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Automated guitar plays more than two dozen songs Pneumatic Guitar Mimics Motion of Human Hand Automated guitar plays more than two dozen songs EE Staff Cool Stuff Jun 4, 2025 When employees at Clippard Instrument Laboratory set out to make a new exhibit for their 2012 trade show schedule, they wanted something cool and unique that would draw attention to their pneumatic and automation products. Their answer is a pneumatic guitar that plays more than two dozen songs with over 36 notes running on 50-psi air pressure. Rob Clippard, the guitar’s primary designer and developer, recalls part of the challenge was making the guitar. “We had myself and a few other engineers working on it, sometimes pulling all nighters,” he says. Others working on the project include Chris Rhodes, Jerry Grotelueschen, Brett Vidal, Bill Clippard and Ed Ehrhardt. The main design challenge was trying to mimic the motion of the human hand. “If you asked 100 engineers how to do this, you might get 100 different ideas on how to build a pneumatic system,” says Clippard. He adds one of the hardest parts was the “fret,” or the control of what would be the left hand that holds down the strings along the guitar’s neck. “You have to come off the strings with a certain velocity to mute the string at the correct time while sliding your hand to position your fingers for the next set of notes,” he explains. “Engineering the movement, positioning, and force feedback systems for this application is hard to replicate in a more cost-effective solution as pneumatics.” There were marketing challenges with the exhibit too. “With this exhibit we are getting people to think about new applications with pneumatics,” explains Clippard. “We are also trying to show that Clippard does more than sell pneumatic components. Our engineers use creativity to design, development, assembly, test, among other functions to simplify the tasks for other companies in terms of effort.” The pneumatic guitar has 58 electronic valves and 62 miniature pneumatic cylinders from 5/32” diameters up to half-inch bore that help mimic the motion of the human hand “fretting” , “picking” and “strumming” the six guitar strings. A Wi-Fi card and iPad with a midi player app control of the pneumatic guitar. All other guitar parts are standard, off-the-shelf units, except the manifolds. Engineers at the company normally custom design their own manifolds in house with Solidworks CAD software. But with this job, they were able to use a vector-based drawing program for tracing the outline of the guitar to guide laser cutting of the manifold and valve subplates. For more information: Clippard Home Solidworks Previous Facebook LinkedIn Copy link Next

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

When a Vancouver-based boutique animation studio outgrew its consumer-grade storage when it took on bigger projects for film, TV, and commercials, it looked to a more scalable solution. Big Animation Dreams Mean Big Storage Needs When a Vancouver-based boutique animation studio outgrew its consumer-grade storage when it took on bigger projects for film, TV, and commercials, it looked to a more scalable solution. Edited by EE Staff Film and TV Nov 17, 2025 Od Studios (Vancouver, BC) started as a boutique visual effects studio with an aim to produce full length animated feature films using the latest technology and production practices. In the video production industry, great work can lead to more work—which means more generated data, and subsequently, the need for more storage. To reach their goal, they knew that they could no longer get by with their older consumer-grade storage solution. Od Studios generates a significant amount of data during production. Their product is the data they produce. Their efficiency was impacted by the low throughput of their previous consumer grade hardware solution. As they grow, the projects they work on become higher profile and their need to produce high quality work increases. Od Studios required a stable solution to finish projects on time and on budget. They needed a storage solution that would allow them to scale and provide them with the flexibility to resolve their specific problems. As a relatively new company, they had been using a product that only offered mediocre throughput that constrained their ability to produce work quickly. The system was slow, and they constantly questioned how many days remained until they pushed the system to failure. As a newer studio with a limited budget, total cost of ownership (TCO) was very high on their list of requirements. They needed to balance affordability with throughput and stability yet wanted flexibility to allow for scaling and future growth. They began researching hardware vendors for a replacement solution, considering Seagate along with competitors that are traditionally used to provide storage solutions in the animation/visual effects production industry. Od Studios wanted the ability to install whichever vendor’s drives they chose, as well as to use the Lustre file system software they selected. They believed that they could achieve performance that was as good as, if not better than, many of the proprietary systems in the market. All photos courtesy of Seagate and Od Studios. In the early part of their selection process, Od Studios appreciated that Seagate’s storage options were different than competitors that locked customers into a single, one size fits all solution where the hardware appliance, installed drives, and software are provided by one single vendor. That’s why the studio chose Seagate’s Exos™ X 5U84 RAID array that provided them with future flexibility and minimal vendor lock-in—a solution that gives them the flexibility to pivot should they ever need to. The 5U84 provides room to grow through a versatile architecture that opimzes TCO for petabyte-scale storage with industry-leading density. Plus, Od Studios can get its data to applications when and where it’s needed with high-speed, high-performance storage. The secure hard drives provide reduced power consumption and adaptive cooling technology to help Od Studios realize cost and energy savings. All photos courtesy of Seagate and Od Studios. The 5U84 is placed behind a Dell server which serves as the Lustre file system’s object storage service (OSS). A second Dell server is used for the Lustre metadata service (MDS). Due to the Seagate array’s design, Od Studios can scale out their system in different ways as needed—although with its extremely large capacity it may be a while before that happens. Another benefit for Od Studios is how the ADAPT RAID on the array allows for rapid rebuild times in case of drive loss. In addition, the ability to use preferred drives in the array, along with using a scalable software-defined storage solution like Lustre, provides Od Studios with the flexibility, scalability, and performance they need out of their storage system. Today, in addition to films, Od Studios also works on TV series and commercials. Its clients include Netflix, Amazon Prime, Canadian Broadcasting Corporation (CBC), Warner Bros., Marvel, and NBC. According to Od Studios Founder and Visual Effects Supervisor, Marc Horsfield, “The ability to scale out is a big win. With Seagate’s Exos X 5U84, we have options to scale, and that flexibility is paramount in an ever-changing industry.” For more information: Seagate Od Studios Exos X 5U84 RAID System Read more articles about filmmaking >>> Previous Facebook LinkedIn Copy link Next

Using the latest in 3D printing along with creative license, this custom car builder is breaking the mold. Restoring Vintage Porsches with 3D Tools and 3D Printing Using the latest in 3D printing along with creative license, this custom car builder is breaking the mold. Edited by EE Staff Sports Mar 9, 2026 It all started with Rod Emory’s grandfather, Neil Emory who was a well-known custom car builder in Burbank, CA. Rod’s father, Gary Emory, was a countercultural influence whose restyling designs ranged from the original “Baja Bug” to race-inspired street variations of the Porsche 911. The unique Porsche 356 street and competition cars restyled and raced by Rod and Gary, whose aesthetics frequently offended brand “purists,” came to be known, fittingly, as 356 Outlaws. Emory Motorsports restores historically significant Porsche race cars and builds 356 Outlaws in their Oregon and California facilities. The spirit of the Emory bloodline remains true today: to make old Porsches far better than they ever were—mechanically and aesthetically. Yet for the ultimate brand enthusiast, the Emory Special , of which only a precious few have been made, is the benchmark for judging others in the genre. Specials are one-off cars whose combination of design and mechanical components will not be duplicated. Images courtesy of Quickparts and Emory Motorsports. With the technical precision required for today’s manufacturing processes, Rod Emory’s creative team needed to marry old-world fabrication techniques with the latest 3D tools and 3D printing from Quickparts. This combination of scan/design technology and rapid prototyping came in handy when a customer asked Emory to help restyle the windshield frame for an early Porsche Roadster. “Our customer wanted to update the windshield design with a lower and leaner profile than the original, while still paying tribute to the car’s design aesthetics,” said Rod Emory. Using data points acquired by scanning, we were able to restyle the “A-pillars” (the parts of the windshield frame that bookend the glass) within the existing parts’ footprint.” Images courtesy of Quickparts and Emory Motorsports. Since computer simulations can only communicate so much, the Emory team wanted to check the new part’s size and fit on the real-life car before committing to full production. So, they decided to 3D print a prototype with help from Quickparts, an on-demand 3D parts printing service whose customers quickly receive no-obligation quotes for their parts while offering fast online workflows and expert advice. Rod explained that, “Quickparts understands the challenges customers face while sourcing this type of service and the need for comprehensive information and material choice. Their website was easy to navigate. We uploaded our model, talked to customer support about the best printing processes for our part and their respective prices, then plotted a path forward.” Images courtesy of Quickparts and Emory Motorsports. Emory settled on SLA output, using an ABS-like grey material. The part arrived quickly within a five-day turnaround in total. Once the part came in it was test-fit into the vehicle while the customer watched, and who then immediately provided feedback about the design. According to Rod, “The 3D printed part itself had very high fidelity and a perfect finish. This kind of “closed-circuit” validation is critical to successful design processes and wouldn’t have been possible without 3D printing,” Rod said. “On a different kind of project, that print could even have been used as a finished part.” For information: Quickparts Emory Motorsports Read more about automotive technology >>> 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

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

Font dels Colors fountain in Andorra’s capital city is automated and synchronized using PC-based control system. PC-Controlled Water, Light, and Audio Installation Font dels Colors fountain in Andorra’s capital city is automated and synchronized using PC-based control system. Terry Persun Stage Events Jun 12, 2025 Fluidra S.A. creates impressive installations involving water, light, and music, including the Font dels Colors fountain. The company relies on PC-based control from Beckhoff, whose openness and flexible approach to creativity open up a whole host of possibilities for designers. Fluidra’s technical skills and Beckhoff’s expertise in automation technology are at the heart of spectacular water displays such as the twin fountains in Plaça de Catalunya (Barcelona), the fountains in La Pedrera Park (Argentina), and the Vadistambul shopping center fountain (Türkiye). These projects contain PC-based control technology from Beckhoff, including TwinCAT 3 PLC/NC PTP and TwinCAT 3 HMI Server as software, plus EtherCAT Terminals and EtherCAT Box modules—which can be installed in a decentralized configuration—acting as the I/O level. The lighting technology is integrated using technology including EL6851 EtherCAT Terminals (DMX master). A CP2216 multi-touch built-in Panel PC allows technicians to control the system as required, call up status messages, and respond to alarms. Developed by Fluidra in collaboration with architects Pere Cervós of Pere Cervós Arquitectura and Ricard de Deus of Causa Estudi Arquitectura, alongside the construction company Locub S.A., the Font dels Colors water display combines an impressive installation with light and music located next to the Gran Valira river and the Puente de París bridge in the heart of Andorra’s old town. This attraction transforms the city promenade into a living work of art that captivates tourists. Another special feature of the project is its innovative, sustainable approach in which the water for the cascades is taken from the river and then reused. Precise synchronization PC-based control allows all the components of the Font dels Colors and other projects to work in perfect synchronicity—from the lighting effects and background music to the dynamic choreography of the water jets and pumps. Fluidra makes full use of Beckhoff’s extensive modular I/O portfolio, which covers everything from simple digital inputs and outputs to motion control and AM8000 servomotors. The communication options with DMX management systems are a key advantage; Fluidra uses these for programming and operating the water installations, for example. Photo: The lighting scenarios and motion sequences created using 3D DMX software are converted into precise, synchronized control signals for the nozzles, pumps, and LED lights, working on the basis of a PC. Fluidra uses its 3D software to create the sequences for its water displays, from the jets and illumination features to the sound system. The control data for the light and water jets is then output via what are known as DMX control universes. These sequence programs are installed on a separate DMX player, which is included in every system. The sequences are transferred to the CP2216 Panel PC via an EL6851-0010 EtherCAT Terminal (DMX slave) and EtherCAT, and are executed in TwinCAT 3 PLC/NC PTP—in other words, converted into control signals for the various components, including the servomotors. Any components with a DMX connection can be integrated directly via additional EL6851 EtherCAT Terminals (DMX master). To allow intervention in the sequences on site, DMX control channels required for this purpose were created for each device in TwinCAT 3 HMI. Operators can also access the system remotely and respond quickly to an alarm message by email. Conserving water resources The solutions from Fluidra and Beckhoff don’t stop at aesthetics and technology, however. Both companies are also committed to using ecological resources sustainably. For this reason, Font dels Colors has implemented a water cycle that significantly reduces consumption and ensures efficient use of the valuable resource of water. In addition, UV filters and disinfection systems have been installed to maintain high levels of water quality without the use of harmful chemicals. According to the experts at Fluidra, this integrated approach involving technological and ecological innovations is setting new standards for planning and constructing water systems. Combining aesthetically appealing water displays with ecological responsibility points the way toward a more sustainable and exciting future for urban spaces. For more information: Fluidra Beckhoff 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

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

Fluid power components help the wicked witch levitate at the end of Act 1. Wicked Technology Defies Gravity on Broadway Fluid power components help the wicked witch levitate at the end of Act 1. Stage Events Jul 22, 2025 Cool Stuff Although Wicked recently came to the big screen, the Broadway edition of Wicked is still playing at the Gershwin Theatre—since 2003—and is currently the fourth-longest running Broadway show. The play focuses on the friendship between Elphaba and Glinda. At the climax of Act 1, a hydraulics system installed and maintained by Atlantic Hydraulic Systems provides the power and control to raise the witch 20 feet above the stage as she sings “Defying Gravity.” The company built their hydraulic system for the play around two Parker pressure compensated 8 GPM hydraulic gear piston pumps with a maximum flow of 7.9 gallons per minute and at 2600 psi pressures. These pumps are specially designed to use mineral oil, fire-resistant fluids. For additional control, the platform that the witch is raised on also incorporates two 15 horsepower, totally enclosed fan-cooled TEFC electric motors. These motors typically operate from a 230/460V three-phase power source, and typically operate from around 1800 rpm to 3600 rpm. The Wicked Hydraulic Levitator, which raises the actress into the air, does not contain an on-board hydraulic power unit. Instead, a remote hydraulic power unit charges up accumulators on the levitator prior to being detached. Proportional valves and redundant circuitry are employed to assure the actress’ safety throughout the show. For more information: Atlantic Hydraulic Systems Previous Facebook LinkedIn Copy link Next

Small details like easy-to-use cases with squeak-free hinges enhance the high-end makeup experience. Innovative Pins Used in High-End Cosmetics Cases Small details like easy-to-use cases with squeak-free hinges enhance the high-end makeup experience. Terry Persun Cool Stuff Oct 27, 2025 There are a wide variety of plastics used in industry today, but only a few meet the demands and requirements for packaging cosmetics, some of which include PET, ABS, PCR and others. Regardless of which plastic material a company chooses to employ, the most important component might not be the cosmetic case itself. Functionality often plays an even more important role than aesthetics. We’re talking about the mechanism used to open and close the case: the hinge. There are a number of methods available to provide the hinge on cosmetic cases, such as snap-on or concealed hinges, butt hinges, and Solid Pin hinges, which have their own challenges. For example, a leading cosmetics packaging company of high-end products used two Solid Pins in their styrene case. The two pins caused the case to squeak when opened and closed. This was because the pins relied on deformation of the plastic for retention, which stressed the material and caused the noise. In addition, the holes had to be misaligned in order to keep the Solid Pins in place. Angular pressure caused by the misalignment along with the solid pins bending, also contributed to the squeaking. Image courtesy of SPIROL. The cosmetics packaging company looked for a new method that would allow multiple opens and closings without making a sound. After some analysis, the company chose to make minimal adjustments to their cases and incorporate SPIROL® Series 550 Cosmetic Coiled Pins as an excellent solution that eliminated the squeaking completely. Needed Modifications The plastic molding customer was willing to modify the existing hole size in the case to achieve the proper friction fit for the Coiled Pin. Further, redesigning the hole in the case allowed the company to incorporate a standard Series 550 Cosmetic Coiled Pin, which also reduced costs by avoiding the need for a custom solution. Rather than misaligning holes in the case, the uniform radial spring force of the Series 550 resulted in a controlled hinge movement. Image courtesy of SPIROL. Uniform radial spring force allows for controlled hinge movement and hinge quality that remains consistent over time. Controlled hinge movement is achieved with wider tolerances and lower molding costs than when a solid pin or cut wire is used. The inherent design of the Series 550 Cosmetic Coiled Pin allows it to flex and absorb impact preventing premature damage to the hole wall. This feature means the quality of the hinge is maintained throughout the life of the product, preventing the lid from flopping open and spilling the contents. In the end, the cosmetic company got a product that created a seamless experience for the user where the lid opened and closed smoothly and stayed securely in place. Overall, the company was able to solve its squeaking problem with minor permanent adjustments and save costs as well. Manufacturing Efficiency The use of the SPIROL Series 550 Cosmetic Coiled Pins simplified the design and manufacturing process. For example, the low insertion force and compression of the pin during installation minimized hinge stress and scrap. SPIROL had designed a pin installation system Model HC Horizontal Dual Pin Inserter to dramatically increase production efficiency with minimal operator training. The Inserter is lightweight and portable for ease of use and flexibility. The cylinder/driving head modules can be moved in and out with ease, and fixture changes are simple, which enables quick conversion from one assembly to another. Pins are delivered automatically to the installation site, eliminating the need for the operator to touch them during the assembly operation. For more information, visit SPIROL . Read more consumer-related articles >>> Top image from CreativeCommons.com . 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