That is where Estone Technology has built its position.

Estone Technology is a rugged computing ODM/OEM engineering and manufacturing partner that helps customers turn product ideas, technical requirements, and early-stage concepts into reliable, production-ready solutions. From rugged tablets and laptops to industrial panel PCs, HMIs, embedded computing systems, medical-grade platforms, and rugged control systems for robotics and autonomous applications, Estone supports customers who need computing platforms built for demanding environments.

The company’s role is not simply to provide hardware. It helps customers bridge the gap between a product vision and a deployable solution that can survive real operating conditions, integrate with larger systems, meet project-specific requirements, and remain supported throughout its lifecycle.

As Sales Engineer Jo Yee Ong explains, “Many customers come to us with a product idea, a PRD, a set of technical requirements, or a market need. Our role is to help turn that vision into a rugged computing solution that can be engineered, manufactured, certified where required, and supported in the real world.”

From computer business to rugged computing partner
Estone’s foundation began with a small computer business known as Stone Computer. In its early years, the company competed in the broader consumer computer market, where differentiation was difficult and long-term value was often limited. Over time, the team saw a stronger opportunity in specialized computing applications, where reliability, customization, engineering support, and long-term product availability mattered more than standard product availability.

That shift became the foundation for what would later become Estone Technology. After adopting the Estone name in 2008 and establishing operations in both California and Ohio, the company moved deeper into rugged computing, embedded systems, and ODM/OEM development for industrial, medical, and mission-critical applications.

Today, Estone works with customers that need computing platforms tailored to specific technical, environmental, regulatory, and operational requirements. Some customers begin with an existing rugged tablet, panel PC, HMI, embedded system, or control platform from Estone’s product portfolio and customize it for their application. Others begin with only an idea, concept drawing, product requirement document, or market opportunity, and Estone helps guide that concept toward a manufacturable product.

This flexibility has become one of the company’s defining strengths.

Moving from concept to deployment
Developing a rugged computing product is rarely as simple as selecting components and placing them inside a durable enclosure. Customers often need to consider display performance, touch functionality, processor selection, thermal design, battery life, connectivity, wireless communication, operating system support, mechanical structure, certification requirements, software integration, firmware behavior, lifecycle management, and supply-chain continuity.

For companies that do not have all of these resources internally, the path from product idea to finished product can be difficult, expensive, and time-consuming.

Estone helps reduce that complexity by supporting customers throughout the product development process. The company can help refine early requirements, identify practical design options, customize baseline platforms, support full custom development, and provide manufacturing and lifecycle support after deployment.

For many projects, Estone can also support certification planning and project-based compliance preparation. Depending on the final product, target market, and application, certification requirements may influence decisions related to enclosure design, material selection, wireless modules, power systems, electromagnetic compatibility, medical-grade requirements, environmental testing, and documentation. By considering these needs earlier in the development process, Estone helps customers reduce redesign risk and move more efficiently toward market readiness.

“Our job is to help customers make the right decisions early,” says Ong. “Small choices in hardware design, component selection, software integration, certification planning, or mechanical structure can affect cost, reliability, serviceability, and product availability years later.”

For Estone, a successful product is not measured only by whether it meets a specification sheet; it also has to perform reliably in the environment where the customer will actually use it. In medical environments, that may mean supporting specialized imaging, cleanability, antimicrobial materials, medical-grade certifications, long-term availability, and integration with clinical workflows. In industrial automation, it may involve panel PCs or HMIs that can operate in harsh conditions, support specific I/O requirements, and integrate with factory systems. In robotics and autonomous systems, the need may involve rugged control platforms, sunlight-readable displays, reliable wireless communication, open architecture support, and project-based compliance considerations.

“When our customers can deploy their systems with confidence, that is when we know the engineering work has created real value,” says Ong. “A successful product is not only about meeting the specification on paper. It also has to perform reliably in the customer’s actual operating environment.”

Flexible platforms, white label solutions, and custom development
Many of Estone’s rugged computing products are designed to serve as flexible baseline platforms. These platforms give customers a practical starting point while still allowing room for customization.

For some projects, adapting an existing rugged tablet, laptop, panel PC, HMI, embedded system, or control platform can help shorten development timelines and reduce risk. This approach can be especially valuable when a customer needs to move quickly but still requires changes to hardware, I/O, enclosure design, firmware, software, branding, operating system, certification path, or integration behavior.

For other projects, customers may need a fully customized product developed from the ground up. In those cases, Estone can help take a customer’s concept, PRD, or market requirement and turn it into a complete computing platform designed for manufacturing and deployment.

In addition to offering rugged computing reference platforms, Estone supports customers that need white label, private label, or fully customized ODM/OEM solutions. For customers building their own product lines, this means Estone can provide rugged computing platforms that are customized to match the customer’s brand, application, market position, and technical requirements.

This support may include custom branding, enclosure modifications, hardware configuration, I/O adjustments, software image customization, packaging support, documentation coordination, and lifecycle planning. For some customers, a white label or private label approach can help accelerate time to market by starting with a proven rugged computing platform and adapting it into a product that can be sold under the customer’s own brand.

For others, Estone can support a deeper ODM development path, helping transform a concept, PRD, or specialized product requirement into a purpose-built computing solution. This flexibility allows customers to choose the development model that best fits their business strategy, timeline, budget, target market, and supply-chain needs.

More than hardware
As connected devices become more advanced, many customers need support that goes beyond the physical device itself. For HMI, panel PC, embedded platform, and connected system projects, hardware is only one part of the final solution. The user interface, operating system, update method, device management tools, connectivity, software environment, certification considerations, and field maintenance strategy all influence whether the final product can be deployed and scaled successfully.

“These projects are rarely just about the device itself,” says Ong. “For many HMI and panel PC customers, the hardware, user interface, update method, and management platform all have to work together. When those pieces are planned together from the beginning, the final product is easier to deploy, maintain, and scale.”

Estone can help customers shape the user experience, support administrative management tools, enable over-the-air update capabilities, and develop companion mobile applications when required. This is especially important for customers deploying connected devices at scale, where remote support and software update capabilities can reduce the need to retrieve products from the field.

By combining rugged computing hardware with practical software ecosystem support, certification planning, and lifecycle support, Estone helps customers move from product concept to deployable solution with greater efficiency and confidence.

Global support and manufacturing flexibility
In many of Estone’s target industries, standard consumer devices cannot meet the requirements for long-term availability, customization, ruggedness, or lifecycle support unless purchased in very large volumes. Instead, customers need a platform that can remain stable, consistent, and supported for years.

This is especially important in healthcare, industrial automation, robotics, autonomous systems, and mission-critical applications, where frequent component changes, supply-chain instability, or limited technical support can create serious operational risk.

To meet those needs, Estone has built its business around four key strengths: cost efficiency, engineering responsiveness, end-to-end solution capability, and long-term partnership.

The company’s global footprint allows it to support sourcing, production, logistics, certification-related coordination, and customer collaboration across multiple regions. With office and support presence across the United States, Europe, Japan, and China, along with manufacturing flexibility in the United States, Vietnam, and China depending on customer requirements, Estone can help customers align production strategy with cost targets, compliance needs, supply-chain resilience, and regional market expectations.

“We support customers from the earliest design discussions through deployment and lifecycle management,” says Ong. “That continuity is important because the product does not end when it leaves the factory. Customers need confidence that their platform can be supported, maintained, and improved over time.”

Supporting growth markets
As customer needs continue to evolve, Estone has expanded its regional support capabilities to better serve key growth markets.

In 2025, the company launched its Japanese subsidiary to support increasing demand from medical and healthcare customers. In these markets, localized collaboration, engineering communication, technical support, and long-term reliability are especially important.

Estone also expanded its U.S. warehouse operations as part of its growing focus on the drone, robotics, and autonomous systems markets. Customers in these sectors are placing greater emphasis on trusted supply chains, localized support, shorter deployment timelines, and project-based compliance considerations, including NDAA- and TAA-related requirements.

Because Estone supports customers across industrial, medical, robotics, autonomous systems, and commercial technology markets, the company also participates in leading industry events around the world. In 2026, Estone exhibited at Japan IT Week, XPONENTIAL, and the National Restaurant Association Show, strengthening relationships across medical, embedded computing, robotics, autonomous systems, and connected commercial technology markets.

These investments reflect where Estone sees strong opportunity in the years ahead. As robotics, autonomous systems, medical technology, industrial edge computing, and connected device applications become more intelligent and more demanding, the need for customizable rugged computing platforms is expected to continue growing.

Turning product vision into real-world solutions
For companies developing specialized computing products, the challenge is not only creating a device that works. It is creating a product that can be engineered, certified where required, manufactured, deployed, maintained, and supported over time.

That is where Estone’s role becomes valuable.

Whether a customer needs to customize an existing rugged platform, develop a white label product under its own brand, or build a purpose-built device from the ground up, Estone helps reduce development risk, shorten the path from concept to deployment, and support the product throughout its lifecycle.

Ultimately, Estone’s goal remains consistent: to serve as a long-term rugged computing ODM/OEM partner that helps customers turn ideas, requirements, and product visions into reliable real-world solutions.

The post Turning Ideas Into Real-World Rugged Computing Solutions<p class="company">Estone Technology</p> appeared first on Manufacturing In Focus.

Beetschen’s background is in engineering, specifically in 3D computer vision, and he has previously worked on mixed reality headsets like Microsoft’s Hololens, a mixed reality device from one of the industry’s biggest players. In his experience, many such headsets and tools often have the same problem in that they try to do everything but end up excelling at nothing in particular. While impressive, they do not provide the help for customers that RealWear can.

RealWear’s suite of devices consists of smart glasses that are designed for particular environments and uses. These are further complemented by associated software and services, which include proprietary applications, custom training, and more. Beetschen explains that the company’s devices, such as the RealWear Arc 3 and the Navigator Z1, are “the first devices in human history that see the world as we do,” able to see through the customer’s eyes and provide help on the level of a personal assistant.

The company focuses on making its devices helpful and easy to use, as its long-term vision is to have a higher throughput between humans and machines than can be achieved via typing on keys or using screens. Devices like its smart glasses can help bridge the gap in user-system interfacing industry-wide. The goal is to have the best hands-free personal assistant technology possible for every person on the planet, something only possible through the technology with which RealWear works. “If the larger companies aren’t doing it, then we will,” says Beetschen.

According to him, so many previous generations of humanity’s ancestors were generally living worse lives than we are, and the company takes a certain amount of inspiration in how hard generations before us have worked to make our lives simpler. He believes it is therefore the responsibility of RealWear to make the future brighter and greater, while leveraging machine learning and artificial intelligence (AI) for good, making it accessible in an intuitive and effortless way.

Being active in a more nascent field of the technology sector, the path to success has not always been neatly laid out and has often required trial and error. Previously, the company had tried providing step-by-step instructions for frontline workers using the device when performing maintenance and inspection tasks. The process of doing so was very rigid, whereas reality is often more fluid and messy, and what worked in theory to get clients up to speed did not always end up working in practice, Beetschen says. With newer technology, supported by AI, RealWear can see what a person is doing in real time and act as a helpful colleague that helps a customer better understand a task while letting them do everything in their own order and style.

When it comes to technology, RealWear is putting a great deal of effort into upgrading and refining its operating systems as many figures within the industry are talking about how human language could be the next key interface with AI devices. Using buttons with a machine, says Beetschen, is very inefficient and time-consuming, so more and more people are using voice as an interface, an approach that the company has been already using for years. As the first truly voice-first operating system, the AI technology within a RealWear device can understand what a consumer wants, map to their settings, and act on their behalf, making it much more natural and faster to use.

The competition often makes their business by working in the consumer space, which Beetschen says is a tempting idea; however, RealWear is ultimately among the few successful players for smart glasses in the enterprise space, making its devices for businesses. The company focuses on the whole experience of its technology as opposed to just individual parts like hardware. This experience starts with the packaging, feel, and visuals of the product as well as with the software experience, operating system, and cloud management solutions.

“We’re the easiest to use and deploy,” says Beetschen, and RealWear is the only company of its kind able to create large-scale, reliable deployments.

As a result, its workforce solutions can be found across many different sectors. One of the company’s notable vertical markets is in warehousing and logistics for companies like Coca-Cola, Beetschen says. In these scenarios, frontline workers use RealWear to connect with an order from a client to obtain precise information quickly and to access other crucial data like visuals and map directions. This has helped employers like Coca-Cola increase their speed by about six to eight percent, a considerable difference.

Elsewhere, Ford has equipped around 1,000 of its American dealerships with RealWear devices and has now built a center where mechanics can use the technology to diagnose problems in its fleet of electric cars and fix them more easily.

While results like these are encouraging, the use of AI is still being perfected. Beetschen says that one current limitation is that a user still needs to provide much of the input to explain the context of what is desired from a prompt, a process that must be repeated every time; however, augmented reality devices like RealWear’s products innately gather the context of what the user is doing.

As the AI powering RealWear is a newer computing platform, there will always be challenges for early adopters. Many of the technology platforms and enterprise software systems of RealWear’s clients are still incompatible, which is why the company provides a whole solution that simply works without the need for legacy setups, just one way in which RealWear has its eyes set on the future and always keeps its customer base in mind.

Beetschen says that it is now time to liberate end users from technology that relies on buttons and screens, but the industry, broadly, is still waiting for a tipping point to help that along and clear up lingering confusion. This tipping point may very well come as a result of a landmark deal that the company is in the middle of making as of press time, which Beetschen says will be the biggest augmented reality deal in human history.

This deal will likely create industry buzz somewhere in the range of summer 2026 to the fourth quarter of the year. “We are living in an exciting time with AI,” Beetschen says, and it is also a good time for RealWear to interface with and leverage AI to help humans do even better. Whether it is outfitting a workforce with hands-free technology or being at the vanguard of an ongoing digital revolution, this team will not be satisfied until its technology can be used to help as many people as possible.

The post Bringing Hands-Free Technology to the World<p class="company">RealWear</p> appeared first on Manufacturing In Focus.

2025 was a great year, says Lean Program Manager Josh Johnston, because MMTC was able to make an impact on myriad companies across the industry. Recently, MMTC, along with its leadership team, has been spending more time embedded in the manufacturing sector so that it can focus on building lasting capabilities for its clients rather than simply providing one-time training.

In fact, he notes that as part of MMTC’s overall strategy, the organization is enhancing its consultative and advisory services alongside its training programs to deliver deeper, more meaningful support to the manufacturers it serves. “Education still remains an important part of what we do,” he says, as its foundation of continuous improvement is built on understanding both the tools and goals of any initiative.

Another focus of MMTC’s has always been to evolve to match its clients’ needs. Specifically, MMTC helps companies diagnose the challenges they face such that they can prioritize projects and initiatives that lead to changes and sustainable results.

While this priority shift has been in the works for years, 2025 was the big push forward into its implementation. To support this approach, MMTC is expanding opportunities for deeper client consultation. Dedicated MMTC Business Solutions Managers work directly with manufacturers to better understand their challenges and connect them with the right expertise and resources to achieve their goals. This approach allows MMTC to serve as a more strategic partner in helping clients strengthen and grow their businesses.

MMTC will not be abandoning its training aspects wholesale, and in line with its commitment to evolving to meet client needs, it is always assessing its offering catalogue to identify both the most in-demand courses as well as those that are no longer serving the industry. Since the team works specifically with small- to mid-sized manufacturers, many of the problems faced by these outfits are those that manufacturing organizations of all sizes are also seeing today.

Johnston says that what differentiates MMTC’s clientele is that many shop leaders tend to take on a number of roles: from general management and operations to hiring, logistics, and more. Often, these leaders don’t have the capacity to step back and think about the long-term future of the business, which is where MMTC often comes in to offer assistance.

MMTC’s business success planning—one of its primary offerings—will help these overworked and busy clients, Johnston believes. This is a process wherein an MMTC industry expert interviews the leadership team of a manufacturing organization to create a comprehensive analysis of where the company is now and compares it to where they want to be. This assessment then evolves into a practical three- to five-year road map that aligns with improvement projects, technology adoption, workforce development, and training. This way, leadership received clarity and relief for future planning while also figuring out how to keep the lights on tomorrow.

Johnston says that manufacturers today are facing greater complexity and uncertainty than ever before, and ongoing challenges, while nothing new, are varied. These include continuing volatility in raw material pricing due to fluctuating tariff policies; the industry facing an aging workforce as well as a limited talent pipeline entering the skilled trades to fill the spots; and all the hype around emerging technologies like artificial intelligence (AI). As one of the biggest global industry buzzwords today, AI is seeing a lot of excitement, yet companies often struggle with implementation and developing strategies to capture return on investment data.

Many manufacturers are hesitant to adopt the technology because they have been burned in the past by technology startups that have sold them unrealistic solutions or poorly-scoped pilot projects, or even pressured staff to adopt misunderstood tools to gain an intended early market advantage. Johnston notes that while there can be gains in efficiency and productivity, it must be implemented thoughtfully and strategically—otherwise, throwing technology onto a bad process only makes the bad process faster, not better.

With this in mind, another major focus for MMTC is to become the trusted advisor for Michigan’s manufacturers in adopting and implementing various AI technologies. As such, MMTC will be expanding its offerings to help manufacturers move out of skepticism and into practical, value-driven applications.

The team spent much of last year creating ways for manufacturers to leverage this new technology, especially since companies that are late to the table risk getting left behind. One such method has been launching a series of courses on AI in manufacturing. In the first few months of 2026, MMTC has launched six new AI-centered courses including AI for Quality Control and Inspection (using AI-enabled visions and camera systems); AI for Manufacturing Leaders (how to introduce these technologies into your organization in a strategic, responsible manner and roll out solutions from the top down); AI for Supply Chain Optimization (leveraging deep research capabilities for in-depth supplier analysis and more); AI101 & AI102 Workshops (focused on generative AI basics and advanced ChatGPT use cases); and Lean Problem Solving With Generative AI (how large language models can be used to expedite effective problem solving).

The new push into artificial intelligence systems for manufacturing is also allowing MMTC to expand physically. A new AI lab in its home of Plymouth will serve as a space for manufacturers to experience new AI technology and simulate an on-premises solution without putting a business at risk. MMTC has also been hosting workshops across Michigan to give industry people a chance to gain hands-on experience with new technology and tools.

This has been a very exciting venture, according to Johnston. “The ‘a-ha!’ moment is one of my favorite parts of the job,” he says. By demystifying these technologies and making artificial intelligence feel less intimidating for new users, MMTC provides a launching point for clients to take back their companies. Its long-term focus will be on helping manufacturers cut through the AI hype, make informed decisions, and realize a measurable return on their outcomes instead of just chasing technology for the sake of it.

Amid today’s market challenges, the Michigan Manufacturing Technology Center is energized by its renewed direction. Last year, MMTC launched the inaugural Manufacturing Insights Survey to capture manufacturer feedback on trends, strengths, challenges, and opportunities. From these responses, MMTC produced the Manufacturing Insights Report, which highlights the concerns and priorities of small and midsize manufacturers across the state while offering actionable solutions and outlining how MMTC can help them. The full report is available at www.the-center.org.

Ultimately, Johnston says, MMTC’s “goal is to not be the best-kept secret in Michigan,” but rather to be a trusted and established aid for Michigan’s manufacturers to call on for anything they need.

The post A Best-Kept Secret No Longer<p class="company">Michigan Manufacturing Technology Center</p> appeared first on Manufacturing In Focus.

The decade started on a hot note for Elcon with the official announcement of its purchase by global manufacturing network The Partner Companies (TPC). Although the purchase was made in 2011, the sale was not made public until 2020. Since then, Elcon has become even more involved with TPC and its more recent acquisitions, all of which have brought more capabilities that can be offered to customers. These acquisitions have included L&T Precision; Photofabrication Engineering Inc.; Pinnacle Precision; United Plastics Group; and Precision Eforming, last year.

All the capabilities from these businesses added to the TPC suite, “integrating well with what Elcon does for its clients and positioning it as a one-stop shop among metal manufacturers,” says Elcon Data Analyst Nikki Do.

Currently, TPC sports 11 specialty manufacturers including Elcon in its holdings, with a physical presence across the United States and sites around the world in locations like China, Mexico, and Wales. It has also received new funding from investors to the tune of hundreds of millions of dollars from businesses like Huntington Bank, and work is still ongoing to continue raising even more capital.

Elcon itself recently completed a semi-merger with another operation in its Bay Area home. Only 10 minutes down the road, the new manufacturing site grants the team more edging capacity and other capabilities. This includes an increased capacity in its factory metal edging line and in refractory metals like tungsten and titanium, elements that are in demand by many of the sectors with which Elcon works closely and that require high-temperature operations.

In the couple of years since we last spoke, Elcon has added diffusion bonding to its services and more people to its team in terms of mulling and processing engineers. “Our value is our engineering team,” Do says. The company’s clients, which include medium-sized and start-up companies, often come to it with a tough engineering challenge in terms of manufacturing, such as creating a product from an obscure, advanced material. In these cases, its engineers have the knowledge to deliver while also being able to inform customers what can and cannot work, making the process efficient and informed.

As things are now, Elcon continues to see great demand from the aerospace and defense sectors for both of its major product lines. With its ceramic metallization and brazing services, the company can provide the sophisticated ceramics that go into missiles, fighter jets, or hyper-sonic applications. Among its specialty products are control grids for waxing wave tubes used for radar application in defense contexts; vacuum coaxial switches for radar systems which are often used with missile guidance; and radio frequency shielding used in planes and jets.

The company is also active in the medical industry—many of its parts are used in electrosurgical instruments in sports medicine as well as electron guns for medical imaging equipment and oncology treatment devices.

These two specific fields, however, are not the only areas where Elcon excels. Do tells us that some customers are in the photonics industry, for which Elcon makes parts for analytical instruments. Headway is also being made into the nuclear energy space with the company’s hermetically-sealed brazing process, used to braze ceramic and metal components together.

Finally, more growth is happening around the burgeoning field of data centers, all of which require considerable cooling for their servers. Elcon manufactures heat sinks and heat exchanger plates that can run coolant through these servers. The company also offers a considerable portfolio of services in the semiconductor industry, an area that promises to keep growing with the burgeoning reliance on—and worldwide interest in—artificial intelligence systems and the aforementioned data centers.

Undeniably, a great deal of growth is happening for Elcon around the aerospace and defense industries specifically, with many more proposals and project requests coming in following an increase in defense spending in the United States, according to Do. However, she indicates that the company is seeing some supply chain issues as certain types of materials and plating metals are currently experiencing shortages; prices have gone up on these materials, putting pressure on both Elcon and its end users. A lot of customers are also demanding faster timelines on projects, which could be influenced by the race to take advantage of funding alongside other market-based constraints.

Thankfully, TPC has been a big help in facing these challenges. “With a bigger footprint in the supply chain, we have leverage with both suppliers and each other,” Do says. This means that if a client has a prototype developed for their project or specifications but is in need of faster output and delivery, some of the work can be given to Elcon’s many sister companies to meet these kinds of goals. Having multiple sites throughout the U.S. has helped Elcon address these issues and given it further weight when negotiating with suppliers, meaning that despite any short-term difficulties, the company still sits in an advantageous position within its active markets.

Going forward into 2026, Elcon will be focusing on integrating both its overall capabilities and the TPC technology stack to provide greater efficiencies for its team, says Do. Having started as a group of companies working on different internal systems, becoming united within the TPC group will likely translate into greater efficiencies that will benefit both employees and customers. The integration also affords Elcon the opportunity to collaborate on engineering solutions within this network of companies. There is still much ongoing work when it comes to trying out new materials and processes, especially involving finding the right fit for a client’s project.

“Our company is well-funded and positioned strategically,” Do says, and is making investments toward solving its customers’ needs across various sectors. Elcon Precision continues to be recognized for its efforts within TPC and even locally, as its titanium surgical mesh product was named one of the top 16 ‘Coolest Things Made In California’ by the California Manufacturers & Technology Association. It also recently passed the ‘six million units manufactured’ mark of tungsten surgical components for one of its medical device company clients and celebrated the production of one million metallized ceramic components for a long-time end user in the aerospace field.

Clearly, this company isn’t slowing down. On its own merits, and with the help of its new parent company, Elcon Precision is poised to keep both its momentum and its growth strong throughout the rest of the decade.

The post A Valuable Merger Allows Engineering to Shine<p class="company">Elcon Precision</p> appeared first on Manufacturing In Focus.

For LIVIO Building Systems, the answer lies in rethinking how these facilities are delivered. Through its LIVIO AI Data Center Factory (LAIF) platform, the company has positioned itself at the vanguard of rapid AI infrastructure deployment, enabling developers to transform land and power into operational AI compute capacity in a fraction of the time traditionally required.

At its core, LAIF is a pre-engineered, multi-trade panelized building system designed specifically for AI data centers. The approach combines LIVIO’s modular wall and roof panels with integrated electrical and plumbing infrastructure, allowing structures to be assembled on site with remarkable speed. The system is designed to support scalable modules ranging from 20 megawatts to more than a gigawatt of capacity, accommodating the massive computing loads required by modern AI systems.

In practical terms, the LAIF approach condenses what would typically be a multi-year development cycle into mere months. Using standardized components shipped directly to the project site and assembled in a LEGO® brick-like manner, the building shell can be delivered in roughly 45 days, with hardware and rack installation following shortly thereafter. A complete AI data center can be converted from “land to compute” in as little as 99 days.

Engineering the next generation of AI infrastructure
The concept builds on LIVIO’s established panelized construction system, which has been evolving rapidly in recent years. In fact, since the company was last featured in Construction in Focus in 2024, two new generations of its building system have been introduced.

Generation 2.0 enhanced LIVIO’s original panelized platform by integrating structural sheathing into wall assemblies and incorporating plumbing and electrical infrastructure directly into the panels themselves. Founder and CEO Navneet Aron says the upgrade dramatically increased the completeness of the company’s off-site manufactured components.

Shortly afterward, Generation 3.0 launched as a fully closed-wall system designed to arrive on site essentially ready for finishing. With the interior surfaces prepared for painting and exterior surfaces ready to accept dry cladding systems, customers can move almost immediately from installation into the finishing phase.

These improvements laid the groundwork for LAIF, which adapts the same manufacturing philosophy specifically for high-performance AI data center environments.

“AI infrastructure is one of the fastest-growing construction segments in the world,” Aron explains. “The challenge is that traditional construction timelines simply cannot keep up with the demand for compute capacity.”

Solving the bottleneck
The surge in generative AI and large-scale machine learning has triggered unprecedented investment in digital infrastructure. Hyperscale technology companies and specialized developers are pouring hundreds of billions of dollars into new facilities, yet the pace of construction remains a major constraint. For many developers, the building itself—not the chips or cooling systems—has become the biggest bottleneck.

This is precisely where LAIF can make an impact. By fabricating building components off-site and assembling them quickly on location, LIVIO’s system dramatically reduces the labor requirements and construction time typically associated with large-scale data centers.

In one recent project in Ohio, LIVIO and its partners demonstrated the potential of this approach, delivering a fully operational AI data center facility within weeks of the project’s initiation. The speed and efficiency of that deployment led the developer to commit to using LIVIO systems across its broader project portfolio.

The LAIF platform also incorporates design features tailored to AI workloads, including compatibility with high-density racks, advanced cooling systems, and integrated infrastructure for power distribution and monitoring.

A platform built for global scale
While AI infrastructure has become the company’s most prominent offering, LIVIO’s building systems continue to serve a diverse range of applications, from residential and commercial developments to specialized structures with enhanced security features. Still, the explosive growth of AI computing is shaping the company’s global strategy. In recent months, LIVIO has seen strong demand not only across the United States but also from developers in the Middle East and other emerging markets eager to build new infrastructure quickly. Saudi Arabia has been one of the first regions where the company has engaged with major development groups, while opportunities are also emerging in parts of Africa and Asia.

As word spreads about the efficiency of its systems, Aron says developers are increasingly drawn to the company’s combination of precision, speed, and cost control.

“A developer anywhere in the world wants the same thing,” he says. “They want to build accurately, quickly, and predictably. Our system makes that possible.”

Reimagining how the world builds
Beyond speed, the company’s technology addresses several structural challenges facing the construction sector. Labor shortages continue to affect markets worldwide, while traditional building methods often struggle with delays, cost overruns, and inconsistent quality. LIVIO’s panelized system reduces on-site labor requirements by as much as 80 to 90 percent while delivering construction accuracy within one-eighth of an inch, Aron says.

“Our mission has been to reduce reliance on a highly skilled labor force on the job site,” he explains. “If we can simplify the process and make it more predictable, we can fundamentally improve how buildings are delivered.”

To help achieve that goal, LIVIO systems are designed to be intuitive to assemble, with clearly labeled components and step-by-step installation guidance.

The road ahead
As the global AI infrastructure boom accelerates, LIVIO expects its LAIF platform to become an increasingly central part of its business. The company is already preparing future generations of its building system, which will introduce additional pre-installed elements such as roofing assemblies, interior doors, and expanded finishing options.

The ultimate goal is to push the boundaries of how quickly complete structures—particularly complex facilities like AI data centers—can be delivered.

“We will continue to deliver to our current customers and expand our markets here nationally and globally,” Aron says. “AI infrastructure is only going to grow, and we believe our technology will play a major role in enabling that growth.”

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The injection molding process involves the use of various materials that can produce parts of reliable quality. These materials can include metal, glass, thermoplastics, and more, while the molds themselves are usually made of steel or aluminum. Injection molding is currently the most common method of part manufacturing and can be used to create a wide variety of machine parts—everything from beverage containers and caps to children’s toys to automotive parts. It is an age-old process still in wide use today, but it is hardly the same as it was hundreds of years ago.

New advancements in industrial technology are allowing the process to be reconsidered. For example, 3D printing is proving to be a way to revolutionize injection molding. Printed molds are typically produced in two configurations: mold inserts in aluminum frames, which are the most common configuration and produce more accurate parts; and standalone molds, in which the mold is fully printed. A piece for The Welding Institute says that 3D printing, also known as additive manufacturing, is ideal for fast prototyping, with turnaround times of one to two per week, and allows for frequent design changes. “This process is also able to produce relatively small plastic parts and components, while also being ideal for complex or intricate designs.”

Mold elements like steel and aluminum are resistant to wear and tear during the molding process but can require a large initial investment. Because of this, molding projects with a lower planned run often need to shift focus away from wear resistance, making certain 3D printing technologies an attractive solution. When high-accuracy part printing processes such as material jetting and stereolithography are paired with temperature-resistant printing materials, printed molds become a good option for manufacturing low-run injection molding dies.

According to The Welding Institute, while 3D printing is currently seeing more widespread adoption, injection molding remains the preferred process for manufacturing plastic parts due to the cost efficiency and quality associated with mass production. However, 3D printing can be preferable for prototyping projects because injection molding tooling design is often expensive and time consuming.

This distinction can be seen in areas such as the medical field, where 3D printing is used for the production of custom items like prosthetics. “Rather than seeing 3D printing as a potential replacement for injection molding, the two technologies should be seen as complementary processes that can be used together depending upon requirements,” according to The Welding Institute, which says that 3D printing is currently best suited for low-production runs of 100 parts or fewer due to the time and cost involved in larger runs.

Moving beyond additive manufacturing—and like many other sectors undergoing similar changes in processes and materials—injection molding is also addressing a shift toward greater sustainability. Companies such as sustainable plastics manufacturer BIO-FED are now openly using compounds made from biodegradable biopolymers and renewable raw materials. Renewable materials can replace traditional injection molding materials like metal, glass, and ceramics with alternatives such as coconut shells and rice hulls. Research into these practices is ongoing, and new materials are being discovered and tested on a regular basis.

In a piece on sustainable plastics manufacturing for Fictiv, David Willson says that the plastics manufacturing industry is shifting toward more sustainable practices, driven by a global desire for environmentally friendly solutions. “Sustainable plastics, designed to minimize ecological harm through renewable sourcing, recyclability, or biodegradability, are driving this change,” Willson writes. Materials such as biodegradable and recycled plastics, including polylactic acid, polyhydroxyalkanoates, post-consumer resins, and thermoplastics, are increasingly being adopted. Bio-based polymers sourced from plants like corn or sugarcane are also appealing, as they offer a lower carbon footprint. “Unlike virgin plastics, which emit 2 to 3 kg of CO₂ per kg during production, recycled plastics can reduce emissions by up to 60 percent, often to 0.8 to 1.2 kg of CO₂ per kg.”

These sustainable practices require additional care, as materials must be carefully sorted to remove contaminants that could affect color or strength. Bio-based plastics often require industrial composting facilities to break them down effectively, making widespread adoption more challenging. In some cases, production can place strain on agricultural resources, such as polylactic acid requiring up to one hectare of land per ton, meaning the transition is not as simple as switching materials without further consideration.

Beyond additive manufacturing and sustainability, other emerging technologies are also influencing injection molding. The industry has become more intelligent and data-driven, combining sensors, algorithms, and electric drives to achieve consistent quality. Artificial intelligence is being used more frequently in injection molding, with direct integration into machines and controllers to help predict and correct process inefficiencies, further automating mechanical operations.

Electric injection molding machines are also gaining traction, offering greater precision and energy efficiency than traditional machines. They provide improved motion control, faster response times, and more repeatable injection processes. However, the initial investment for electric machines remains high, and maintenance has become more specialized. Like 3D printing, electric alternatives are promising but come with their own challenges.

Further technological advancements will continue to drive innovation in the injection molding sector as smart manufacturing technologies increase efficiency through real-time monitoring and improve quality through Internet of Things sensors. Predictive maintenance can help reduce costs by limiting equipment failures and labour expenses, while data analytics can enhance flexibility and supply chain planning.

Injection molding, and plastics manufacturing as a whole, are entering an especially dynamic period of innovation and sustainable development. The topic remains prominent at major industry gatherings such as the annual Medical Design and Manufacturing (MD&M) trade show, which regularly features injection molding among its key subjects. As global demand for machine parts continues to rise year over year, innovation in processes like injection molding is increasingly important, particularly as customers expect more responsible and efficient production from industries that have existed for centuries.

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New developments
According to Chief Executive Officer Alex Lawton, after the company’s merger with iron casting business Renaissance Manufacturing Group in spring 2024, higher-volume green sand casting was brought into the mix. Green sand casting employs a mixture of water, clay, and sand to make molds, with ‘green’ referring to the moisture content of this economical and adaptable method that helps the mold keep its form as the molten metal is poured in.

Since we last spoke, various service components of the business were also fortified thanks to the brokerage of standalone machine shops. New capabilities have been made possible since the merger, and time is being spent on working to integrate and harmonize several companies into one. Marketing and Communications Coordinator Nate Vandergrift states that cross-site collaboration has grown in the past year, with products that can be made at several Lawton facilities.

Other developments include the KUKA RMC90 robot, currently in a development phase, which is an upgrade from the old pattern of foam tools, Lawton tells us. The robot is a way to skip the tooling process, which is better for speed and quality levels as well as for the environment. The company is also multiple years into a project around its enterprise resource planning software in its production facilities, and has added customer relationship management software called HubSpot. The team also continues to be open to artificial intelligence in the form of large language models, which has made running certain internal processes like human resources and data collection and reporting easier.

A top focus has been the assimilation of the group of Lawton companies as they better understand how to work together. This went from a company with disparate businesses in the same market to a more centralized, integrated offering, and the goal is to deliver the capabilities of these parts in a more consistent way to the customer. “We want to do more business across more locations with the culture we know and like,” Lawton says.

Mastalir adds that it is important for Lawton’s people to understand the full capabilities of the company, especially because salespeople have been accustomed to only promoting the products and services under their own roof. In expanding, these people need to be able to know all the things that can be added to the portfolio of customer service and become experts in the entire business.

The vision of the company’s business strategy is to become supermarket-like, offering a matrix within the business and each plant to serve customers on every possible thing they may want when it comes to iron, steel casing, and more, says Lawton. Lawton Standard can handle any manner of volume, offers a service group, and provides numerous value additions like machining. These make it an ideal one-stop shop for iron and steel.

Smart and sustainable
Since summer 2024, all the company’s sites are ISO 9001, ISO 14001 and ISO 45001 certified. Lawton notes that less energy consumption leads to a better work environment because of efficiency, and since 2022, the company has diverted nearly 10,000 tons of spent foundry sand from landfills to be put to use in manufactured soil, layering for construction projects, and concrete and brick-making. Mastalir adds that both customer interest and corporate mandates are trending more toward involvement in sustainability efforts, an area in which Lawton Standard has outpaced a lot of its competition.

Around 15 years ago, the mindset around sustainability tended to involve understanding and keeping track of agencies with which companies needed to be in compliance, as well as determining which ones were truly concerned with making an impact, Lawton shares. Over time, the business underwent the Wisconsin Sustainable Business Council’s Green Masters Program to enhance its knowledge, implemented an environmental management system that works in tandem with its quality management, and joined the Wisconsin-based Green Tier initiative. Green Tier allows organizations in the state to align business practices with sustainability-based targets through committing to environmentally friendly practices.

Lawton Standard has since become one of the first foundries and overall companies to qualify for Green Tier 2, which is reflective of its general drive toward improvement in all areas and its desire to be a better community member, a value important to the company and its customers.

Navigating the waters
It has been a challenging few years following the COVID-19 pandemic of 2020, says Lawton. 2021 to 2022 saw an explosion in demand and lead times, with the goods economy going wild. Although this has since rebalanced, the industry is still weak. While not quite at crisis levels, recessionary effects are being felt thanks to fluctuations following the 2024 election.

Lawton Standard has found pockets of strength in niche areas like artificial intelligence because of components it can provide to service data centers and waterworks systems with an infrastructure focus (to replace aging pumps and valves). The company has tried to hunker down through tough times while developing aspects like sustainability, software, and robotics, Lawton tells us.

He believes that businesses are very adaptable, especially in the United States, and his company will indeed adapt as long as it knows the playing field. The team spends a lot of time building relationships with its customer base, aiming to show prospective and long-time clients alike that Lawton and its companies will always be close by. “You’re never more than 10 feet away from a casting,” says Vandergrift, which illustrates the company’s focus and commitment to the customer experience.

Alex Lawton is optimistic about 2026 being a return to strength and growth. “We will create our own luck by going after the right things,” he says. Lawton Standard is always thinking about the markets it serves, with the goal of being highly diversified company-wide. The business continues to grow in markets like defense, with the desire to expand into areas like agriculture, and this growth will likely persist in the years to come. Vandergrift adds that while employees do age out and retire, there are many industry programs seeking to drum up more students to become interested in the foundry industry.

Lawton Standard does not need to focus on acquisitions per se but will remain open to opportunities while also giving time to initiatives like mechanization and process improvement. The next period of strength for the company will likely see it in a better position than in its last one, and according to Mastalir, the team will make sure it is ready to rise above the competition and give the customer the best experience possible. At Lawton Standard, the work will always be aimed at ensuring that the company is growing with its customers as they come back time and time again.

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Fully certified to ISO 9001standards, the company relies on robust processes, from organizational structure to quality reporting and customer engagement, to drive consistent, mutually successful outcomes.

Overlanders Manufacturing has been active in Western Canada since the late 1970s, but over the last 18 to 24 months, much of the company’s capabilities have seen considerable in-house upgrades. For example, the team has rolled out new advanced laser automation capabilities, including the AI-powered and Industry 4.0-ready Prima Power Laser Genius+ laser cutter with additional parts-stacking robot—the company’s biggest capital purchase in several years.

Recently, Overlanders upgraded its Abbotsford facilities and now has the capacity to house pieces as large as the new Prima cutter, which takes up a large part of the building. The company has also expanded and created more dedicated space for assembly lines, including a dedicated assembly line that moves beyond simply bending, cutting, and painting metal. New robotics incorporated into the bending process further the company’s goal of weaving automation throughout its processes and allow a single operator to run several machines at once with greater accuracy.

When it comes to automation and technology, these are catch-all terms that Plant Manager Adam Stephenson believes should not be thrown around casually. Instead, Overlanders Manufacturing has always kept its finger on the pulse of the technology making waves in its field and how it can be employed to enhance the company’s capabilities. “It’s not just about replacing a machine but about increasing capability,” he says. This process is highly methodical by nature, but Stephenson explains that the Overlanders team subscribes to the mentality of seeing a business as a journey. While some companies are very goal-oriented, Overlanders Manufacturing will never be at a final ‘perfect’ state and is always looking to improve itself, which keeps everyone involved hungry and searching for better ways to serve clients.

The company also stays abreast of the latest best practices in safety and incorporates them into its processes. Even though Overlanders Manufacturing has been around for nearly a half century, Stephenson says that leadership is always interrogating itself and exploring how to best provide top customer service while balancing safety and efficiency, often while syncing its systems with those of its customers and considering client satisfaction through that lens. Since the company’s work can be found in a variety of industries including energy, medical, construction, transportation, and more, safe and reliable practices are paramount to its continued success.

Overlanders Manufacturing has proudly been part of the Exchange Income Corporation (EIC) family for quite some time, having been acquired in 2006, and EIC has been a fundamental part of why it has stayed ahead in the industry. The business is also an active collaborator with its fellow EIC-owned companies, including BC-based machine shop Hansen Industries, learning and sharing from one another’s processes. Hansen has become a close partner, as both companies share overlapping capabilities and benefit from one another’s capacity. There is much work that can be done within this partnership, says Stephenson, to optimize output and deliver greater capabilities and flexibility to customers.

He explains that such collaborations can take a number of forms, such as working with the Manufacturing Safety Alliance (MSA) on safety presentations and training. Industry learning is a big part of a typical year, with an example being factory tours Overlanders recently attended in October as part of a presentation for the Abbotsford Chamber of Commerce’s annual manufacturing industry tour through the area. Events like these are part of the company’s strong local presence, as is its participation in the MSA’s Make It Safe conference, also in October.

Certainly, this has been a busy year for Overlanders Manufacturing judging by the volume of customer demand, and this has led to a strong bottom line as the year draws to a close, despite ongoing market turmoil. As well as the ability to effectively support clients in both Canada and the United States, the company has also been able to extract information on customer needs to regarding shipping internationally, which has had its own difficulties this year. With many challenges in the current market, the team aims to be flexible, always looking for new opportunities. “We are able to adapt our process to what people need, even during challenging times,” says Stephenson.

Looking ahead to a new year, he says that the company will be spending a lot of its time determining how to increase both its capacity and efficiency. This is Overlanders Manufacturing’s biggest goal and will prove the strength of its lead times. There are also big plans to optimize the company’s existing systems and expand equipment in the areas where it has been most successful in order to align with that growth. Customers are eagerly continuing to order, so the company wants to make sure that it has the right equipment to deliver, as well as the right people in its workforce to achieve these goals.

The team has grown quite a bit—including Adam Stephenson’s joining—in the past year, and he believes this growth will continue based on the company’s overall strength across 2025. “The biggest driver of success is continuing to be a leader in what we do,” he says, and quality is one of the reasons people choose Overlanders Manufacturing time and time again.

Having been around for so long, Overlanders Manufacturing has robust processes and core tools in place that give customers the assurance and peace of mind they need. The team has also since spent its tenure establishing itself in its local community of Abbotsford and the greater Vancouver area. This can be seen in its social media presence as the business openly celebrates both the cultural diversity of the area it calls home as well as the many people who make up its proud and capable workforce.

There is no doubt that 2026 is shaping up to be an exciting time for Overlanders Manufacturing. Continuing to promote the strengths of its approach to customer relationships and industry partnerships, this team has been able to keep busy and work hard through challenging situations. At the same time, it stands out in the minds and memories of customers, peers, and the people who make it work every day.

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Two sides to the business
Alltrista’s Director of Sales, Andrew Piersall, says that the business caters to two distinct market segments.

The first market segment is the medical sector, where Alltrista focuses on medical devices and packaging products, with a product assortment relating to drug delivery, wound closure, diagnostics, oral dose packaging (including certified child-resistant caps), and vision care. Unlike its consumer packaging side, all the products on the medical side are custom-specific and thus unique to each customer.

The other market segment served by Alltrista is the consumer packaging side, to which the company offers both packaging and closure solutions for markets including food & beverage and health & beauty. This side of the business has a relatively broad product portfolio, including a multitude of stock offerings such as bottles, bottle caps, lip balm, dosage cups, and other associated products. Within consumer packaging, Alltrista’s custom capabilities make up a large part of the business, providing unique solutions to each customer’s request.

Piersall says that commercially, Alltrista’s customers (especially medical customers) tend to focus on risk management and speed-to-market in their dealings, mainly via effective project execution. Therefore, suppliers like Alltrista that can provide this value to customers help them be successful.

Sustainability initiatives are also a large focus of the company. Alltrista partners with customers aiming to meet the environmental commitments of highly regulated fields to provide sustainable solutions. Generally speaking in this regard—and across all segments—the company is home to high cavitation molds with short cycle times, lightweighted plastic bottles and caps, and a small manufacturing cell footprint.

It’s not easy for any business to make a mark on the plastics industry, but Piersall says that a distinguishing aspect of Alltrista is its ability to be both customer-focused and agile. These qualities allow the company to provide end-to-end solutions to customers quickly, meeting customers wherever they may be in the lifecycle of a product. “We have demonstrated willingness to invest in our customers,” he says. Alltrista’s mindset is that its customers’ successes are its own successes.

Going for gold
The company continues to make an impression, and in 2024, Alltrista was highlighted in the PMMI report, Innovation in Can/Bottle Beverage Packaging, which explores the latest developments in beverage packaging as exhibited at 2024’s PackExpo. Alltrista was proud to be featured in the report’s materials section, spotlighting the AllCap™ 1881 beverage closure, a lightweight water bottle cap that enhances productivity, is customizable, and delivers cost savings without compromising on quality. The company utilizes the latest energy-saving infrastructure support systems with variable frequency drives on all its electric motors, resulting in a significant reduction in energy consumption per cap produced.

Christopher Weikart, Senior Vice President of Innovation at Jadex, says that one of the things that brings him the most company satisfaction is Alltrista’s approach to sustainability. In fact, the company recently earned a gold medal from EcoVadis, an independent ESG global platform that evaluates businesses based on sustainability objectives, covering areas like environmental stewardship, labor and human rights, and sustainability in the procurement of materials. Weikart says that the gold medal is evidence of Alltrista’s category-leading commitment to ecological responsibility and is a point of pride internally, placing the company in the top five percent of companies surveyed in the 12 months leading up to the award.

For Alltrista, crafting and refining sustainable practices happen daily. A tangible example of sustainability in its business practices is the light-weighting of several of its manufactured products, meaning a reduction in the amount of material in a product without compromising quality (as seen in the company’s award-winning beverage cap). This is typically the result of unique product design attributes, something the company has become adept at achieving.

Spearheading these practices internally has led to many benefits, including reducing the company’s Scope 1 & 2 emissions, product weight savings, and the identification of new materials, such as post-consumer recycled resins (PCR), for use in future projects.

The year ahead
Vice President of Operations, Jeff Hall, says that Alltrista’s focus moving into 2026 will be on both strengthening its operational excellence and investing in its people. The company will be expanding its automation capabilities and upgrading its equipment to improve precision, consistency, and efficiency across molding lines.

“Our goal is to build highly adaptable operations that combine high-precision automated manufacturing with the highest quality products,” Hall says, “which will position the company to meet the ever-evolving needs of customers as well as sustainability standards for years to come.”

Hall says that from a manufacturing standpoint, one consistent challenge across all market segments is establishing a skilled and trained workforce. Moving into the new year and the foreseeable future, Alltrista will be placing a strong emphasis on workforce development, as new talent will need to be trained on molding, process monitoring, and quality systems.

Pace-setting product launch
Weikart explains that one of the company’s biggest customers is in the healthcare industry, so there will be a particular product launch next year (among several others) that will aim to benefit these customers and others like them. This product will be an improved version of a medical device that Alltrista has manufactured for a long time, involving the incorporation of an antimicrobial compound into a polymer resin before molding the mixture into a finished wound care device.

This device has simplified the customer’s manufacturing operations, improved their product quality, and enhanced product reliability for patients susceptible to surgical site infections. After this launch, the customer is expected to undertake a complete conversion of the product line thanks to this technology.

Honoring its history of longevity, Alltrista drives innovation, from light-weighting caps to advanced medical devices, guided by operational excellence and sustainability. While the company has gone through changes, and has many noteworthy events on the horizon, its ability to adapt and maintain success relies on one constant: its employees. “Ultimately,” says Piersall, “our people are our biggest asset.”

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Brand and Marketing Manager, Ryland Thiel, says that Tornado Infrastructure Equipment’s solutions have become even more capable with the evolution of technology over the years. This is key, as, when an excavation operation digs a hole as part of a project, it will typically run across hidden electric or gas lines when using a backhoe or dozer machine. This can result in strikes to these lines, leading to a potentially hazardous or dangerous situation with impacts to nearby infrastructure.

Hydrovac technology is the answer to this, avoiding such impacts by offering a more controlled dig site that effectively resolves the risks of digging. Hydraulic excavation applies high-pressure water to break up the soil and create a slurry, and unlike digging, this method will not damage underground utilities. A vacuum system on the truck suctions up that slurry into a debris tank that can then be transported for disposal offsite. Because the excavation is precise, only removing the necessary amount of soil, less backfill is needed when the job is done. It even works in winter, where hot water swiftly loosens frozen soil.

Many North American municipalities are now calling for companies with these capabilities to provide excavation services using hydrovac trucks, and requirements like these have, in turn, created a clear pathway for Tornado’s products to find clients while further accelerating its market growth.

Over the past few years, the company has seen huge gains in its production rates, increasing production from around 80 trucks annually to around 120, with a 2025 target of 180 trucks and an additional milestone of having sold over 1,800 hydrovac trucks since 2008.

This growth in production rates has meant year-on-year profit growth as well, especially thanks to strong deals made with business partners who supply Tornado vehicles to their clients through a dealership infrastructure. Thiel tells us that unit sales have more than tripled—from 87 units in 2021 to 320 in 2024—and profit has grown by over $100 million.

The business has also expanded through mergers and acquisitions; just this year, Tornado acquired CustomVac Services, which has dealt with hydrovac services in the hazardous waste space. Tornado is also set on growing its operations facilities and is building another 5,000-square-foot facility in Red Deer, Alberta that will focus on production and help the company meet the growing demand for its products. Finally, the company has recently signed new deals with partners such as Ascend Hydrovacs out of Calgary, Alberta, to produce a new type of truck to be launched this year under the Ascend brand.

When it comes to what makes the company distinct in its field, Thiel says, “Quite simply, our products are the best in the industry.” Being of extremely high quality, all components needed to produce the best Tornado end products are sourced from top name brands.

Thiel is appreciative of the company’s suppliers, who give Tornado a competitive edge thanks to quick turnaround, leading to reliable and durable products. For example, the company employs a 24”-diameter core drill that makes for easier concrete removal on job sites as well as site repair that will reduce job time and not impact the environment.

At present, Tornado is looking to keep pace with rapidly evolving innovation in the industry by introducing the Vortex System 2.0, which has only recently arrived to market. Vortex 2.0 is a centralized information system that reports on the monitoring of different components on the vehicle and provides diagnostics, including a troubleshooting process directly in a van body. Thiel explains that this is an onboard interface/screen that displays the results of more than 100 sensors on a vehicle to report diagnostics and performance information—anything from a complex blower’s cubic feet per minute (CFM) rate to whether or not a filter needs to be changed. One can control functional vehicle components through electrical wire or even operate the vehicle itself using the system.

The Vortex 2.0 system serves to benefit operators, Thiel says, and can operate in any climate across Canada and the United States. For those who operate and manage a fleet of hydrovac trucks in a city, the real-time monitoring system permits all trucks to be tracked remotely via a global positioning system. This allows for a greater degree of planning in preventative maintenance scheduling, which in turn, keeps downtime to a minimum.

Certainly, this has been a volatile and unpredictable year for countless businesses, but thus far, for Tornado, there have not been any negative effects to production-related growth alongside its growing client demands. Thiel notes that, although there is ongoing uncertainty in the North American market (as well as globally) with challenges relating to the tariffs imposed by the United States, Tornado has not seen any tariff-related consequences or risks to its growth projections, and is proceeding with a sense of momentum and confidence.

This dynamism is evident as the company continues to expand its existing product lines and introduce new ones as well. For example, when it comes to hydrovac truck operations, spraying water into the soil creates a mixture that cannot be disposed of like typical concrete or asphalt; this newly created material needs to be disposed of at specific locations, which can often mean expensive dumping fees that are passed on to the customer.

There is a solution to this, however. Thiel tells us that at a utility event in October 2025, the company will be announcing its line of trucks which use compressed air instead of pressurized water to break down material. He points out that, although these have seen wide use in the European market, these trucks essentially do not yet exist in North America, so this fleet will be a huge asset to the excavation industry in the coming years.

Never resting on its laurels, Tornado Infrastructure Equipment will continue to focus on research and development, as well as providing a customer-centric approach, Thiel affirms. Continuing to provide the highest quality product in its industry is made possible by focusing on client needs and designing products with intent, while also providing relevant solutions to support customers’ daily operations.

To this end, Thiel says that digital and technological solutions are increasingly finding a home within the company’s wheelhouse. “It’s a digital age, and we are venturing rapidly into it,” he affirms. This includes finding solutions through technology to connect companies, truck operators, operations management workers, as well as customers and partners into a platform that will let Tornado further boost the quality of its service and product delivery while addressing manufacturing and supply chain challenges.

Adopting technological solutions will be a continued focus in the future to provide a more optimal customer journey, as well as tracking and monitoring the company’s performance through each point of interaction with customers over the typical 25-year life-cycle of a Tornado product. And as always, to address customers’ challenges, the company makes use of direct feedback to help gather intelligence on where it needs to focus its attention. Thiel believes that this approach will ensure that the team is aiming at providing quality end products while simultaneously searching for new business opportunities and markets to diversify its excavation equipment products. “Improving our customers’ journey, wherever that can be achieved” has been and remains the calling card of Tornado’s one-of-a-kind service in its field, he says.

As Tornado Infrastructure Equipment looks to the years ahead, its commitment to innovation, customer satisfaction, and product excellence remains unwavering. From its humble beginnings in 1984 to its position today as a leader in hydrovac technology, the company has never lost sight of the values that built its success: quality craftsmanship, responsive service, and continuous improvement.

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