The first event occurred just before Christmas in 1924, when representatives of light bulb manufacturers met in Geneva, Switzerland. This international group formed something called the Phoebus cartel to control the global light bulb market. Among other issues, the cartel was concerned about the longevity of their products; at the time, household light bulbs lasted an average of 1,500 to 2,000 hours before they needed to be replaced.

This lengthy lifespan benefited consumers but was a drag on new sales. So, the cartel devised a scheme to develop shorter-lasting bulbs, then poured money into R&D to make this goal a reality. By altering the filament and other technical interventions, the lifespan of household light bulbs was reduced to about 1,000 hours. The Phoebus cartel eventually fell apart, but its signature achievement remained a crucial step in the move toward planned obsolescence.

Planned obsolescence received another boost in the later years of the 1920s as a way to address a crisis in the American automotive industry. While the car had proven to be an overwhelming success, vehicle manufacturers were worried about market oversaturation. Many drivers were content to stick with one car for years on end before buying another.

To goose sales, Alfred Sloan, CEO of General Motors, came up with an ingenious idea. Instead of launching a brand-new car each year—a move that would have been prohibitively expensive—GM introduced the notion of an “annual model change.” Automotive manufacturers would tweak their lineup each year, adding new colours, enhancements, and other features to existing vehicles. Many of these modifications were minor, but it didn’t matter; the objective was to make old models seem hopelessly passé. The plan worked, and buying the latest model each year, even if your current car worked fine, became seen as a marker of wealth.

These examples highlight the different types of planned obsolescence. There is manufactured obsolescence (products are deliberately produced using materials with a limited lifespan), systemic or technical obsolescence (upgrades are introduced that render older products useless), and stylistic obsolescence (consumers are told they will be uncool and out of touch if they don’t buy the latest and greatest version of an already available product).

If the light bulb conspiracy exemplified manufactured obsolescence, systemic obsolescence is commonplace in the consumer electronics industry. Think of software updates that aren’t compatible with older computers and laptops, or electronics with parts that can’t be replaced. Stylistic obsolescence is rampant in the smartphone industry, where small changes are irresistible to tech enthusiasts who want to stay ahead of the curve.

Planned obsolescence keeps consumers buying, which in turn is good for the economy. On the downside, the need to constantly buy new goods results in mountains of cast-off electronics, clothes, household items, cars, and other consumer wares.

Other issues abound. Manufacturing frequently involves the use of what are called “conflict minerals,” minerals commonly found in regions wracked by war, poverty, and abusive governments. Some of the gold, tin, and tungsten used in electronics and other goods is mined in the Democratic Republic of Congo, which has been embroiled in extremely violent civil warfare for decades.

The constant churn of new consumer purchases also prolongs economic abuses in developing nations. Many electronic products and other products subject to planned obsolescence are produced in low-cost overseas nations. As long as demand for brand-new items remains strong, miserable working conditions will prevail in such locales.

The profligacy inherent in planned obsolescence has produced a large backlash, as evidenced by the rise of the “right to repair” movement. Consumers are demanding information on how to fix electronics and other manufactured goods, and leaning into a trend called “BIFL.”

“BIFL stands for Buy It For Life, and the acronym encompasses both an approach to shopping as well as a description of products that are designed and manufactured to last a lifetime. Buy It For Life items can last the life of the owner or the accepted life of the product, or they might come with an ironclad warranty such that you won’t have to purchase the item ever again,” explains Roxanne Dawson in a February, 2024 article in Forbes magazine.

The BIFL movement is being spurred by consumer self-interest and concern for both the environment and global economic disparity. Purchasing long-lasting products is a good way to limit the amount of consumer goods in landfill, the need for conflict minerals, and exploitative, low-cost, offshore manufacturing practices.

While Buy It For Life has become a new buzz phrase, the movement has very old roots. Prior to the Industrial Revolution, pretty much all consumer goods were BIFL. Peasants who bought shoes from a cobbler could be expected to keep them for years, mending them when necessary. Even if they paid for repairs, keeping footwear for long periods was more affordable than tossing out old shoes and buying new ones constantly.

There are two major drawbacks to Buy It For Life wares: they are generally more expensive than conventional consumer goods and harder to find. If you do a comparative analysis, however, buying a single pricey item might be less expensive over the long run than having to purchase the same item multiple times at a lower price.

As for availability, major media outlets such as Forbes, Wired magazine, and the New York Times have all compiled lists of recommended BIFL products and the companies that make them.

The Forbes list includes Merino wool socks from a firm called Darn Tough, which are ideal for hikers but can be used by anyone fed up with constantly buying replacement socks due to rips, tears, and holes.

In terms of kitchenware, Forbes recommends the Field Company No. 8 Cast Iron Skillet, a pan that the makers claim will last for decades, and the Le Creuset Dutch oven. The latter features enamel coating and requires some care, as it needs to be washed by hand and you’re not supposed to use metal utensils with it. On the plus side, it offers longevity and reliability.

The list from Wired, published in February 2025, includes the Shun Cutlery Sora 8-Inch Chef’s Knife (the contributor who posted this product sharpens it twice a year), the HMPLL Whetstone Kit (a set of whetstones to keep kitchen knives in peak cutting condition), and a Sonder Los Angeles Walnut End-Grain Cutting Board for slicing, which is less likely to warp than other versions.

Wired also recommends the Dualit Classic 2 or 4-Slice NewGen Toaster (originally designed for commercial kitchens, these hand-assembled toasters are extremely reliable and hardy) and the Weber Original Kettle 18-Inch Charcoal Grill, a simple design with tub, ash catcher, metal legs, and plastic wheels that lasts for ages if kept covered or stored in a garage when not in use.

Birkenstocks are also featured on the Wired list. While these slip-on sandals are frequently mocked as hippie footwear, Birkenstocks are actually very durable if kept in good condition with water and stain repellent, cleaning solution, and similar care.

Interestingly, Wired also includes a few old-timey items, such as the Lamy 2000 Extra-Fine fountain pen—if you don’t mind replacing the ink, a fountain pen can last for decades, unlike disposables—and Zippo lighters. Introduced in the 1930s, Zippos became hugely popular due to their reliability. They can also last for decades if users are willing to replace the wicks and flints.

The New York Times list, published in September 2025, covers a wide swath of consumer goods, including men’s jeans. It offers two BIFL jean brands: A.P.C. New Standard dungarees, which are pure cotton and “fashionable but not trendy,” and 3sixteen CT-100x denims. The latter are made with heavyweight denim that is tough to break in but very long-lasting.

And people with home gyms might want to investigate the Rep Fitness Kettlebell, a simple set of colour-coded weights with wide handles and a lifetime warranty for U.S. and Canadian customers.

Beyond these goods, some items have always been made with BIFL in mind. High-end musical instruments, for example, can be used for decades or even centuries. Among guitarists, playing a 1959 Stratocaster or 1965 Gibson SG in excellent condition is a point of pride. The movie The Red Violin centers on a priceless instrument passed between different owners over three centuries. The violin’s age is not considered a detriment but rather an attraction.

Of course, not everything lends itself to BIFL. While buying the latest car model each year just to stay trendy might be excessive, only an expert mechanic, or someone who lives near a repair shop, would likely feel comfortable driving a 1944 Buick Roadmaster on their daily commute.

“Some categories lend themselves well to lifetime purchases: homewares, outdoor gear, and heirloom clothing came up in my research,” writes Dawson. “Other categories, like beauty products, technology, and trendy fashion, encompass products that you will likely need to replace over time for safety, utility, and comfort. As a general rule, regardless of product type or category, following the manufacturer’s care instructions will help prolong the life of the items you buy.”

Planned obsolescence was never an accident; it was a strategy, engineered in boardrooms and refined over decades to keep consumers spending. But awareness is a powerful counterforce. As the BIFL movement gains momentum, shoppers are increasingly voting with their wallets, choosing quality over novelty and durability over disposability. In the end, buying less but buying better may be one of the simplest and most consequential choices a consumer can make.

The post Built to Break, Built to Last<p class="company">The Rise of Buy-It-For-Life</p> appeared first on Manufacturing In Focus.

Arguably, the biggest new development has been the company’s initiative of pre-engineered, configured-to-order (CTO) products to complement its customized solutions.

For Grotnes, CTOs offer multiple benefits including “faster delivery times, common platforms of parts, and spare parts that can be used across different models,” explains Vice President, Jim Zielinski. That said, customer specs sometimes demand a tailored approach, which is why Grotnes will never abandon custom work. “The custom side will always be part of our business. It’s our DNA… but the organization is trying to align itself around repeatable platforms,” he says.

Grotnes continues to build machines for four main technologies: expanding, shrinking, roll forming, and spinning. Expanding processes involve shaping metal parts for pipe couplings, jet engine components, metal containers, and the like. Shrinking entails the exact opposite procedure and aims to reduce and shape parts for motor frames, conveyor rolls, and exhaust components. Roll forming involves bending hoops of metal, while spinning is a metalworking technique based on mechanical rotation. Closing tools, used to seal or close items such as pail lids or the tabs on large-size paint cans, are also becoming a growing category.

Monumental as the introduction of CTO solutions might be, there have been other big changes at Grotnes as well. For a start, the company is going through “a digital transformation” that entails “the leveraging of AI where it makes sense in the business,” says President Mike Walker.

To this end, the company will soon launch Grotnes’ AI assistant, a tool that could be compared to Amazon’s AI-enabled, voice-led personal assistant Alexa, but for internal use only. “There’s no gateway to the outside world. It’s utilizing AI’s ability to search our databases, our files, our drawings, our pdfs, to be able to respond quickly,” explains Walker. “We’re very careful right now to adopt it where it really adds value to the company… We’ve spent a significant amount of time really focusing on, ‘How does it add value and help our customers at the end?’”

It is quite the leap for a firm that traces its roots to 1898 and a decision by one Charles Grotnes to open a machine works operation in Chicago. That business initially focused on manufacturing metal rings to hold barrel staves together. The company founder and namesake invented a time-saving machine to shape and stretch these metal rings to an appropriate size, and things took off from there.

At present, Grotnes serves the oil and gas, general industry, automotive, aerospace, rigid packaging, forging, and tanks and appliances sectors. The company uses the term ‘tanks and appliances’ to characterize its work for the power distribution and appliance markets with the tanks in question being metal storage containers.

“We do metal forming machines for large tanks that are typically used for isolation transformers, so there’s the power distribution angle, and then, from the appliance standpoint, tanks for things such as water heaters, drums for washers and dryers, dishwashers, and things like that,” Zielinski explains. Over the past year, aerospace and automotive generated the most business, a pattern that is likely to hold steady in 2026, he adds.

He has noticed something of a resurgence in the market for catalytic converters, the devices that reduce harmful exhaust emissions from combustion engines. Since large, commercial trucks would require huge electric batteries, thus limiting payloads, concerns about battery size have stalled the drive toward vehicle electrification in certain sectors. With gas and diesel-powered trucks still dominating, the demand for catalytic converters remains high. This trend is good news for Grotnes, which has been a pioneer in making machines that are used in catalytic converter production.

The company has maintained its ISO 9001:2015 certification and is gearing up to get certified when the new ISO standard (9001:2026) is released later this year. As befitting an ISO-certified company, quality assurance procedures here are rigorous. The company utilizes a coordinate measuring machine and other inspection equipment to ensure that all parts are shaped and sized correctly. Completed machines are subjected to rigorous factory acceptance testing procedures at the plant. If the machine achieves these benchmarks, it gets shipped to a customer, and the system is then put through site acceptance testing at the client’s worksite to determine that everything is in perfect working order.

“ISO is a very big part of our business and really drives the quality in our organization. We embrace that in a big way, especially the continuous improvement side of it. Every employee in our organization is able to submit improvement suggestions regardless of their position in the company,” says Walker.

The advent of a configured-to-order line is further proof of the company’s commitment to continuous improvement, he continues. Offering pre-engineered solutions will enable Grotnes to “focus on a standard design and continue to refine it for our customers’ needs and bring additional value by bringing costs down and benefits up,” he explains.

Company officials are well aware that excellent equipment requires servicing and upkeep. As such, the team kicked off a preventative maintenance initiative called the Grotnes Service & Spares Club last year. Customers who join the club receive discounts on spare parts, labor, training, phone and remote support, and other maintenance measures. The overall aim is to keep client equipment in excellent condition.

At the time we last spoke, the company maintained sales and service branches in Monterrey, Mexico and Atlanta, Georgia. While the Mexican branch is still flourishing, the Atlanta operations have been relocated to Niles. This transition has drastically reduced turnaround times for some products; solutions that might have taken a month to produce and ship in Atlanta now take maybe 48 hours, according to Walker. The company continues to ship products around the world and works with European sales partners as well.

Grotnes also runs a facility called Formitt Metal Labs as well as an in-house machine shop. Formitt Labs does prototyping and feasibility testing for customers as well as research and development. Recent equipment purchases for the machine shop, meanwhile, include a lathe and a wire electric discharge machine. The company’s five-year growth strategy includes the possibility of offering machine shop services as a separate business component for customers, a strategy that would build on already existing competencies. “We have customers who are not interested in a capital purchase and just ask us to do the production for them,” notes Zielinski.

In terms of promotion, Grotnes regularly attends trade shows. Last year, the company took part in FABTECH USA in Chicago—the top conference for fabricating, finishing, welding, and metal forming in North America, as well as Fabtech Mexico in Monterrey, Mexico. It also showcased its metal forming skills at the 40^th Space Symposium, a major aerospace event which took place in Colorado Springs, Colorado in April 2025. The company has revamped its website as well, with a view to adding updates regarding its configured-to-order (CTO) offerings.

All told, roughly 43 people work at Grotnes. Beyond the requisite education levels and skills, the company seeks applicants who can think on their feet and offer creative solutions. Personnel must be prepared to pivot in the face of challenges, think outside the box, and adapt to changing circumstances since “ours is a pretty fast-paced technology business,” says Zielinski.

Current challenges include dealing with the rising cost of materials, due in part to tariffs imposed by the United States and other nations. That said, “The biggest challenge for us continues to be the ability to hire the right people, and secondary to that, finding them. Every position in our company is really a skilled position,” states Walker.

To address this issue, the company instituted a four-year apprenticeship program which blends hands-on training with classroom learning. Apprentices attend evening classes at Lake Michigan College, which is based in Benton Harbour, Michigan and has a campus in Niles. The program just graduated its first apprentice, who specialized as an electrical technician, and apprenticeships are also available for machine builders and machinists. There are ongoing discussions about expanding the program to include engineering.

For a near-term forecast, Walker circles back to CTOs and AI. “Completing our journey on the CTOs is really critical to us,” he shares. “It’s not something that’s going to happen overnight; it’s not something that’s quick, because it’s got to be right.”

As for artificial intelligence, “We’ve come up with some pretty interesting initiatives,” he says. “Three years from now, I think we’ll [have a lot] to talk about… We believe it’s going to help us tremendously.”

The post Making the Machines that Run Industry<p class="company">Grotnes</p> appeared first on Manufacturing In Focus.

“We build trailers for people who work hard. That’s our mission. That’s who we design for, that’s who we respect,” says Francis Wieler, head of Marketing.

Regardless of the industry served, the company’s trailers are used by “working professionals who rely on this equipment daily,” he adds.

Products of the highest standard
RawMaxx has recently launched a variety of new trailers as well as an advanced solution called 3D Configurator. The latter enables prospective customers to create digital trailer designs on a computer screen based on their input, while the new trailers include the G7X Series, GDX Knight, DTX Deckover Tilt, and SGX models. Wieler describes the G7X Series as “an evolution of our GTX Series.” While the GTX trailer is 102 inches wide, the G7X is narrower, at 83 inches. As such, the new G7X Series represents a more affordable option for clients looking for a trailer that is both maneuverable and compact.

Trailers in the G7X Series include the versatile Bumper Pull model, which is available in 20, 22, and 24-foot lengths and comes with a front toolbox, powder coat finish, and a gross vehicle weight rating of 14,000 pounds (the measure of the total weight of a fully-loaded trailer).

The G7X Gooseneck trailer is another model in the new G7X Series, also available in 20, 22, and 24-foot lengths with a 14,000-pound gross vehicle weight rating and front toolbox. The G7X Gooseneck trailer offers exceptional stability and is well-suited for heavy loads.

The company’s GDX lineup consists of general duty dump trailers, a category popular with contractors. The new GDX Knight trailer features 10-cubic-yard capacity, 41-degree tilt angle, and a manual tarp system. The trailer offers durability and efficiency, and loading and unloading is a cinch. The GDX Knight is designed “for crews who consistently push heavier materials or higher volumes. It has structurally reinforced walls and increased capacity,” says Wieler.

The DTX Deckover Tilt is also designed for handling heavy loads, with a GVWR of 14,000 pounds. This model boasts 17-degree tilt angle and a hoist-lift system fitted with a 5×16” cylinder for speedy and efficient loading and unloading. An upgraded version offers a gross vehicle weight rating of 20,000 pounds.

The SGX trailer, meanwhile, has a gravity-tilt design, an 8,000-pound gross vehicle weight rating, and is suitable for moving boom lifts, scissor lifts, and cherry pickers.

Some of these trailers feature the Milwaukee PACKOUT system, an innovative, modular storage setup comprising various chests, boxes, and cooler units for heavy-duty storage. Milwaukee PACKOUT “gives operators an organized space and secured tool storage placement under the trailer directly,” Wieler explains.

Quality from the start
RawMaxx was founded in Mexico in 2017 with a focus from the start on manufacturing heavy-duty steel trailers. “While the product line has expanded significantly, the core mission has remained the same: build strong, dependable trailers,” says Wieler.

Manufacturing and design work is all performed in-house aside from a few components such as axles and hydraulic systems, which are obtained from trusted outside suppliers. The company uses CNC laser cutters, press brakes, plasma cutters, and other machinery to self-perform its engineering, fabrication, welding, assembly, and finishing. “We maintain control over our production process to ensure consistency in quality,” says Wieler.

The company sells its products through an extensive dealer network—most based in the United States, with a few in Canada. While clients cannot buy directly, Wieler sees this as an advantage.

“We do not sell to end users,” he says. “This allows us to focus on manufacturing products and development. It also helps keep the price lower, because we can sell a full load to a dealer, which ensures that the customer is going to get a better price. If somebody from New York buys a trailer from us directly, the cost of shipping that one trailer is going to be more than if we ship seven or eight trailers on one load.”

People-powered service
At present, the company employs 600 people, an increase of about 40 from this time last year. The spike in personnel can be attributed to increased demand for the products in the United States.

When it comes to new hires, RawMaxx looks for people with a strong work ethic, a willingness to learn, a team mindset, a sense of accountability, and an alignment with the company’s values of integrity, hard work, expertise, innovation, and adaptability. “The culture overall here is blue collar, performance-driven, with a focus on continuous improvement and respect for the craft,” Wieler says.

The company prides itself on being “non-corporate,” he adds. There is no rigid company bureaucracy; issues are dealt with right away, and do not require months of meetings, memos, and analysis to address.

Customer support is offered via the company’s nationwide dealer network, and to this end, RawMaxx offers spare parts, replacement parts, service guidance, technical assistance, product updates, and warranties including five years for axles, three years for structural issues, and one year for paint. “If a customer has an issue, we work directly with the dealer to ensure that it’s resolved quickly and properly,” says Wieler.

In addition to its customers, the company believes in supporting charities and its workforce, with charitable endeavors including funding for a local orphanage and an overarching commitment to its nearby communities. And the RawMaxx team is happy to help fellow staff members through rough patches with financial aid or other forms of assistance. Staff members “will always stand together and support each other in times of need or when surrounding communities are in need. The entire team will rally and organize food, clothing, and financial drives. It’s part of the culture here at RawMaxx,” says Wieler.

Safety, of course, is also central to the company culture. Workers receive comprehensive safety training with established protocols in case of accidents or mishaps. Personal protective equipment including helmets, work boots, and googles, are mandatory and paid for by the company.

Making customization easy
RawMaxx has also forged a partnership with prominent automotive celebrity Dave ‘Heavy D’ Sparks, who co-starred on the reality show Diesel Brothers on the Discovery Channel. Heavy D shouts out the company’s innovative design, superior components, focus on safety, excellent customer service, wide array of products, customization, and heavy-duty construction in his glowing testimonial on the company website. Heavy D also participated in the launch of 3D Configurator at the North American Trailer Dealers Association (NATDA) 2025 show in Nashville, Tennessee and praises the solution in a company YouTube video.

3D Configurator, as mentioned, allows potential customers to view digital trailer models based on their selections regarding size, specifications, options, colors, and models. Customer input is used to add or remove details, and the ensuing image can be viewed from multiple angles, giving clients a clear sense of what they are buying. Customers “can see where every dollar is going. They can see visually what the trailer is going to look like,” states Wieler, adding that the 3D Configurator “is a tool to give as much confidence to the buyer as possible.”

The solution has earned the company industry kudos and took first place in a competition for ‘Best in Show for Services & Software’ at last year’s NATDA conference.

Facing challenges
While optimistic, Wieler is well aware of certain challenges facing the company, including volatility in the trailer sector. Underlying this volatility are rising material costs, supply chain changes, and regulatory developments. RawMaxx addresses these issues “through strong dealer and supplier relationships, in-house manufacturing control, operational efficiency, and strategic pricing adjustments. We focus on stability and long-term relationships rather than short-term reaction,” says Wieler.

Going forward, the company has plenty of new ideas, enhancements, and product concepts in the pipeline. “There’s always new stuff that comes out. We have a few engineers who consistently look at the market, look at what the needs are out there and what people are asking for. It can take months or years to refine something before we do release a new type of trailer.”

Over the next few years, Wieler also hopes to see the company strengthen its dealer network even further, continue to innovate on the digital front, and maintain its reputation for durability and integrity.

“Our goal is sustainable growth, while protecting product quality and brand reputation. That’s very important. There are a lot of people who depend on RawMaxx to make a living, whether it’s the people building the trailers or the people who depend on them to get their job done,” Wieler states. RawMaxx plans to be there, serving all of these people with quality, innovation, and integrity, for the long haul.

The post New Products, New Partnerships, and New High-Tech Solutions<p class="company">RawMaxx</p> appeared first on Manufacturing In Focus.

The paper manufacturing industry, as it is called in government records, covers everything from pulp and paper mills to companies that make paper products. Pulp mills separate cellulose fibers from other wood impurities, while paper plants form these fibers into sheets, which manufacturers then cut and shape into various wares.

The North American pulp and paper sector is both very old and very large. The first American paper mill was founded in 1690 in Pennsylvania, while the first Canadian paper mill opened its doors in Quebec in the early 1800s.

As of 2024, there were nearly 800 establishments in Canada within the pulp, paper, and paper products segments, and together, they generated over $17.2 billion in exports that year, reports Canadian Industry Statistics.

The American paper manufacturing sector, meanwhile, employed more than 350,000 people in December 2025, according to the U.S. Bureau of Labor Statistics. The overall U.S. pulp and paper market was valued at over $52 billion in 2023 by international research firm Fortune Business Insights.

Yet for all its size and success, the pulp and paper sector suffers from an image problem. Rightly or wrongly, people often associate papermaking with clear-cut forests, old-fashioned sawmills, and mills polluting water with effluent.

Such critics would be surprised at the extent to which the industry has embraced new technologies, methods, and materials. The aim is to modernize the sector while making it more eco-friendly. These are timely goals, as new opportunities beckon for pulp and paper companies even as traditional markets decline. While demand for newsprint shrinks, e-commerce has spurred a huge increase in door-to-door deliveries, which means far more packaging.

High-tech solutions for the pulp and paper sector include sensors and camera systems that track performance, collect data, monitor quality, and detect slight changes in equipment that could necessitate preventative maintenance. Remote monitoring allows staff at a pulp or paper mill to keep track of processes and machine performance even when they are not on site. An Internet of Things (IoT) network can compile input from sensors, cameras, and other tools, analyze the data, and offer suggestions for improvement. Some firms have begun to utilize IoT sensors to monitor and control the moisture of wood chips and to track raw material flow during production.

Regardless of the solutions or tools used, the prevailing message is the same: “digitalizing” pulp and paper mills can boost revenue and improve performance.

“Beyond efficiency and sustainability, the mills that embrace digitalization typically see throughput gains between five percent and 10 percent, yield improvements of up to five percentage points and significant material, chemical, and energy savings… For Canadian pulp mills, digitalization represents a high-impact, low-capital investment strategy for maintaining global competitiveness,” wrote Keijo Pyörälä in April 2025’s Digitalizing Pulp Mills in Pulp and Paper Canada magazine.

Going forward, the advent of Artificial Intelligence (AI) could add a whole new dimension to pulp and paper production by offering enhanced solutions, suggestions, and historical examples.

Robotic systems are also becoming more common within the paper industry. Robots are particularly well suited for repetitive jobs such as monitoring quality, product handling, palletizing, depalletizing, and unloading rolls of paper. Using robotics in this manner can improve efficiency, boost safety by removing the need for humans to work around massive rolls of paper, and cut costs.

If robots are a useful addition when it comes to paper production, some companies are looking to add a dash of electronics to paper itself. “Smart paper,” as it has been dubbed, consists of paper with embedded lightweight radio-frequency identification (RFID) tags. These tiny electronics can transmit and receive information, a highly useful capability for applications such as school textbooks, interactive books, or medical diagnostics.

In addition to adding technology to plants and electronics to paper, companies might want to take a closer look at their base materials. To this end, a wide array of non-wood pulps can be used to produce paper, potentially saving forests in the process. This category includes “stone paper,” which is exactly what it sounds like, paper made from 80 to 85 percent CaCO₃ (calcium carbonate, a natural compound found in some rocks). It is a niche product for now but does represent an alternative to cutting down trees and putting them through chemical-laden pulping and paper making processes.

“Not a single tree or drop of water are used to manufacture stone paper materials, nor any of the harmful acids, dyes, and bleaches otherwise required to whiten and treat pulp and paper,” says the website of BC’s Stone Paper Solutions Ltd. Stone paper production requires only a fraction of the energy needed to make traditional paper and entails a drastically smaller carbon footprint, says the company.

If stone paper seems unconventional, there are plenty of plant materials including wheat straw, flax, reed, bamboo, and hemp that can also be used to make paper. Bamboo in particular offers several advantages, as noted in a 2021 paper by Kelly Buchheit, Alternative Fibers in the Tissue and Towel Industry from Solenis LLC of Delaware: “Bamboo captures more carbon dioxide and releases more oxygen while requiring less maintenance than trees,” writes Buchheit. “Bamboo is harvested by cutting the stalk but leaving the root intact, which can reduce deforestation.”

Bamboo also lends itself well to the pulping process, a bonus for companies concerned about sustainability and efficiency. “For pulp manufacturers, bamboo is the easiest non-wood fiber to pulp, allowing for conventional chippers and similar cooking conditions to hardwood, which enables the fiber to be used in conventional continuous digesters,” notes Buchheit.

Offering a viable alternative to plastic is another way that pulp and paper companies can shine. Bags and packaging made from non-biodegradable plastics have dominated the consumer goods market for decades, causing significant ecological harm. The challenge has been to find a paper-based solution that does not get soggy and weak when wet and can hold up as well as plastics.

To this end, Dublin, Ireland-based Smurfit Kappa Group launched a Better Planet Packaging Initiative with materials substitution in mind. Smurfit’s contributions to this field include AgroPaper (sustainable and biodegradable paper made from long pine fibers that offers a suitable replacement for polyethylene), TopClip (a paper-based, 100 percent renewable replacement for plastic shrink wrap that can be used to bundle cans), and a new paper pallet wrap (a completely paper-based alternative to polyethylene stretch wrap designed to secure loads on pallets). Smurfit, listed among the top pulp and paper manufacturers in the world circa 2023, has since merged WestRock of Atlanta, Georgia to become Smurfit WestRock.

Other developments that could push the pulp and paper industry forward include “dissolving pulp” (DP) and recycling. DP is a raw material gleaned from wood cellulose that can be dissolved in solvents and transformed into man-made cellulosic fibers (MMCFs) such as lyocell, viscose, and modal for textile manufacturing. MMCFs can be used as a replacement for synthetic materials such as nylon and polyester, which are derived from petroleum. DPs offer decent performance without the negative side effects associated with fossil fuels.

Of course, one of the simplest ways to go green and reduce costs at the same time is to make new paper from old paper. Manufacturers can save forests—and money—by using recycled paper instead of virgin fiber from trees. New de-inking processes, which eliminate contaminants from recycled paper, hold the promise of improving the quality of the final product.

From AI to paper with embedded electronics, automation, sensors, and wood alternatives, North America’s pulp and paper sector has multiple ways to go high-tech for a sustainable and profitable future.

The post Pulp, Paper, Progress<p class="company">Innovation Reshapes a Legacy Industry</p> appeared first on Manufacturing In Focus.

While such components have been around since the 19^th century, the company has a very modern mindset, as evidenced by its flexibility, creativity, and unique four-day workweek.

“Our products power the systems that everybody uses. Without transformers and inductors, you don’t have electronic devices or electricity to feed them,” notes President and Engineering Manager, Tom Bresele, P.Eng.

The Region of Waterloo is host to two universities, one of which, the University of Waterloo, is an engineering/computer science powerhouse. The area also boasts the Perimeter Institute for Theoretical Physics, a world-renowned research centre, and the company BlackBerry Limited (formerly Research in Motion), a pioneering smartphone developer. Google, Shopify, Honeywell, and OpenText all have a presence in the community.

Against this state-of-the-art technology backdrop, Electronic Craftsmen continues to thrive. In addition to producing quality products, it has endured by offering stellar client support and a spirit of humility.

“We have a very talented engineering team whose main focus is custom design,” shares Vice President of Finance, Kathy Hastie. “That seems to attract some of those niche markets that need the extra attention,” she says, adding that they “take the time to get to know our customers and what their specific objectives are. We take the opportunity to ensure that customer service is at the forefront of what we do. We’re in the tech centre of Canada, being in Waterloo, but we’re not a new technology. This kind of technology has been around since electricity distribution.”

Old-fashioned as the company’s products may be, the team is “always willing to adapt to the changing marketplace,” says Bresele. Electronic Craftsmen’s design work is all self-performed, with a company database containing thousands of unique designs for inductors and transformers. And even though the firm’s heritage dates back decades, it remains open to new concepts and ideas. “We’re always making new transformers and new inductors for new applications,” states Bresele.

In practise, this means taking a hybrid approach to manufacturing. Some of the company’s high-volume parts are made in China, while more complex components are produced in Waterloo, where it maintains an in-house machine shop that produces custom moulds and parts. Electronic Craftsmen can perform winding, soldering, and coil assembly, among other services, and can custom-grind ferrite to tolerances of 0.001 inches (a ceramic material commonly used in electronics magnetics).

The company sells its products across multiple sectors, with the aircraft parts and industrial controls markets generating the most business activity. Other sectors served include water treatment systems, induction heating, conventional and LED lighting, airport security, rail transportation power systems, and naval sonar systems.

As the company name implies, craftsmanship is central to everything it does. In the past, Electronic Craftsmen followed the Canadian Standards Association Z299 quality assurance guidelines. An ISO 9000 precursor, Z299 certification denoted an ability to achieve rigorous quality assurance benchmarks. Today, Electronic Craftsmen is an ISO 9001 and AS9100 registered operation, the latter being an aerospace standard.

Quality Manager, Otilia Vandici, M. Eng., ensures that standards are upheld and that the company stays up-to-date on regulatory changes and new quality assurance requirements. It undergoes a survey audit each year and a full audit every three years. Vandici “does a great job of making sure we’re adhering to and implementing the evolving quality standards,” notes Hastie.

The company was established in 1956 by Hugh Watt, whose last name seems entirely appropriate for the founder of an electronics company. Over time, there have been ownership changes and tweaks to the company name which was, for a while, called E Craftsmen; no matter the name, however, the importance of maintaining good workplace relationships has been a constant throughout the company’s history. “We really appreciate the employees we have,” says Hastie. “We take pride in the longevity of our team at Electronic Craftsmen. Many of our employees have been with us for more than 30 years, with some surpassing 40 years of service.”

Electronic Craftsmen’s personnel—a team of 48 at present—enjoy some unusual perks such as a four-day workweek, a workplace benefit that stems from the company’s experience during the recent COVID pandemic. Even though the company stayed open as it was deemed essential in building parts for medical test equipment, management was concerned about COVID’s impact on its employees. Many other businesses had been closed by government order or had switched to remote work, making day-to-day life difficult. “We wanted to give our staff a little extra time to get out, get their groceries, while staying safe. So, we decided to close our doors on Wednesdays for our team to have an extra day,” explains Hastie.

The concept went over so well, high-level discussions were had about making the temporary measure permanent. Fueling these discussions was research about the positive benefits of a four-day workweek in the Netherlands. A decision was made to approach staff with an intriguing proposal based on their existing work schedules: employees enjoyed two paid 15-minute breaks a day, plus an unpaid lunch. “We asked for our team’s input and support. We needed to ensure that the change would benefit our employees without compromising our quality standards or customers expectations,” recalls Hastie.

Team members responded enthusiastically and a temporary measure instituted during a pandemic became standard company policy. Staff who perform their usual 32 hours of work a week do not have to come in on Fridays but still get paid for the time off. “We call it a bonus day,” she says. The company’s adoption of the four-day workweek is further proof of its flexibility and concern for its workforce.

The company received a huge promotional boost in 2019 when it was featured on the Discovery Channel’s How It’s Made show. Filmed in its facility at 73 Schaefer St. in Waterloo, the episode offered a step-by-step description of the inductor manufacturing process. Beyond this, promotion largely consists of word-of-mouth referrals from satisfied customers. In part because the company has been around so long and has such a good reputation, Electronic Craftsmen has a sizeable share of repeat customers, and universities around the world frequently contract it for various goods.

“We make parts, even one-offs, for research and development for University projects, and when those graduates go out in the field, they remember the company that made this one-off and we get repeat business that way,” explains Bresele.

When it comes to challenges, Electronic Craftsmen faces many of the same issues affecting other manufacturers across Canada. These include an aging workforce since, just as skilled industrial workers tend to skew older, young people are not flocking to apply for transformer and inductor jobs. Tariffs imposed by the United States on a variety of goods have also proven to be a major obstacle. The company is “taking a measured approach as it awaits further updates on export taxes,” says Hastie.

Most parts made at the Waterloo facility are CUSMA-compliant (the Canada-United States-Mexico Agreement being the latest iteration of a North American free trade pact). While this is helpful, many of the company’s customers are also reeling from international tariffs, adding to woes. For all that, Electronic Craftsmen remains “a Canadian-controlled, private corporation,” that serves an incredibly important function, notes Bresele with pride.

Staff members are optimistic and point out that new hires who do come on board are often familiar with cutting-edge technology, which bodes well for the future. Going forward, “I think we’re going to see a change in our staff, of course,” Hastie shares. “As some of our workforce considers retirement, we are focusing on attracting the younger generations to bring their new ideas and skillset into the industry. We’re going to see some interesting changes in the next five years.”

There are no plans, however, to allow robots and AI-controlled computers to run this venerable electronics firm. Bresele concludes: “As technology changes, we will adapt to use the tools to aid and design but manufacturing will remain hands-on here because of the custom work we do.”

The post Old-fashioned Technology with a Modern Twist<p class="company">Electronic Craftsmen </p> appeared first on Manufacturing In Focus.

Lighter weights are usually attained by swapping heavy parts for lighter ones, using fewer components, and optimizing designs. The first method comes with a serious caveat: materials for airplanes and cars need to be rugged, tough, and resistant to corrosion. A tinfoil plane or car would certainly be lightweight but hardly practical or safe.

Given this, automotive and aerospace manufacturers often use composites for lightweighting. Composites are created by blending materials to produce a strengthened hybrid material. Concrete—a mix of cement, water, gravel, and sand—and plywood—created by affixing multiple layers of thinly cut wood together—are examples of composites used in daily life.

In automotive and aerospace circles, fiberglass—polymer resin mixed with glass fiber—and carbon fiber reinforced polymer (CFRP) are commonly used composites. The latter is particularly prized for its strength and is several times stronger than most metals while being significantly lighter. Metal and plastic decorative vehicle parts can be substituted with components made from polyurethane foam. Aluminum alloys, magnesium alloys, and steel alloys are also popular in automotive and aerospace.

Composites are typically used in tail and wing sections, fuselages, and interior components in airplanes, says “Materials Matter: The Science of Lightweighting in Aerospace,” a September 12, 2024 article in Quality magazine.

During World War II, the de Havilland Mosquito, a British plane made partly with laminated wood, was one of the first aircraft to feature the widespread use of composites. After the war, aerospace mogul Howard Hughes spearheaded development of the H-4 Hercules flying boat, aka “the Spruce Goose.” An enormous, eight-propeller transport plane, the Spruce Goose featured thin, laminated layers of birch. While the Spruce Goose was not lightweight and never entered commercial production, it pointed the way forward in terms of innovative use of composites.

Skip ahead to 2009, and the Boeing Corporation of Chicago introduced the pioneering 787 Dreamliner, a passenger jet with a structure comprised of 50 percent composite material. “The 787 Dreamliner was the first commercial passenger aircraft designed with advanced composite materials in the wing, fuselage, and empennage primary structure,” states the Hexcel Corporation from Connecticut, which provided advanced composite materials for the aircraft.

By utilizing CFRP among other composite materials, Boeing reduced the weight of the 787 Dreamliner by one-fifth compared to a typical plane. Hexcel provided advanced composites for other Boeing passenger jets such as the 737 MAX and 777X.

In 2013, Airbus of France introduced a composite-containing plane of its own, the A350 XWB passenger jet. Once again, almost half, by weight, of the A350 XWB consisted of composite material. Airbus aims to produce zero-emission commercial planes in the near future, a challenging goal that will almost certainly require greater use of composite materials.

Composites have also been featured in spacecraft, which makes sense given that anything sent into outer space needs to be both ultra-low weight and extremely fuel-efficient. Unlike airplanes, spacecraft cannot make emergency landings if they run low on fuel due to unforeseen circumstances.

“Composites have been used in space applications for decades and their use continues to grow. Composite applications can be found in human spaceflight vehicles, satellites, and payloads, and the launch vehicles that are used to get these to space,” according to the Society for the Advancement of Material and Process Engineering (SAMPE), adding that, “Solid rocket motors and pressure vessels for fuel and gas storage are typically reinforced with composites.”

Composites are “the standard for ablative and other high-temperature components in rocket motor nozzles and re-entry heat shields dating back to the Apollo era,” the society continues. High-modulus, carbon-fiber-reinforced laminates are commonly used on spacecraft while carbon fiber laminates are commonly used on payload support structures and satellites.

In the automotive sector, General Motors was one of the first domestic manufacturers to use composites in a major way. The 1950s-era Chevrolet Corvette was built with fiberglass body panels, a pioneering move at a time when such parts were usually made from steel. During the 1970s, the Organization of Petroleum Exporting Countries imposed tighter controls of oil exports, causing gas prices to skyrocket and spurring further interest in lightweighting.

“Replacing heavy steel components with materials such as high-strength steel, aluminum, or glass fiber-reinforced polymer composites can decrease component weight by 10 to 60 percent,” notes a U.S. Department of Energy report. “A 10 percent reduction in vehicle weight can result in a six to eight percent fuel economy improvement.”

In 2015, the Ford Motor Company became a lightweighting leader when it used aluminum instead of steel in the body of its F-150 pickup truck. Switching to aluminum reduced the truck’s overall weight by roughly 700 pounds. The F-150 proved enormously popular and Ford used aluminum on subsequent models such as the F-150 Lightning, a fully electric pickup truck.

Two years after the groundbreaking F-150 model was introduced, Fiat Chrysler used magnesium to lightweight its Pacifica minivan. GM’s Sierra pickup truck for 2019, meanwhile, boasted a CarbonPro truck bed made from advanced carbon fiber/thermoplastic composites.

In addition to being more fuel-efficient, such vehicles “can carry additional advanced emission control systems, safety devices, and integrated electronic systems without increasing the overall weight of the vehicle,” notes the Department of Energy report. Lightweighting is particularly beneficial for offsetting the weight of heavy batteries and motors in hybrid and electric vehicles, adds the Department of Energy.

Optimizing design is another way to lightweight planes and cars. The general concept is to use advanced technologies such as computer-assisted design (CAD) software to enhance existing designs or create new designs that emphasize lower weight. Custom molding can also be part of the process. “Rather than machining a sheet stock or block into the component’s shape, a custom tool is designed to mold the part from a lightweight material,” reads “How Light Can You Go?” a technical paper from General Plastics Manufacturing Company of Tacoma, Washington.

Thermoforming is another factory-floor method applicable to lightweighting. “This drape or mold forming process is easy to use and ideal for shaping shallow slopes and angles where machining would be more wasteful or time consuming,” states the paper.

A final method is to simply use fewer components. “As production processes and materials evolve, components can often be removed from assemblies entirely, while still meeting structural, flammability, and thermal requirements,” notes a May 9, 2022, blog post titled “What is Lightweighting and Why is it Important?” from the Boyd Corp, a firm that specializes in thermal solutions and sustainable engineered material.

Additive manufacturing will likely prove to be a wildcard within lightweighting circles. For aerospace production, the benefits of using 3D printing and advanced manufacturing techniques include design freedom where “engineers can create parts with complex geometries without sacrificing precision or increasing waste,” says Axiom Materials, Inc. of California. Other benefits include weight reduction and rapid prototyping. “Because prototypes can be manufactured more quickly, the entire design and testing process moves along at a faster pace,” says Axiom. Many of these points can apply to automotive manufacturing as well.

Still, 3D printing is slow compared to traditional production processes and is typically reserved for making spare parts or speciality items rather than mass-producing parts at this time.

While much of the focus on lightweighting concerns airplanes and automobiles, other manufacturers are also embracing the trend. “In the consumer electronics and medical industries, lowering the weight of a wearable or handheld device can enhance user comfort, extend the amount of time between recharging, and reduce shipping costs,” notes the Boyd Corp report.

For all that, automotive and airplane makers have a vested interest in creating lighter but durable versions of their vehicles and planes, and to this end, researchers continue to explore the use of new composites and other lightweight materials.

Growing environmental awareness among the public will likely hasten the move toward lightweighting. Manufacturers are eager to position themselves as green, and reducing fuel consumption by reducing weight is a good way to go about this. Government fuel mileage mandates are another spur, while advances in technology are making it easier to develop lightweight-friendly designs.

“Advanced software tools, incorporating techniques like topology optimization, artificial intelligence (AI), and machine learning (ML), enable engineers to design lighter and stronger components by removing excess material while maintaining structural integrity,” notes Materials Matter: The Science of Lightweighting in Aerospace. “AI and ML can analyze vast amounts of data to identify optimal design parameters, predict performance outcomes, and continuously improve design efficiency.”

The post Lightweighting<p class="company">The Art of Making Tough, Durable, Low-Weight Cars and Planes</p> appeared first on Manufacturing In Focus.

Terradyne Armored Vehicles was originally launched in 2011 as a segment of Canadian auto parts giant Magna International. The company, which focused on armored vehicle production from the beginning, was spun off as a standalone entity in 2014, and last year marked its eleventh anniversary as an independent business.

Terradyne offers four main models under its Gurkha line, named after the famously tough soldiers from Nepal who have fought for Great Britain since the 19^th century. These models consist of a light armored patrol vehicle (Gurkha LAPV) which weighs 16,000 pounds (7,258 kilograms) and measures 6,116.9 mm x 2,454.2 mm x 2,645.6 mm; a rapid patrol vehicle (Gurkha RPV) weighing 15,500 pounds (7,031 kilograms) and measuring 6,207.5 mm x 2,454.2 mm x 2,499.2 mm; and a multi-purpose vehicle (Terradyne MPV) weighing 16,500 pounds (7,484 kilograms) and measuring 6,356.8 mm x 2,454.2 mm x 2,633.9 mm.

The company’s fourth model is a civilian limited-edition vehicle (Gurkha CIV) that weighs up to 13,500 pounds (6,123 kilograms) and is 6,207.5 mm long x 2,454.2 mm wide x 2,499.2 mm high.

The biggest change at the company since we last spoke in August 2024 has been the release of “a new variant of an existing model,” shares Sales Manager Lucus Witzke. The new variant represents “a first for Terradyne—an armored vehicle for law enforcement specific to EOD, which stands for Explosive Ordnance Disposal,” he explains.

The MPV FORT (Forward Ordnance Response Team) EOD recently made for the City of Tampa, Florida was a variation of the MPV for law enforcement, and will be used by a police bomb squad, Witzke says. The purchase was part of a two-vehicle deal, with the other being a standard law enforcement model. “We have delivered it and are now marketing it to other law enforcement agencies,” he says.

In addition to the FORT EOD, Terradyne has also tweaked another model to create a tactical emergency medical services (TEMS) vehicle which is “basically an armored ambulance,” Witzke says. The TEMS vehicle is also being marketed to law enforcement clients.

These models are built on Ford F-550 Super Duty truck frames and are fitted with a 10-speed automatic transmission, 4×4 shift on the fly, and V8 turbo diesel engines. “We use the Ford F-550 chassis for all Gurkha models, so we are limited to what direction Ford goes in. From what I’ve heard… for the Super Duty lineup, there are no electric or hybrid engines in the forecast,” Witzke says. Fuel capacity for all four models is 40 gallons (151 litres), and each model is equipped with a four-wheel vented disc anti-lock braking system.

All models save the CIV feature armor plating (with the armoring available as an option on the civilian model as well). The CIV is the only Terradyne vehicle that is available to the public at present. This is a brawny, dark machine that would definitely make an impression on city streets.

Witzke cites the materials that go into the company’s vehicles and its customer support as Terradyne’s points of difference in the market. Technical specifications state that armor plating on the LAPV, MPV, and RPV warrants a B7/STANAG 2 rating, a military standard set by the North Atlantic Treaty Organization (NATO). And Gurkha vehicles are subjected to intensive third-party testing involving live ammunition and explosive blasts.

Terradyne does not claim its vehicles are completely bullet- and bomb-proof, but simply well-protected against such threats. Plating on the LAPV, MPV, and RPV is fairly light as far as armor goes, and in addition to being well-fortified, Gurkha vehicles are relatively quick, which is an important factor when conducting police raids or rescuing wounded soldiers under fire. The wheels on Gurkha vehicles feature special inserts that keep the tires in workable condition even after they have been punctured by bullets or shrapnel, while the windshield glass is also tough and resilient in the face of gunfire.

In addition to producing top-of-the-line machines, Terradyne works hard to serve its clients. The company maintains a steady supply of spare parts and tires and can manufacture replacement components upon request. It is receptive to customer feedback and can customize its basic product line, as evidenced by the FORT EOD vehicle. “Something we’ve learned over the years is our customer service apparently is next-level compared to our competitors, so that has given us an advantage,” notes Witzke.

Design and manufacturing duties are handled in-house, with Terradyne employing roughly 50 people and producing around 100 vehicles each year. Each armored car takes between 20 and 24 weeks to complete—which seems a long time until you consider the standards each vehicle needs to meet. Not every truck on the road is designed to withstand a barrage of bullets or a grenade attack.

Gurkha vehicles are sold either through dealers or direct to customers, and the company’s most popular vehicle varies from year to year. For 2025, the MPV proved to be the most in-demand model, says Witzke.

Certainly, Terradyne takes pride in all its high-quality vehicles and holds both ISO 9000 and 14000 certification. It is also registered with the Controlled Goods Program, an initiative run by the Canadian government. Thanks to this registration, Terradyne is authorized to export its military-style vehicles.

Back in Canada, Terradyne is among a handful of qualified potential suppliers for a Canadian Armed Forces light utility vehicle (LUV) replacement initiative. Ottawa intends to spend up to $1 billion on a new “protected, lightweight, multi-role, and highly-mobile ground wheeled vehicle,” states the website of the Canadian Defence Review, a military journal.

Between 2,000 and 2,200 replacement vehicles are needed in total, “with up to four variants: command and reconnaissance vehicle; utility vehicle; military police vehicle; and cable-laying vehicle,” says the journal. The program also involves “ancillary equipment, integrated logistics support (ILS), and an in-service support solution.”

To be sure, Terradyne has a good shot at winning work with the LUV program, due in part to the amount of Canadian content that goes into its Gurkha line, says Witzke.

The company is also excited to be participating in the World Defense Show in Riyadh, Saudi Arabia in early 2026. This will be the first time Terradyne has attended this event. “There are a lot of Terradyne vehicles operating in the Middle East as of today,” Witzke says. “Other opportunities might be there. Our end-goal is to expand our presence from what we already have there.”

When it comes to promotion, the company relies heavily on trade shows to highlight its products. “We’re very particular,” says Witzke. “We do some print advertising with law enforcement in the U.S. and Canada, but a lot of [our promotional efforts] are trade shows. We find it’s a lot more effective to physically get a vehicle in front of somebody, as opposed to sending pictures.”

As for challenges, he cites tariffs and “increased prices in the supply chains.” The most consistent challenge, however, is simply the nature of the armored car business. “The sales cycle is very long; it’s a big-ticket item. There are a lot of hurdles that need to be overcome in that process.”

Going forward, Terradyne wants to stay in Newmarket and produce more armored cars from its core lineup in addition to interesting variants, such as the FORT EOD and TEMS vehicles. Witzke anticipates “further expansion of our footprint in key areas: Canada, the United States, Europe, and the Middle East,” while the company continues to hone its expertise.

In the early days, “we were the new kids on the block that nobody had ever heard of,” he says, adding that the client base “is a very tight-knit group, especially in law enforcement. They talk with each other and share reviews of what equipment is good. It takes a very long time to develop a reputation.” Terradyne Armored Vehicles is well on its way.

The post Specialty Vehicles for Specialized Situations<p class="company">Terradyne Armored Vehicles</p> appeared first on Manufacturing In Focus.

LasX’s new PhotonX Lab, which opened in September 2024 at its headquarters, is intended to be a research and development hub for rapid, intelligent laser materials processing. To this end, the space boasts a variety of equipment including short-pulse infrared (IR) and ultraviolet (UV) lasers, high-power ultrashort pulse IR and green lasers, high-speed scanners, motion control, and low and high-powered carbon dioxide lasers, among other gear.

“PhotonX enables our engineers and customers to collaborate closely on next-generation applications across packaging, medical and life sciences, and aerospace and defense. The goal is simple: provide a space where new ideas can be proven quickly, evaluated rigorously, and scaled efficiently,” explains LasX President Ryan Falch.

The lab will enhance LasX’s ability to prototype, then test and validate various laser processes to reduce risk for customers, speed the passage of breakthrough products to market, and upgrade manufacturing performance, he adds.

There is no shortage of other developments beyond the PhotonX Lab. Probably the biggest single change since we last spoke in September 2023 for Manufacturing in Focus is “the expansion of our laser materials processing capabilities through the introduction of new LasX equipment platforms,” says Senior Development and Engineering Manager Ethan Dinauer, son of company Chief Executive Officer and Co-founder William Dinauer. “Over the past year, we have added near-IR, green, and UV laser technologies with nano-, pico-, and femtosecond pulse durations, delivering higher precision, faster processing speeds, and improved material compatibility,” he explains.

These changes have enabled LasX to deliver cleaner edges, tighter tolerances, more robust turnkey systems, and improved multi-material processing.

LasX’s new equipment platforms are designed to support three of the company’s main markets: fast-moving consumer goods (FMCG) and packaging—a category that includes everything from packaged foods and beverages to soap, shampoo, and toothpaste—medical and life sciences, and aerospace and defense.

While the company also serves the graphic arts, textiles, and automotive sectors, the three segments cited above “offer the highest growth rates… FMCG and packaging continues to represent a significant growth engine, driven by the demand for atmospheric control, easy-open features, mono-material packaging solutions, and direct-to-package laser marking,” Falch tells us.

For the packaging segment, he points to the new LaserSharp® Marking solution, unveiled in November 2024. Developed in partnership with consumer products giant Procter and Gamble, the LaserSharp Marking system offers multiple benefits: consistent, top-quality results even during high-speed production; design flexibility, even in areas that can be hard to reach; permanent, high-resolution surface marking; and a digital configuration that offers maximum agility in response to changing graphics and text.

LaserSharp Marking is also ecofriendly since it doesn’t use traditional shrink label and pressure-sensitive adhesive (PSA) materials, inks, or anything else typically utilized for label applications. LaserSharp Marking can thus reduce waste while bolstering clients’ sustainability initiatives, which is all the more reason why LasX is confident that the system will be a success.

“Within packaging, LaserSharp Marking is positioned to become one of the most dominant application categories in 2026, supported by major brand-owner initiatives around sustainable printing, variable data, and inkless marking,” Falch explains.

At the time of our previous feature, the company was gearing up for the launch of the Proton λ laser process controller (the second part of the product’s name refers to “Lambda,” a letter in the Greek alphabet). The controller has since been launched and proven to be highly successful, offering high-speed laser processing and superb resolution, and facilitating new raster applications (a type of pixel-based laser marking). Proton λ also provides fast laser marking (a process that places indelible images on materials) and can be incorporated into the company’s existing laser equipment lineup. “Since the introduction of the Proton λ controller, we have continued to strengthen our LaserSharp process control ecosystem,” Falch notes.

The company has also expanded “its portfolio of equipment platforms,” he continues. “These platforms serve as starting points for application-specific solutions across scoring, perforating, micro-machining, laser marking, and surface modification.”

These achievements are somewhat par for the course for a company that has been ahead of the curve for decades. LasX was founded in 1998 to fill a perceived gap in the manufacturing sector: “the lack of a flexible modular option for laser material processing” as the company’s website puts it. A year after LasX launched, it began to design and build industrial laser processing modules (LPMs), which are critical for processing flexible materials. LasX’s LaserSharp® Processing Module is key to its materials processing capability, along with intuitive LightGuide operator software.

Recent “software enhancements in LightGuide have improved recipe control, diagnostics, and integration with automation and vision systems,” Falch points out.

In 2022, LasX released a machine platform called FreshFocus, a pioneering laser system that perforated and laser scored packaging to make it both breathable and easy to open. Breathable food packaging has tiny holes that allow in oxygen, extending shelf life.

In 2012, LasX established a life sciences group with ISO 13485 certification. The group has full-service contract development and manufacturing organization, currently focused on applications involving thin-film laser converting and microfluidic technology.

Earlier this year, LasX announced it had made significant microfluidic modifications to biosensor electrodes produced by global medical equipment manufacturer, Linxens Healthcare. The modifications were intended to “enhance the functionality of our electrodes, enabling real-time continuous blood parameter measurements and expanding diagnostic possibilities,” explained Linxens in an article posted on the LasX website.

And LasX’s European branch, founded in 2016 and based in Germany, continues to thrive. “LasX has strengthened its European engagement by adding Clive Jacobs, Director of Global Strategic Partnerships, to lead key account development across the region,” says William Dinauer. “Clive works closely with our European Solutions Engineer, Hendrik Kleinfeldt, to support both the FMCG and packaging markets with a particular focus on our LaserSharp Marking initiatives.”

For LasX, leading-edge solutions are only part of the equation. The company has long emphasized the importance of excellent customer service. Among other measures, its ClearCut® service program offers a lifetime of enhanced customer support in the form of training, remote assistance, discounts on labor and parts, equipment performance checks, and upgrades to software. The benefits of ClearCut include optimized performance, avoiding unpleasant surprises through preventive maintenance, accelerated training, software upgrades, and a comprehensive maintenance plan.

Plans are afoot to make ClearCut even bigger and better. “Soon, we intend to expand the ClearCut program to offer on-site process support to help customers optimize recipes, validate materials, and accelerate production readiness and on-site and virtual operator training, allowing teams to become fully proficient faster,” says Falch.

LasX also offers a global solutions team made up of experts who assist clients in various ways. Sometimes, this assistance is focused on a specific project involving laser material processing or new manufacturing methods. Other times, the collaboration is broader-based and involves large firms that need outside help because their own internal development teams do not have the laser expertise.

The team is highly active and on an expanded mission. “The team now operates within a more focused execution model, aligning resources to our primary markets and adding new business development personnel to ensure we remain deeply connected to customer needs,” says Ethan Dinauer. “The global solutions team strengthens responsiveness, improves cross-functional collaboration, and ensures that every customer benefits from experts who understand both their industry and their long-term production goals.”

This strong emphasis on customer support reflects the company’s determination to be more than just an industrial laser systems provider. The idea is to provide solutions, which means offering as much assistance as needed. This inclusive, far-reaching approach has helped LasX stand out from competitors.

“LasX is unique because our equipment and contract manufacturing solutions combine intelligent laser processing, turnkey automation, and precision engineering into a single, performance-guaranteed ecosystem,” states William Dinauer. “The LaserSharp Processing Module and fully integrated LasX equipment platforms are engineered around each customer’s exact application. This includes process development, system design, automated material handling, vision/SPC (statistical process control), and lifecycle support, all delivered with the high reliability required for demanding commercial production environments.” It’s a formula that has served the company well since the beginning and will continue to fuel innovations in high-performance laser materials processing.

The post A New Lab and New Opportunities for this Leading Laser Company<p class="company">LasX</p> appeared first on Manufacturing In Focus.

“Previously, we provided a relatively niche product into our market segment. Joining RAFI has dramatically increased our product offering to our customers,” says Dean Hotvet, Director of Sales and Marketing.

CEO and President Tihomir Tesic agrees. “As a small Midwest company, you’re sort of limited to what you can get out to the market.”

The company was last profiled by Manufacturing in Focus in November 2023. At the time, the merger with the RAFI Group (a world leader in electromechanical components, electronic assemblies and systems, and engineering services) had just occurred, and RAFI North America has since rebranded, retooled, and recalibrated its focus.

The team continues to work out of a 55,000-square-foot Milwaukee plant, providing services including full production, sheet-fed printing, designing and engineering, optical adhesive lamination, environmental testing, laser cutting, and more. Products made at this site include specialty circuitry and capacitive touch sensors (devices which enable fingertip manipulation of capacitive touch screens in computer tablets, smart phones, et cetera). RAFI North America also makes membrane switches, which are Human Machine Interfaces (HMI) that are used to open or close circuits when pressure is applied. Membrane switches are made by applying layers of printed film and other kinds of material.

While retaining all its existing competencies, new services and products have been added to RAFI North America’s portfolio. “We have been making internal changes to accommodate new products,” Hotvet explains. “We have brought on the assembly of some high-value products [including] ultrasound control panels. There may be 10 to 15 different parts in the bill of materials for a membrane switch; an ultrasound control panel has 400 parts in the bill of materials. It’s a dramatic change in how products flow through the plant, and we’ve had to retool some aspects of the plant for that.”

Custom work remains RAFI North America’s forte, although the company does maintain a components segment that offers off-the-shelf products, he adds.

As Xymox, the company produced solutions for the appliance, food equipment, medical equipment, gas pump, power distribution, hand-held devices, and wearables markets. RAFI North America still works in these sectors but is looking to expand into construction and agricultural equipment and off-road vehicles, among other sectors. The merger has allowed RAFI North America to tap into the knowledge and resources of its huge parent company, pushing the firm to a new level and broadening its supply base. “Within the RAFI Group, RAFI North America is now considered the center of excellence for printed electronics and related products,” says Hotvet.

In terms of suppliers, “we have a larger ability to pull from within, as we’re now part of the RAFI Group. Our vertical integration is increasing, which simplifies our supply chain,” says Tesic.

Back in Germany, the RAFI Group stands well-positioned to gain from its decision to bring Xymox Technologies into the fold. Thanks to recent trade deals and tariffs, the RAFI Group is eager to expand its manufacturing footprint in the U.S. By making products in America, the RAFI Group can be closer to its U.S. customer base while avoiding tariffs and other barriers that are making international trade an increasingly costly affair, Tesic explains.

Certainly, RAFI North America is more than up to the challenge of producing high-value products. The company is ISO 9001:2015 certified and ITAR (International Traffic in Arms Regulations) registered. (ITAR is a body of U.S. imposed rules regarding the sale and purchase of defense-related weaponry and similar products.) If all goes to plan, RAFI North America should attain ITAR certification in the near future, says Tesic.

The company has a well-documented quality assurance process for products that fall under the legacy or “Xymox side of the business,” he continues. And solutions of greater complexity such as ultrasound control panels are put through an even more comprehensive QA process that entails automation, a variety of tests, camera systems that scrutinize parts for flaws, and other forms of electronic scrutiny.

RAFI North America has around 90 employees at present, compared with 88 at the time of our previous profile. “We look for employees who have the right balance of hard and soft skills,” notes Human Resources Manager Krista Pitman. “We seek candidates who have the technical competence, relevant education, and level of experience we are looking for, paired with someone who has excellent teamwork, communication, and problem-solving skills.”

She explains, “Our culture is that of a small company with the support of a much larger company. We care about our employees, and they care about one another and our customers. This is demonstrated through daily actions that are rooted in finding the best solutions… We’re a very family-centric company,” she shares.

For all the firm’s technical prowess, RAFI North America’s success largely stems from its unique culture, Tesic adds. “At the end of the day, we can come up with the wildest ideas of how to make the product, but growth and success… is ultimately based on the morale and culture in the company.”

Indeed, RAFI North America’s values include Integrity (“Act the same when no one is watching”); Results (“Always strive for continuous improvement through achieving goals”); Service (“Treat our customers with an attitude of service”); and Employees (“A healthy business that has healthy employees teaches healthy lessons for business, personal growth, sound minds, and healthy bodies”). And the team believes that it’s also vital to maintain open communication, motivate staff, and make the workplace fun.

The company’s combination of a progressive, supportive culture and robust technical skills has not gone unnoticed. A product called SAFETY TOUCH®, produced through a RAFI Group/RAFI North America collaboration, earned industry kudos last year, being named one of OEM Off-Highway Magazine’s Top New Products of 2024 in the operator cab category. SAFETY TOUCH® also received a German Innovation Award in the Excellence in Business to Business Electronic Technologies category.

“Obviously, we’re very proud of the honor of achieving [these awards]. SAFETY TOUCH® was developed by our German colleagues,” states Hotvet.

SAFETY TOUCH® acts as a super-capacitive touch screen, offering displays and data and enabling operator input. Intended for use in construction, forestry, and agricultural machines, SAFETY TOUCH® allows operators to control machine functions via a touchscreen that normally would require separate buttons or switches. By reducing the number of switches needed in a control console, SAFETY TOUCH® makes it simpler to run machinery and helps the operator focus, reducing the odds of an accident occurring. The product has garnered an enviable Performance Level D rating (an ISO machinery-related safety level concerning risk reduction).

RAFI North America is also working on “an encoder with a programmable haptic response,” says Hotvet. The product is called Smart Haptic and utilizes haptic technology, the science of simulating tactile sensations through hardware or software. Ever set your cell phone to “vibrate” mode (causing it to shake when a call comes in) or felt and heard an alert emitted by your wearable FitBit (letting you know when a certain exercise-related benchmark has been reached)? If yes, then you’ve experienced haptic technology in action.

RAFI North America is also looking at a product it calls “a steering joystick. That is, literally, where you use a joystick to operate a vehicle. We’re also doing a lot of work with strain gauges,” says Hotvet, referring to sensors that are used to measure strain.

The company is also keeping a close eye on “megatrends” such as Electric Vehicles (EVs) and cybersecurity, he adds.

Over the next five years, RAFI North America wants to “aggressively grow the U.S. market,” become a leading supplier in the agriculture machine sector, enhance its medical offerings, and “add more value to the products we’ve already made,” says Tesic. The team is also examining the possible benefits of adding Artificial Intelligence (AI) to HMI systems, as well as opportunities posed by autonomous vehicles and equipment.

“Wherever the market goes, we feel like we can be a step ahead and offer solutions to the customer base,” says Tesic. “We really focus on how to solve people’s problems… I think where RAFI really shines is offering a solution that helps the customer at the end consolidate their suppliers, components, or process. It’s all about efficiency at the end.”

The post These HMI Specialists Rebrand, Retool, and Recalibrate<p class="company">RAFI North America</p> appeared first on Manufacturing In Focus.

The business specialized in solutions that speak to a bygone era in cinematic history, when movies were shot on celluloid film. The company made film and chemical processing equipment, drybox air systems—also called dry cabinets, storage systems to protect film and film gear from humidity and contaminants—and silver recovery cells, which are commonly used in darkrooms to recover silver elements from chemicals used to process film.

“From ’76 on, any major motion picture you’d see in the movie theatre had gone through something he had made,” states Daniel with pride. During the 1990s, moviemakers started to transition from celluloid film to digital technology and demand for celluloid film-related equipment dropped sharply.

In 2000, Valenzuela suffered a heart attack and his son-in-law stepped into the breach. At the time, Daniel was working as a Los Angeles County deputy sheriff; he was an experienced lawman but knew little about metal manufacturing. Nonetheless, the LA County Sheriff’s Department gave him a six-month leave of absence to manage the business as Valenzuela recuperated.

Few of Daniel’s policing skills were applicable to his new role, other than the ability to suss out “if employees were trying to get something over on me,” he jokes. He did, however, have a naturally inquisitive nature, a good work ethic, and an outsider’s perspective. He peppered the shop floor staff with questions and worked hard to make changes in a business that was struggling at the time.

“At the end of the six months, my wife and I decided that I would stay there and continue with the company and help make it great again. They did their best sales they ever had that year,” he recalls.

In 2004, Valenzuela closed his business and sold his equipment to Daniel and his wife Petra. The company name was tweaked from Metal Engineering, and the business was moved from an 8,000-square-foot space to the 15,500-square-foot facility it currently occupies. Petra passed away earlier this year, so the firm is now solely run by Daniel and his son Bryce, Project Manager.

At present, the company is eagerly anticipating the arrival of a special laser welding system to augment its service lineup. The order was placed after the company researched the laser welding system and found much to its liking.

“The gist of it is it welds faster than MIG welding, which right now is the fastest form of welding,” explains Bryce. “It uses more precise and direct heat than TIG welding, and it delivers full penetration in a single pass… a job that would normally take you an hour, you can do in 15 minutes without any metal fatigue.”

The system is “very easy” to learn, he continues. He expects that the leading-edge solution will arrive by December of this year.

As with most services at Metal Engineering & MFG., laser welding will be handled in-house. The company’s motto, ‘Where Craftsmanship and Technology Meet,’ reflects its devotion to technological solutions and old-fashioned skill. The company has its own machining and welding equipment and uses CAD software for planning, and, if it needs to subcontract anything out, it relies on a handful of trusted partners.

As a custom metal fabricator, Metal Engineering & MFG. often works as part of a larger team of contractors for the commercial, residential, and specialty markets. Once a project is completed, the company offers maintenance, although such services are not often needed.

“Nine times out of ten, our products don’t require any maintenance,” Bryce says. “The only time that ever happens is, say, for a water feature—if the chemicals are imbalanced and the chlorine levels are way too high, sometimes that causes stainless steel to rust. In that case, we come out and perform the maintenance and tell them what’s wrong with their water. But that’s very rare.”

Even if most modern films are made using digital technology, the company still does some work for the silver screen. The last big film the company worked on was Once Upon a Time in Hollywood, a Quentin Tarantino thriller shot on Kodak 35mm film. Tarantino’s use of old-fashioned film stock necessitated the use of old-fashioned accessories. “We made all the film reels for all the movie theatres in the nation to run the film and the traveling boxes for those films,” Bryce explains.

While Metal Engineering & MFG. does not do much movie work these days, it has developed a new niche doing metalwork for theme parks and casinos. “We get hired by contractors,” says Bryce, “and through them, we do a lot of work for theme parks. You can’t walk through one of their parks without running past products that we make.”

About a decade ago, the company did secondary metalwork at a huge theme park area. The team also contributed to a striking 39-foot-high fountain featuring three stylized sculptures of women embedded in a column rising from a base. 22,000 lbs. of stainless steel support the fountain and its sculptures, built for the lobby of the Palazzo, a high-end casino and hotel that is part of the larger Venetian Resort in Las Vegas.

“Water comes from the top, from a chalice all the way to the bottom, which is the floor below. Everything underneath is stainless steel,” Daniel says. “We do a lot of water features as part of the team that puts them together; we do the metalwork.”

Personnel levels at Metal Engineering & MFG. vary depending on the nature of projects at hand. On a big assignment, the company might use as many as 30 employees, while for most work, the firm relies on a core of roughly 12 staff members. When hiring, the company likes applicants who are “go-getters,” says Bryce. “We try to hire people who mesh well with everyone, too.”

Indeed, the company aims to cultivate a family-like atmosphere, lending out shop trucks, for example, for employees facing car problems. Employees can use the shop trucks to save on repair bills. For their part, employees are expected to be honest and focused on quality. “I tell every employee, whether they’re new or old, ‘If there’s a mistake made, don’t try to hide it. Just come up and say, ‘Hey, I messed up’ and let’s try to figure out how to fix it,’” he tells us.

In terms of quality, “I never want to hear the words, ‘It’s good enough.’ Any company can do good enough. They’re not hiring us to do good enough; they’re hiring us to do better,” adds Daniel. “We’ve got to try to make this the best that we can. If something doesn’t work right, we’ll step back and see what happened: ‘What caused this?’ Then we’ll correct it.”

In a similar fashion, Metal Engineering & MFG. takes a strict line on safety, with regular safety meetings and ample and readily available PPE.

Promotion of Metal Engineering & MFG. is largely a matter of word-of-mouth endorsements. The company does attend trade shows but primarily relies on customer referrals or general contractors hiring it back for new projects. Being that the company is still relatively small, “I would say the biggest challenge is that the industry is kind of changing—more and more companies are favoring big business, big corporations. What we’re doing to solve that problem is really focusing on our quality and our customer service,” says Bryce.

The team is also pondering the possibilities of opening an operation in Florida, perhaps in tandem with some customer operations. “We’re in talks to see if that’s a viable option,” Bryce says. And of course, the company can’t wait to start using its laser welding solution once it arrives.

Looking ahead, “We want to continue to be more of a leader in technology,” Bryce asserts. “That’s the biggest thing with metal manufacturing—integrating technology into what you’re doing and not being afraid of it, whether that’s integrating an AI model into our quoting services, laser welding, or any other new technology that’s coming up. There are a lot of new things emerging right now.”

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