limits, the company found a solid partner in maxon. The two teams closely collaborated to meet a challenge: adapting the components to demanding environments while respecting the robot's design and modularity constraints. Integrating the motors into the Orbita joints was a challenge as it was necessary to reconcile performance, compactness, and reliability while respecting Reachy's humanoid design. maxon met this challenge with a series of integrations including different motors, gearmotors, and sensors. For example, the maxon EC-45 flat motor featured an optimized winding design and powerful magnets. Its efficient heat dissipation enabled continuous operation at high performance levels while its flat design facilitated integration in confined spaces. The MILE inductive encoder was the perfect complement to the flat motors, offering high resolution and precision. The inverted-signal encoder was extremely resistant to magnetic and electric fields, as well as to dirt. It was directly integrated into the motor. GPX32 gearboxes offered over 90% efficiencies to ensure smooth and efficient movements. Their robustness ensured reliable handling, even under demanding conditions. From left to right: EC flat, ECX torque, GPX gearhead. Images courtesy of maxon. Additional components included maxon’s ECX22torque motors and GPX22C gearboxes. Compact and powerful the motors provided exceptional torque densities for precise motion, while their iron-core windings and multipolar design guaranteed the optimum energy efficiency necessary for dynamic, real-time movements. The gearboxes delivered exceptional power transmission, and their modular design made it possible to create customized solutions for customers. According to Kevin Schwartz, Sales Engineer at maxon, “The compactness and performance of the motors were essential to respect Reachy's humanoid design while increasing its load capacity.” Overall, the integration of maxon solutions has pushed the limits of Reachy, making it a platform as powerful as it is modular. Lead image courtesy of Pollen Robotics. For information: Pollen Robotics maxon Flat motors Gearboxes Sensors Read more about robots >>> Previous Facebook LinkedIn Copy link Next

Rushed and dangerous scenarios require equipment that's safe and reliable. Here's how the aerial ladders on firetrucks just got safer. Fire Trucks Get a Ladder Safety Upgrade Rushed and dangerous scenarios require equipment that's safe and reliable. Here's how the aerial ladders on firetrucks just got safer. Edited by EE Staff Cool Stuff Nov 17, 2025 Amity Fire & Safety serves the Fire & Equipment industry by producing swivels, telescopic waterways, weldments, machined parts, and pins for extremely demanding applications. Their international customer base includes industry giants such as KME (Kovatch Mobile Equipment), Pierce Manufacturing, and Rosenbauer. Amity’s customers manufacture the fire trucks that are seen at local fire departments around the world. KME custom manufactures the broadest family of aerials in the fire service and incorporates IQAN E-Control™ (motion control system) in their trucks to ensure a high level of safety. Ladder base swivels allow for rotation of the aerial ladder while acting as a pass-through for water and continuous hydraulic and electrical circuits. The position of the aerial ladder on a fire truck needs to be monitored to reduce risk of injury and damage to equipment. Although Amity used limit switches to monitor whether the ladder was within certain degrees of rotation, the proximity switches still couldn’t monitor the accurate position of the ladder within that range. Safety swivel side and top view. Images courtesy of Advanced Micro Controls, KME, and Amity Fire & Safety. Without knowing the absolute position of the aerial ladder, damage or injury can occur in several ways. Trucks could tip over when the ladder’s range of movement is exceeded. This could happen during a short jacking operation where a narrow jack spread is used to avoid obstacles such as parked cars. Damage can also occur when bringing the ladder to cradle position. When the ladder is brought back into the resting (cradle) position, misalignments can damage the cradle ears. On mid-mount ladders, pump panel damage can occur when the aerial ladder is brought below grade (too far down). Outrigger jacks fully extended. Images courtesy of Advanced Micro Controls, KME, and Amity Fire & Safety. Accurate Positioning By using an absolute analog DuraCoder®, Amity is able to acquire the accurate feedback they need. The DuraCoder recognizes where the ladder is within the 0–360 degree revolution without guesswork. When the ladder is at a low angle, the operator is now capable of automatically stopping rotation at a pre-set point known to eliminate risk of damage to the body of the truck and injury to firefighters during a rescue operation. When KME upgraded to their Parker IQAN™ (motion control system), they realized that the grey scale encoder they had initially specified would no longer meet their voltage output requirements. Additionally, an excessive amount of mathematical programming was required with the grey scale encoder; and together, Amity and KME set out to find a more efficient solution. “If we want to be successful, we have to get to that next level.” DuraCode® absolute encoder. Images courtesy of Advanced Micro Controls, KME, and Amity Fire & Safety. Signal Changes After reviewing all of their options, KME contacted Amity with the solution: an AMCI DuraCoder with integrated cable. The DuraCoder’s analog output signal eliminated much of the mathematical programming that was necessary with the grey code encoder. With the integrated cable, KME no longer needed to produce their own cable, simplifying wiring and installation, and ensuring the IP67 sealed rating. The DuraCoder is installed in an area of the truck that is exposed to water mist during firefighting, high pressure wash downs, and airborne contaminants from smoke and ash. AMCI’s DuraCoders are designed to provide consistent reliable feedback while preventing water and contaminant ingress. With the DuraCoder, KME’s IQAN “E-Zone™ system stops rotation or elevation of the ladder when the operator attempts to position the ladder in a pre-defined zone (cab avoidance, body avoidance, and short jack operation). This eliminates the possibility of cab or body damage and makes operation of the device on the short jack side of the vehicle safer, according to the KME product brochure. Amity’s concerns when selecting an encoder included its ability to withstand heavy shock and vibration caused by the truck’s engine, onboard generators, and road vibration. The DuraCoder is resolver based, meaning that it was designed to provide absolute position feedback without plastic disks or magnetic components, enabling it to withstand high levels of shock and vibration. Amity Swivel with AMCI DuraCoder. Images courtesy of Advanced Micro Controls, KME, and Amity Fire & Safety. The optional 5/8-inch stainless steel shaft boasts exceptional shaft loading, and the high shock and vibration rating provides reliability where most sensors fail. The IP67 rated product line comes standard with either a ¼-, 3/8-, or 5/8-inch stainless steel shaft and an oversized double row sealed bearing. Additionally, DuraCoder brand encoders are available in six different versions, including SSI, Digital, Analog, Incremental, DeviceNet, and Ethernet/IP. Amity was able to change out the original optical encoder for the AMCI DuraCoder quickly and easily. The units’ industry-standard mounting pattern made it easy to replace the existing encoders. While the standard lead time for the AMCI DuraCoder is three weeks or less, Amity could not wait that long. Because AMCI designs and manufactures their products in-house, they were able to expedite the process, sending the full shipment out within a few days. After an easy installation, Amity’s swivels were ready to be sent off to KME. For more information: Advanced Micro Controls Absolute DuraCoder Amity Fire & Safety Kovatch Mobile Equipment Read more about cars and trucks >>> Previous Facebook LinkedIn Copy link Next

A student team gained valuable STEM experience by developing an underwater remote operated vehicle using commercially available industrial-grade components. Industrial Devices Used in STEM Project A student team gained valuable STEM experience by developing an underwater remote operated vehicle using commercially available industrial-grade components. Geoff Gardener, North Paulding High School Cool Stuff Jul 9, 2025 Exploration of both the deep sea and of outer space share a lot in common. Both are extremely unforgiving environments where it is very expensive to create manned vehicles to carry out missions. As automation has become more capable, robotics and unmanned remote operated vehicles (ROVs) are used to execute much of this work. Underwater ROVs operate in challenging environments, which means that industrial-grade automation products are a natural fit to support these designs. Also from EE: Escape Room Experience Uses Automation Tools Although, ROVs are controlled remotely by human operators, most have some degree of on-board automation, combining mechanical, automation, and other skillsets. To develop young talent to support this field, Monterey Peninsula College—via a grant from the U.S. National Science Foundation—has established a program called the Marine Advanced Technology Education (MATE) Center. MATE promotes marine engineering by inspiring and challenging students to learn and creatively apply STEM skills for solving real-world problems. Part of the program is the MATE ROV Competition, which offers five different contest classes, each based primarily on skill and not strictly by age group. At North Paulding High School in Dallas, GA, a number of students make up the “WhaleTech” team. Some of them have participated up to seven consecutive years, starting in middle school. Each year, the competition organizer publishes challenges and mock mission profiles simulating real-life conditions, with various restrictions. For example: dive to a pipeline simulation at a given depth, strategically remove a “bad” pipe segment, replace it with a new section, and bring the bad portion to the surface. The team builds a ROV to meet those challenges, and along the way they must act and present themselves as a professional company by developing technical documentation, conducting research, and selecting products. Throughout the process, the team must learn and follow safe practices, assemble and test the ROV and subcomponents, and even do a bit of marketing. The Details Many ROVs look a lot like aerial drones, with propellers arranged to provide thrust in various directions. Just as aerial drones use propellers to provide constant lift and control motion, an underwater ROV does the same, but it can also use an additional mechanism to adjust its buoyancy. Cameras and lights are common on ROVs, and many also have robotic arms and manipulators to perform tasks. Many of the monitoring and control needs mirror the types of functionalities needed by industrial automation control systems. AutomationDirect has a long history of supporting student STEM efforts, and this underwater ROV project exemplifies just how important it is for industry to support education. For the 2024 competition, the WhaleTech team needed to develop a well-controlled ROV with an extensible gripper. The buoyancy mechanism, gripper, cameras, propellers, and other components would need to be supported and arranged in a chassis, which meant that some design effort would have to be in parallel and iterative to achieve the functionality and create an integrated form factor. As part of the process, the team used cardboard mockups and 3D printing, and then they created many structural elements cut out from high density polyethylene (HDPE). The buoyancy engine is used to actively alter the buoyancy of the vehicle so the ROV can rise, descend, or stay at a fixed depth (Figure 1). A sealed cylinder compresses the fixed air volume, displacing it with water, which results in changing the overall density of the apparatus. Figure 1: The buoyancy engine consists of a specially modified pneumatic cylinder, driven by a stepper motor and an AutomationDirect SureStep stepper drive, to provide accurate control with minimal power consumption. (Photo courtesy of North Paulding High School.) After selecting an industrial-grade cylinder, the team needed a powerful yet controllable way to actuate the piston portion via a linear screw drive mechanism. After some trial and error, and investigation of technologies readily available from AutomationDirect, the team found that a stepper motor could do the job admirably. A stepper motor can continuously turn in either direction and be commanded in increments as small as 1.8 degrees per step, driven by an AutomationDirect SureStep stepper drive commanded by an Arduino nano. A stepper motor draws no power when idle, it works well within the available power budget, and there is no rebound when the target position is achieved. The buoyancy engine is also outfitted with a pressure sensor used to store depth data into the on-board computer, and a wireless transmitter to communicate this information to the surface computer for a graph display when the ROV surfaces. Similarly, the gripper assembly incorporates an AutomationDirect SureStep rotary stepper motor driving a screw shaft to provide the motion required to extend or retract a mechanism, which in turn opens or closes the gripper (Figure 2). Because this assembly must articulate, it is connected to the controller using a watertight flexible cable. Figure 2: The WhaleTech project team found the right cable assembly for the gripper by researching the AutomationDirect catalog where they found cut-to-length cable solutions that met their technical needs. (Photo courtesy of North Paulding High School.) In previous competitions, the team had experienced issues with umbilical cables—running from the ROV to the surface—that were not flexible enough to allow precise movements in the water, or were insufficiently shielded and therefore susceptible to electromagnetic interference (EMI). To solve these issues, the team researched cables on the AutomationDirect website and found products with better flexibility and improved resistance to electrical noise. Further, the team occasionally used AutomationDirect’s phone support to iron out details. As a result of their design and execution efforts, the WhaleTech team won first place in the Ranger class of the 2024 MATE ROV Competition. While some members are graduating and moving on to new work and educational endeavors, a new crew will assemble next year and work to build upon their successes. For more information, visit AutomationDirect . Previous Facebook LinkedIn Copy link Next

A rehabilitation of Atlanta’s historic Fountain of Rings earlier this year included the installation of a new, transformative technology that’s dramatically improved the water feature’s programming capabilities. Fountain Technology Transforms Iconic Water Feature A rehabilitation of Atlanta’s historic Fountain of Rings earlier this year included the installation of a new, transformative technology that’s dramatically improved the water feature’s programming capabilities. Theme Parks Sep 4, 2025 Cool Stuff Built nearly 30 years ago, the enormously popular LED-lighted show-style water feature comprises more than 250 manifold-mounted precision jet nozzles supplied by several large dry pumps. Designed to reflect the iconic interlocking Olympic rings, this choreographed display has become one of Georgia’s most photographed attractions, delighting guests with daily performances of synchronized water, lights, and music. Led by Texas-based fountain design firm The Fountain People, the comprehensive restoration effort included the installation of 256 new display nozzles and an integrated LED ring light fixture for dramatic color-changing effects. The project also added plug-and-play connections and a new water feature show panel with a touchscreen interface that allows operators to select among up to ten choreographed musical fountain shows. Video courtesy of The Fountain People. Further improvements included modernized pump and filtration systems, fog system repairs, and remote access capabilities that give staff greater control over the fountain’s operation. Perhaps the most exciting addition brought by the renovation, however, was the installation of a new fountain valve technology that’s enabled vastly richer nozzle effects and choreographies, thrusting the historic attraction into a new, growing class of elite manifold-based fountains and water features. Until recently, manifold-based water features such as the Fountain of Rings used a water switch, a three-way valve installed at each nozzle that allows on/off nozzle sequencing. The ability to independently control spray height for each nozzle, however, has always required a distributed pump architecture where each nozzle is controlled by its own VFD-driven effect pump. This approach required extensive submerged electrical infrastructure but allowed for show flexibility where programmers could provide complex effects such as waves, variable height chase scenes, and more. Now, this same level of control is available among manifold-based water features. The Robotic Water Switch Developed by Texas-based aquatic robotics company SplashBotix, the SplashValve is a single-axis, fast-acting robotic valve that uses a specially shaped diverter to bring proportional nozzle height control to manifold-based water features for the first time. The Fountain People’s restoration effort marks one of the first and largest uses of the new technology, representing a new standard in manifold-based water feature design and programming. SplashValves are three-way valves installed at the nozzle, designed to divert incoming water to effect or bypass. Unlike water switches, however, SplashValves can also divert water to varying proportions of effect and bypass, enabling both on/off and spray height control. Capable of cycling up to four times per second, SplashValves marry the speed and on/off action of a conventional water switch with the height control flexibility of a VFD-driven effect pump. Image courtesy of The Fountain People. SplashBotix is a division of ARM Automation, an industrial robotics and automation firm with more than 30 years of experience developing high-performance motion systems for semiconductor, aerospace, and factory automation. Unlike other technical suppliers in its industry, SplashBotix takes much of its design and engineering inspiration from the world of industrial automation. For this reason, the story of SplashBotix and the SplashValve challenges assumptions about where advanced robotics and automation principles can provide value—not just on factory floors, but in public and municipal spaces as well. Design Features The secret behind the SplashValve’s advanced flow control capabilities lies in its clever electro-mechanical design. Rather than using a pilot switch to control the flow of water, the SplashValve uses a specially designed, servo-actuated diverter. Set inside the SplashValve’s bore, the diverter rotates 90-degrees between effect and bypass, incrementally changing the nozzle spray height as it shifts its position. Fully enclosed, the SplashValve’s servo motor transmits motion to the diverter through magnetic actuation, a clever static-seal design that makes the SplashValve virtually leak-proof. Image courtesy of SplashBotix. Composed mainly of 316 stainless steel and a proprietary blend of wear- and chemical-resistant plastics, the SplashValve also offers advantages over competing solutions when it comes to maintenance and durability. Effectively a one-inch diameter pipe when the diverter position is at full effect, the SplashValve allows most fountain debris to pass right through to the nozzle, making screen filters largely unnecessary. When clogs do occur, SplashBotix has made the diverter easily accessible for maintenance personnel, who can remove the diverter from the magnetic coupling, clean the valve and return the diverter back to the SplashValve all in less than a minute. From a fountain engineering and design perspective, the SplashValve represents a major paradigm shift. By bringing proportional control to manifold-based systems, the SplashValve is enabling designers to deliver world-class shows without the cost, complexity and power requirements of installing hundreds of VFD pumps. For municipalities like Atlanta and other stakeholders, this means richer experiences for guests, safer public amenities, and less frequent, less costly maintenance. For more information: SplashBotix ARM Automation The Fountain People Previous Facebook LinkedIn Copy link Next

Unique cooling solution is optimized to provide cooling for an electric Vertical Take Off and Landing aircraft capable of traveling flight distances of 1,000 km. Electric VTOL Aircraft Unique cooling solution is optimized to provide cooling for an electric Vertical Take Off and Landing aircraft capable of traveling flight distances of 1,000 km. Terry Persun Cool Stuff Jun 10, 2025 Conflux Technology designs, engineers, and produces additive manufactured heat exchangers for a variety of thermal challenges in multiple industries. Recently, they unveiled a collaboration with AMSL Aero, an Australian aircraft manufacturer involved in building the world’s most efficient long-range zero emissions electrical VTOL aircraft. Also from EE: Electric Race Car Uses 3D-Printed Components Under the first phase of the project to develop hydrogen fuel cell cooling for AMSL Aero’s Vertiia VTOL aircraft, Conflux developed three heat exchanger concepts, each focusing on minimizing weight and volume while managing continuous heat loads and reducing drag. The ultimate goal was to enable flight distances of up to 1,000 km. Already at its second phase, the company will optimize the design and manufacture of a full proof-of-concept assembly to evaluate its performance within Vertiia’s hydrogen fuel cell powertrain. According to Michael Fuller, CEO & Founder of Conflux Technology, ““Hydrogen fuel cells represent a transformative technology in Australia’s pursuit of sustainable energy solutions. We are proud to incorporate our heat exchange technology to enhance the efficiency and performance of Vertiia’s hydrogen fuel cells. Together, we’re advancing innovation in creating world-leading sustainable air transport.” The Conflux cooling solution will be optimized to provide cooling for high transient heat loads experienced during vertical take-off, landing, and hover operations. Weight, performance and packaging size are key constraints for aeronautical hydrogen powertrains. Geometrical freedoms granted by additive manufacturing means heat exchangers for these systems can be lightweight and conform to the space available. Conflux’s unique thin-walled, patented designs deliver thermal performance and low drag. Photo: A closeup of Conflux Fins AMSL Aero chairman Chris Smallhorn said: “In Vertiia we are building a hydrogen-electric aircraft that flies record-breaking distances at Formula 1 speeds, making Conflux Technology, with its storied history of innovation in motorsport and aviation, the perfect partner for us. Conflux’s AS9100D manufacturing and quality certification is critical in enabling Vertiia to become the world’s first long-range passenger-capable hydrogen VTOL.” Working together, the companies are pioneering a future where clean energy and cutting-edge engineering drive the aviation industry toward a greener and more sustainable future. This engagement further expands Conflux’s presence in aerospace applications, leveraging additive manufacturing to develop high-performance heat exchangers for next-generation aviation. Applications now extend across propulsion system cooling, transmission and gearbox cooling, environmental and avionics cooling, and power electronics cooling. As the demand for sustainable solutions accelerates, additive manufacturing is setting new performance benchmarks, delivering advanced thermal management solutions that conventional methods cannot achieve. Watch: News video of the Vertiia For more information: Conflux Technology AMSL Aero Previous Facebook LinkedIn Copy link Next