“A semiconductor, often called a chip or microchip, is a material used for electrical conductivity. Its conductivity falls between a conductor and an insulator, giving it the unique ability to control the flow of electricity in electronic equipment and devices,” explains Innovation, Science, and Economic Development Canada (ISED).

For now, the long-established and innovative Canadian semiconductor sector is thriving. It continues to succeed in global markets, capitalizing on an increasingly digital and green economy. “Canada is recognized as an R&D and design hub, with world-leading expertise in high-value areas such as compound semiconductor fabrication and advanced packaging,” adds the ISED.

Indeed, semiconductors have become ubiquitous. They power virtually all electronic devices and systems, including appliances, smartphones, computers, automobiles, medical equipment, and satellites. From agriculture to aerospace, medical to mining, nearly all sectors rely on chips and semiconductor-driven sensors and systems.

Semiconductor production consists of three main segments: design and testing; fabrication; and assembly with final testing and packaging. The design phase, covering validation, verification, and testing, can take years and requires significant investment. Fabrication involves etching components onto silicon wafers, while the final segment focuses on assembly and packaging. Most chips are made from a single element—silicon—while compound semiconductors combine two or more elements to offer superior power and speed for next-generation applications such as EV power electronics and 5G/6G data transmission.

A new organization called FABrIC, dedicated to accelerating the Canadian semiconductor sector, has come on the scene as a collaboration between ISED and CMC Microsystems. It is backed by over $220 million from the federal Strategic Innovation Fund (SIF), and its mission is to lower barriers for Canadian companies developing semiconductor manufacturing processes, creating IoT products and services, and exporting to global markets.

“Funds from FABrIC will be distributed across startups, established firms, and post-secondary research institutions. Consistent, stable funding is critical if the industry is to grow and scale over the long term—something FABrIC provides,” said Gord Harling, CEO of CMC Microsystems, in a July 2024 EE Times article. In June, FABrIC awarded several million dollars to fund 20 projects pitched by promising firms.

Beyond FABrIC, Ottawa has provided direct cash infusions to several companies. In March 2023, the federal government allocated $36 million from the SIF to Ottawa-based Ranovus to boost domestic manufacturing and production of semiconductor products. In April 2024, the Trudeau government invested another $60 million in the sector, funding projects including IBM Canada’s semiconductor packaging plant in Bromont, Quebec.

“Semiconductors are part of our everyday life. They are in our phones, our cars, and our appliances,” stated François-Philippe Champagne, Minister of Innovation, Science and Industry. “Through this investment, we are supporting Canadian innovators, creating good jobs, and solidifying Canada’s semiconductor industry to build a stronger economy.”

Ontario and Quebec share Ottawa’s enthusiasm. “Ontario has emerged as a strategic hub for the industry that powers our modern world,” claims Invest Ontario. “Semiconductor and electronics businesses can find success in Ontario at every stage of the product lifecycle by tapping into the province’s R&D prowess, advanced manufacturing capabilities, and vast market potential.”

The Government of Ontario estimates that the province is home to roughly 180,000 electronics jobs, accounting for about half of Canada’s total. In 2022, semiconductors contributed more than $800 million to Ontario’s GDP, with exports exceeding $1 billion. Canada’s Semiconductor Council (CSC), a national trade group, supports the sector through services and research. CSC identifies Toronto/Markham, Ottawa/Kanata, Montreal/Bromont, and Sherbrooke as major hubs, while Waterloo, Saskatoon, Calgary/Edmonton, and Vancouver are growing ecosystems.

In June 2025, CSC released Strengthening Canada’s Semiconductor Talent Pipeline for Global Competitiveness based on industry leader surveys. Nearly three-quarters of firms surveyed anticipate doubling in size over five years, calling for thousands of new engineers. However, 80 percent of leaders cited talent shortages as the single biggest barrier to revenue and growth.

“Canada has a significant opportunity to add billions of dollars to its GDP by expanding the talent pool required to support the projected growth of the country’s semiconductor industry,” reads the CSC report.

The report points to several reasons for the shallow talent pool:
• Competition from other tech industries
• Talent drain to the United States
• An aging workforce nearing retirement
• A limited number of Canadian graduate students in relevant programs

To address these challenges, the report suggests:
• Streamlining immigration for skilled workers in in-demand sectors
• Enhancing graduate programs in semiconductor-related fields
• Investing more resources in STEM education
• Easing repatriation of Canadians who moved abroad
• Engaging retirees who still wish to contribute

While trade turbulence adds complexity with the threat of tariffs, Canada’s semiconductor industry seems to be doubling down on collaboration and diversification. And Harling noted that “Canada’s focus on design and niche technologies such as photonics and compound semiconductors means the country’s semiconductor industry is less likely to be affected by tariffs. You can send an email with a design in it. It’s not going to get a tariff barrier.”

Beyond trade deals, there is still plenty that can be done at home to ensure a strong, profitable semiconductor sector. “Canada’s semiconductor industry has the potential to significantly boost the national GDP by addressing the talent shortage that is currently limiting its growth. With talent being identified as the number one barrier to expansion, targeted initiatives and strategic investments in workforce development can unlock tremendous economic value,” reads the CSC report.

Canada’s semiconductor future hinges on design excellence and developing a robust, skilled workforce through strategic investments such as FABrIC and SIF funding. Without boosting STEM education, streamlining skilled immigration, and engaging seasoned professionals, talent shortages will curb growth and weaken Canada’s competitive edge. By filling these gaps, diversifying trade, and leveraging its R&D strengths, Canada can meet global demand, spark further innovation, and cement its leadership in the semiconductor revolution.

The post Canada’s Semiconductor Revolution<p class="company">Building a Skilled Workforce and Driving Innovation Forward</p> appeared first on Manufacturing In Focus.

Perhaps the most widely used metal material for building today is steel, thanks especially to its versatility as a resource. In a blog post for Built: The Bluebeam Blog, Erin Flynn Jay writes that demand for it has rapidly increased lately due to rising amounts of skyscraper construction. “Steel is an essential component for high-rise buildings due to its functionality and strength,” she writes. Steel is produced when iron ore and scrap metal go through the process of basic oxygen steelmaking (BOS) which uses a blast furnace, and/or electric arc furnaces (EAF) which use scrap steel or direct reduced iron (DRI).

An offshoot of this material is stainless steel, which is more appropriately used for applications that are found outdoors or that require a greater degree of hygiene, since stainless steel is more weather-resistant and cleaner for use by humans. The process of creating stainless steel is very different from its namesake, however, as it is an alloy that contains iron as well as many other elements like nickel, nitrogen, carbon, and more (including at least 10.5 percent chromium). These elements make it more resistant to corrosion; they are all melted together as raw materials and the material’s attributes are created through forming, heat treating, and cutting and shaping.

Aluminum is another versatile metal that occupies its own proprietary segment of the metal construction space. Like steel, aluminum has its own specific process known as the Hall-Héroult process, which dissolves the oxide alumina in molten cryolite. Unfortunately, the Hall-Héroult process consumes a lot of electrical energy and can produce significant amounts of carbon emissions. It can also be responsible for producing fluorocarbon compounds as a byproduct, which can add to both ongoing air pollution and climate change, so it is not an especially efficient process.

Copper is still used in electrical wiring and plumbing found in traditional homes, and in more aesthetic applications. According to Metal Supermarkets, “Copper can also be used for fascias, roofing materials and other ornate components, popular on buildings such as churches and cathedrals.” Various countries across both Europe and Asia are among the top copper ore smelters—China especially—and the methods for doing so can differ depending on geographic location and the environmental regulations within.

Other types of metals also have various uses in construction. For example, brass performs and is used very similarly to copper. Conversely, while cast/wrought iron has been overtaken in architectural usages, it can still be found in smaller applications closer to home, from the family car to skillets and more. Finally, lead is still used in certain construction contexts because it is considered easy to work with (i.e. roofing, paints), although prolonged lead exposure can be harmful to humans, so its use is heavily monitored for safety reasons.

After one of these materials is produced, it is moved to job sites and locations worldwide. An article by DFreight details the various methods used to ship metals and materials around the globe. First, ocean freight is described as “a cornerstone of global trade,” especially when shipping metal in bulk. This can be achieved through the use of bulk carriers and container ships, the latter of which are easier to handle, more efficient, and protect from weather and the elements. Conversely, air freight is a method that allows for speed, efficiency, and global reach. Shipping via plane tends to cost more than ocean shipping but can make up for it thanks to these other factors.

Compared to these two avenues, though, land vehicles like trucks and trains are perhaps the most tried-and-true methods of metal transportation. Trucks can be beneficial for smaller quantities and shorter distances, says DFreight, while railways can be helpful in connecting production sites to ports or distribution centres. When it comes to materials like steel, it is moved via specialized cargo haulers made to ship objects of particular size, since steel is often too large and heavy for typical commercial vehicles.

Countless brands in myriad fields today are considering how to make their processes more efficient—not only in terms of speed but also energy efficiency. One way that metal fabricators can improve the efficiency of the entire metal fabrication process is through embracing automation. Escofab states that tools like CNC (Computer Numerical Control) machines and laser cutting can automate metal fabrication to exact specifications and in much less time than traditional methods. Furthermore, custom fabrication can streamline the process by sending parts or sections pre-assembled for a client to easily assemble on site. By reducing labor requirements and improving client workflow, custom fabrication “can make a substantial difference in both project timelines and budget allocations.”

A blog post by Andy Smith for Prince Manufacturing explains that the use of lean manufacturing principles can increase productivity for metal fabricators. Lean manufacturing is a philosophy embraced by many businesses across innumerable sectors that follows a series of concepts that optimize performance while minimizing waste. These principles include simplification through keeping an organized workplace, being exact in what materials customers will need for a successful project, and continuous improvement through eliminating waste, reducing costs, and increasing efficiency.

The steelmaking process is very carbon emission-intensive. Caitlin Swalec, research analyst at Global Energy Monitor, writing for CarbonBrief, says that the iron and steel industry is responsible for as much as 11 percent of global carbon dioxide emissions and fabricators need to embrace carbon-neutral practices sooner rather than later. Steel fabrication specifically can—and should—enhance efficiency through automated fabrication technologies such as beam line technology, which is used to speed up the process of cutting and drilling steel beams. This tool reduces the time spent on steelmaking while increasing worker safety by not requiring a human to perform the measurements and cutting.

No matter what aspect of metal manufacturing is being examined, a great deal of thought and effort is being put into its processes to make them better than they were yesterday. For such a valuable industry the world over, metal fabrication simply cannot live up to its promise of becoming more efficient and meeting changing global efficiency standards without undergoing constant evolution in the ways that metal is created, shipped, and used. The future of the industry lies not only in greater speed and precision but also in cleaner production, smarter logistics, and stronger collaboration across sectors. As automation, lean practices, and carbon-reduction strategies continue to take hold, fabricators are not simply shaping metal—they are reshaping the very framework of construction and manufacturing for decades to come.

The post From Material to Final Product<p class="company">Metal Manufacturing for Construction</p> appeared first on Manufacturing In Focus.

Despite the shifting international landscape, VEXOS continues to provide its customers with cutting-edge technology alongside superior service and exceptional supply chain efficiency, growing its market share in the smart grid infrastructure, communications, computing, and security industries. Also serving the medical, automotive, military, and aerospace industries, the company has deep expertise in managing the entire electronic product life cycle on behalf of its clients, a service that significantly enhances ease of ownership. This comprehensive approach spans value engineering services for product development as well as prototyping and new product introduction (NPI), product evolution, maturity, and end-of-life phases. Leveraging its global network of facilities across North America and Asia, Vexos delivers these services at scale, ensuring consistency, flexibility, and cost efficiency for customers worldwide.

While EMS forms the mainstay foundation of its capabilities, Vexos also provides Custom Material Solutions (CMS). From PCBs to plastic and metal parts, CMS is a key growth vertical to serve original equipment manufacturers (OEMs) and new emerging technology companies.

Serving a broad range of clients from its facilities in Toronto, Ontario, Canada; Vancouver, Washington, USA; Ho Chi Minh City, Vietnam; and Dongguan, China, VEXOS expanded its North American presence last year to include a state-of-the-art, 40,000-square-foot EMS footprint in Juarez, Mexico to improve and maintain overall company efficiencies. To achieve such growth, the VEXOS team has worked tirelessly to increase capacity and efficiency. The company also acquired ControlTek in Vancouver, Washington, in September 2023, and earlier this year, it announced the completion of expansions to this facility, which include a cleanroom, a fourth surface mount technology (SMT) line, and Inovaxe custom storage.

In Asia, VEXOS announced an 8,000 square foot expansion of its Ho Chi Minh City facility, focused on box builds and assembly processes. The company also enhanced its SMT lines to increase capacity. In addition, VEXOS has moved its Dongguan operations to a newer facility near the Guangdong technology hub.

Backed by strong collaboration with its Markham operations, the company’s newest Mexico facility is in the final stages of achieving ISO 9001 certification. This upcoming certification will affirm the facility’s commitment to a rigorously managed quality system, driving consistent processes across services, from exceptional box build assembly to PCBA manufacturing and testing. Vexos’ Markham site also received the prestigious AS9100D certification—and reflects, in the words of Senior Vice President of Global Business Development Cyril Fernandes, the company’s strong growth within the aerospace industry. In addition to growth within the aerospace industry, the company has also seen notable increase in business from Fortune 500 companies, a development that holds tremendous promise for its continued success.

Initially launching in 2024 with two SMT lines, the Juarez, Mexico facility now offers four lines and is anticipating further growth in the near future. “We do think that we will get to six SMT lines within the next six to 12 months—a tripling of capacity in 18 months,” says Fernandes. “We have weathered the [geopolitical] storm quite effectively,” he continues, highlighting the facility’s impressive growth since its opening during trying times and its role in achieving such resilience.

To further boost the entire company’s efficiency, with the Juarez facility as his main focus, VEXOS announced the appointment of Hadi Farashahi as Senior Vice President of Operational Excellence in early September this year. VEXOS has reviewed its processes in detail to identify opportunities for improvement that will streamline the customer experience while boosting productivity. “Our global footprint provides customers with significant flexibility in choosing the site of production for their products being manufactured, ensuring the most effective landed cost for their good. A key element of effective landed costs is a significant focus on operational excellence. The addition of Hadi to our senior management team is tangible evidence of our commitment,” Fernandes explains, illustrating the company’s need for such strategic measures.

The VEXOS Vancouver facility collaborates with service-disabled veteran-owned small business (SDVOSB), CTEK2, to develop ‘set-aside’ capabilities for United States government tenders typically reserved for minority-owned businesses. “This initiative leverages our core skills to enable companies to engage with the U.S. government through this set-aside,” Fernandes says of this latest initiative.

“We’re very excited to be partnered with CTEK2,” seconds Erin Fortin, Director of Marketing and Strategic Analytics.

Taking another look at its Asian facilities, the company is also developing ways of expanding its Custom Material Solutions to offer custom commodities to its customers. Leveraging economies of scale, VEXOS provides significant savings on high-demand materials from trusted partners with whom it has had decades-long working relationships. Such products include custom-printed circuit boards, plastics, metals, displays, power supplies, and more.

Building on this innovative model, VEXOS is establishing centers of excellence in partnership with leading CMS partners in Thailand, Malaysia, and Indonesia. These centers provide expert guidance on materials and engineering capabilities, enabling SMEs to access premium-quality products at competitive, big-buyer prices—a level of value typically reserved for large-scale enterprises. By breaking down these barriers, VEXOS empowers smaller firms to compete globally, fuels industry innovation, strengthens the global economy, and transforms traditionally exclusive industrial markets.

When it comes to the team that keeps this formidable force in motion, Fernandes’ message is positive: “We’ll continue with the approach that we’ve been taking. We’ll continue driving the value proposition that we have, which is enabling us to grow business organically and inorganically,” he says. In the same breath, Fernandes underscores how COVID-19 brought about a lasting transformation in the company’s approach to supply chain management, changing how it does business for good.

As VEXOS continues its global expansion, Fernandes hopes for the company to retain its unique character—one of warmth and camaraderie. While this leader is open about the challenges of a team spread across the planet, he points out that online platforms do help bridge the gap to a large extent. To cultivate a sense of organizational unity, the company introduced an operational excellence program to help guide teams toward synergy in effective ways. “We have a really strong management presence and communication with the global team,” says Fortin. “I think that’s an important part of our success.”

With changing horizons ever present, VEXOS maintains its sense of resilience as it continuously adapts in the face of global transience. What remains unchanged, however, is its promise of unwavering commitment—commitment to quality, evolution, and service excellence.

The post A Global Rise<p class="company">VEXOS</p> appeared first on Manufacturing In Focus.

When Paul Koziorowski talks about his father’s journey, it’s clear that ProtoTier’s roots run deep in both craftsmanship and entrepreneurial spirit. “My dad was a mechanical engineer in Poland,” he recalls. “He had a business there doing plastic injection molding, so he had that entrepreneurial kind of spirit about him. When we immigrated to Canada, he saw there was a market for prototypes and thought he could start something of his own.”

The early days weren’t easy. Paul’s father had to navigate a new language, a new business environment, and the challenges of establishing credibility in a competitive manufacturing landscape. What he brought with him, however, was a rare combination of technical expertise, business acumen, and the willingness to work hard and adapt. That foundation helped him quickly find his footing, first working for other manufacturers and then taking the leap into entrepreneurship.

After gaining valuable experience in the Canadian automotive industry, Paul’s father partnered with a trusted colleague to form what would eventually become ProtoTier-1 Inc. The company name itself reflects its niche: prototypes for Tier 1 suppliers, the key manufacturers who supply directly to automotive OEMs.

In the world of automotive manufacturing, Tier 1 suppliers are optimized for high-volume production. Their equipment, workforce, and supply chains are geared toward producing hundreds of thousands—sometimes millions—of identical components. But when it comes to producing prototypes or low-volume, short-run projects, those same large-scale operations can be inefficient or impractical. This is the gap that ProtoTier was designed to fill. Its sweet spot is runs of 3,000 to 5,000 pieces, a scale that is too small for many large manufacturers but perfectly aligned with ProtoTier’s capabilities.

The company specializes in runs as small as a single prototype or as large as a few thousand components. The processes it uses mirror those of full-scale production facilities—stamping, forming, welding—but with a leaner, more agile approach that allows for rapid turnaround and cost effectiveness. “We manufacture in the same kind of ways as a production company would,” says Koziorowski, “however, we do it in a very cost-efficient way because we’ll do a lot of the parts trimming and holes on the laser as opposed to actual tooling, like you’d see in a production facility.”

This approach is particularly valuable in the prototype phase, when designs are still being refined. Instead of investing heavily in permanent tooling that might have to be scrapped if the design changes, ProtoTier uses flexible methods that allow for quick adjustments.

ProtoTier’s bread and butter is stamping and forming sheet metal, often for complex parts with multiple bends, curves, and cutouts. The team’s expertise lies in internal automotive components: hinges, latches, dash assemblies, brackets, and structural braces. These are not cosmetic parts, but critical elements that contribute to a vehicle’s safety, function, and durability.

A typical project begins when a customer provides a Computer-Aided Design (CAD) file. From there, ProtoTier unfolds the design into a flat pattern, determines the most efficient way to cut it, and programs its laser cutting systems to produce precise blanks. Those blanks are then formed on hydraulic or mechanical presses, using custom tooling created in-house on CNC machines. Sometimes the formed parts are finished on a 5-axis laser cutter, which allows for intricate trimming and the creation of features that would be difficult or impossible with traditional stamping dies.

Because ProtoTier controls so much of the process internally, the team can maintain tight tolerances and ensure that each part meets exact specifications, whether it’s a one-off prototype for testing or a few thousand pieces for a limited production run. Indeed, one of ProtoTier’s defining advantages is its commitment to doing as much as possible under one roof. This not only speeds up production but also safeguards intellectual property, a critical concern in industries where design leaks can be costly.

“As much as humanly possible, we do in-house,” Koziorowski says. “There are certain processes we just can’t do, like coatings or anodizing, but all the manufacturing we can keep here, we do. It allows us to maintain quality, speed, and control.”

And the benefits go beyond security and lead time. By keeping all stages of manufacturing in close physical and operational proximity, engineers and machinists can collaborate in real time. If a part needs to be adjusted, they can make changes on the fly instead of waiting days or weeks for an outside supplier to respond. This agility is one of the reasons customers return again and again.

While ProtoTier’s mainstay is automotive prototypes, sister company CanadaDocks is an example of how necessity can spark innovation. The idea emerged during the economic downturn of 2007–2008, when automotive work slowed and the company faced tough decisions. One of the partners needed a dock for his cottage, and rather than purchasing one, the team decided to build it themselves. “There was no real intention at that time to grow the company or go into that field,” Koziorowski shares. “It was created out of the need to survive and keep employees employed as long as possible.”

That single dock evolved into a product line and eventually into a brand that has carved out a place in the modular aluminum dock market. CanadaDocks’ products are designed for easy assembly, durability, and resistance to the harsh conditions of Canadian lakes and rivers. And just as in the automotive sector, precision manufacturing is a key selling point. The same laser cutting and CNC machining capabilities used for auto parts are applied to create perfectly aligned dock sections and accessories.

The synergy between the two companies goes beyond shared equipment—skills in design, material selection, and manufacturing processes flow both ways. Innovations developed for automotive clients often inspire improvements in dock designs, and vice versa. The result is a rare level of cross-industry creativity that keeps both companies competitive.

Yet for all its technical capability, ProtoTier’s defining trait might be the way it treats its people. With fewer than 30 employees, many with tenures exceeding a decade, the workplace operates more like an extended family than a factory. “We’re a small shop, and everybody’s almost like an extended family,” Koziorowski says. “We treat everybody fairly and respectfully as you’re just not a number here. We spend more time at work than at home, so we try to make sure it’s a place people want to be.”

Flexibility is a core part of that culture. Employees can adjust their start times to accommodate family commitments, and time off for personal events is met with understanding rather than pushback. Monthly barbecues in the summer, an annual Christmas dinner, and at least one off-site team-building event each year reinforce the sense of community.

It’s an environment where Monday mornings don’t feel like a grind. “It’s surprising on a Monday how many people will still be smiling and joking around compared to other places,” Koziorowski notes. The lighthearted atmosphere doesn’t mean a lack of discipline; when deadlines loom, the team works together to deliver.

While automotive manufacturing remains the backbone of ProtoTier’s business, the company has steadily diversified, taking on projects for American manufacturers seeking to keep production in North America, as well as clients in industries where production volumes are too small for traditional manufacturing plants.

The push toward electric vehicles has also brought new opportunities, and ProtoTier has produced battery cooling trays and other specialized components for EV manufacturers. The company’s ability to adapt quickly to new designs makes it an attractive partner for companies in fast-changing industries. “With the push for electric vehicles, we’ve started to do some electric car parts,” Koziorowski tells us. “With our knowledge and tools in-house, we’re very flexible.”

Rather than chasing rapid expansion, ProtoTier focuses on sustainable growth. The company owns land that could be developed, especially for CanadaDocks, but its priority is building customer relationships and expanding capabilities. “We’re content with our size right now,” Koziorowski says. “The growth we’re looking for is in outside automotive markets, diversifying the portfolio.”

At its core, ProtoTier’s success comes down to a blend of technical excellence, adaptability, and a genuine commitment to people, both employees and clients. The company’s ISO 9001 certification formalizes its dedication to quality, but the real proof is in the loyalty of customers and the longevity of staff members.

From a father’s vision in Poland to a thriving second-generation enterprise in Canada, ProtoTier’s story is one of resilience, creativity, and the value of keeping things close to home. This company has shown that a small, highly skilled team can compete with industry giants, not by outspending them, but by outthinking them.

As Paul Koziorowski puts it, “We’re not trying to be a big corporation. We’re a small shop where everybody knows each other, and that’s how we like it.”

The post Family Values, In-House Expertise, and a Vision for Lasting Success<p class="company">ProtoTier-1</p> appeared first on Manufacturing In Focus.

Based in Lexington, North Carolina, Think-PLC specializes in industrial automation controls but is developing a reputation as a systems integrator, blending hardware and software to create solutions for clients. Last profiled in Manufacturing in Focus in April 2023, Think-PLC has a fruitful partnership with German tech giant Siemens, the latter firm renowned for creating automation controls (among other high-tech products) for the industrial, manufacturing, healthcare, and transportation sectors, to name a few.

Think-PLC sets itself apart from the competition as the only Siemens Factory Automation and Machine Tool Solution Partner on the East Coast; the only Siemens Run MyRobot Experience Solution Partner in the U.S.; the only Siemens Braumat/Sistar Solution Partner certified in the U.S.; and a Rittal EPlan Exclusive Partner.

Solutions are brewing
Think-PLC CEO and Founder Bobby Cole tells us that the industry event in question was called Brewlogix, a symposium that Think-PLC hosts about four times a year. “We piggybacked on the craft beer craze to get folks to come network,” he shares. “We started these events years ago, and they’ve caught like wildfire. Instead of the traditional lunch and learn, people come out and enjoy a craft beer as we do a short deep dive into some technology.”

The pivotal Brewlogix event was held at a restaurant run by the Aviator Brewing Company, headquartered in Fuquay-Varina, North Carolina. For this gathering, Cole gave an address on Braumat, a Siemens process-control solution designed for the brewing sector. In the rapt audience, unbeknownst to Cole, and paying particularly close attention, was his host for the evening.

“I finish up and go to the bar to finally get a drink, and there’s the CEO of Aviator Brewing, Mark Doble. He said he really liked my presentation. He told me, ‘This is cool stuff; I’d like to hear more from your team and the Siemens folks,’” recalls Cole.

Doble’s company had been experiencing growing pains at the new craft brewery it had opened, and Doble describes his travails and the solution he found in a YouTube video: “Beer is very labor-intensive to produce. We were managing a lot of the process manually, taking temperature readings, monitoring boil times with stopwatches. Then, we moved to a 60-barrel system, which you cannot manage manually at all.” Software that was supposed to regulate this 60-barrel brewing system “was clunky and didn’t really work. So, we reached out to some friends at Think-PLC.”

Shortly after the Brewlogix event, Doble ordered Braumat software to manage his expanded brewing operations, tasking Think-PLC with installing the system and incorporating it into his new equipment. Think-PLC technicians “took what he had bought and retrofitted it, which we’re very good at. We were able to take what was good—which was the stainless-steel tanks, pipes, and all that stuff—keep it, and add a new control system that met his needs,” continues Cole.

In the video describing the project, Doble appears delighted with how things worked out. He praises the “awesome software” from Siemens, which “helps us manage the automation from front to back.” And he describes Think-PLC as “an outstanding partner—they basically saved us,” he says.

“Think-PLC came highly recommended by industry professionals,” Doble says. “We contacted Think-PLC and they immediately came to our rescue. We collaborated on the software development and were able to complete a working system fairly quickly. We were back in business! Think-PLC overcame challenges related to legacy hardware and made the system work.”

This gave Doble’s company “something we didn’t have before: true flexibility,” he shares. “We can now make changes on the fly and tailor the platform to match the real-world needs of our brewing process. This kind of adaptability has been a game-changer. We’re able to fine-tune operations, improve efficiency, and cut down on manual tasks—ultimately saving on labor costs and, even more importantly, valuable time. It’s exactly the kind of control we need to keep pushing forward and growing,” he continues.

“Think-PLC absolutely crushed it on this project. From the moment we brought them in, they were responsive, professional, and fully committed to getting us back up and running. They took the time to understand our unique setup, collaborated closely with our team, and delivered a custom solution that actually worked—and worked well. They navigated some tricky challenges with the legacy hardware and still managed to implement a reliable, flexible system that improved our overall efficiency. Overall, their performance was outstanding, and we couldn’t be happier with the results.”

When asked about the Aviator project, Cole is modest but does note that Doble was brewing beer within two and a half weeks of the installation.

More than just winning respect from a new client, the Aviator Brewing assignment highlights a big change in Think-PLC’s mission. Founded in mid-2019, the firm initially focused on designing and building automation controls (indeed, the PLC in the company name refers to “Programmable Logic Controllers—devices used to observe performance, compile and transmit data, and control automated processes, robotic systems, and machinery). In addition, the company did retrofit work, repairing and extending the life of legacy control systems. Nowadays, Think-PLC still performs these tasks but has considerably broadened its mandate.

Gold standard
Since our previous profile, the firm has “morphed into something more than what our humble beginnings were, which was just in industrial controls. Today, we’ve become the gold standard for what a systems integrator is,” states Cole. The team helps its customers cut their manual labor by hundreds of hours each week and see a return on their investment in just under a year.

The company has also expanded its workforce and manufacturing space from 22 individuals when our last profile ran to 34 today. Approximately 20,000 square feet of space has been added to Think-PLC’s manufacturing facility in Lexington, which is where most fabrication and manufacturing work is still performed. The company also operates an East Tennessee branch, which has expanded to meet growing customer demand and address the “lack of companies like ours in that territory,” says Cole. “We continue to add people there.”

As well as consolidating the Tennessee branch, the company wants to grow its reach in the Northeast, possibly opening a site in New England. Aerospace and data centers are booming in the area, and “from a sales perspective, those are the markets that you need to be aligned with right now,” notes Cole.

The company is UL certified, is a Rockwell integrator, and is a Siemens Solution Partner for factory automation, drives and motion, and machine tool systems. Think-PLC partner vendors include FANUC robotics and Alba manufacturing, which designs and makes conveyor systems.

The first and only go-to
Aviator Brewing isn’t the only prominent customer to have recently availed itself of Think-PLC. The company recently completed a project for Anduril, a leading defense contractor from California. Think-PLC utilized Siemens SISTAR process control software at an Anduril plant manufacturing Barracuda-M cruise missiles.

“The vertical for defense and aerospace was looking for someone to implement software for Siemens, and we were the first and only go-to,” says Cole.

The Anduril assignment also underlined the capabilities of the SISTAR system. While they share similarities, the Braumat automation system is specific to brewing, while SISTAR can be used “across the board, from making food to brewing beer to making rocket fuel,” says Cole.

New staff, new standards
Think-PLC used to do minimal promotion, relying mostly on word-of-mouth for new business; this has changed, and the firm now employs two full-time sales staff. The new team helped push revenue from roughly $7 million at the time of our previous profile to $11 million in 2024, and the company’s growth strategy includes a new corporate office with an additional 30,000 square feet of capacity.

With its growth and increase in personnel, Think-PLC continues to use a multi-step process to hire new staff. Prospective employees take written tests designed to gauge their industry knowledge and personalities, using material developed by business writer Patrick Lencioni to deduce a candidate’s strengths and weaknesses. “We’ve improved not only the technical questions that go into the questionnaire; we’ve improved the personality profiling as well. We’ve onboarded a few other personality trait skill sets,” Cole shares.

Once someone is hired, Think-PLC takes care to integrate them into its operations in a speedy, seamless way. “It’s very frustrating for people if they show up to your organization and you’re not prepared for them. They come prepared to work, and you don’t have their computer ready, or they’re not set up in your system, or people don’t know they’re coming on board. Those are things that frustrate not only the internal team but the individuals themselves,” notes Cole.

A new framework
Think-PLC’s penchant for organization and order is also evident in its use of an Entrepreneurial Operating System (EOS), which began last year. These systems offer a framework of tools and concepts that enable companies to formulate comprehensive, easily understood plans, processes, and duties. Think-PLC has utilized its EOS to document core processes and streamline operations, among other tasks. An EOS “gets all the players on the same bus, and cleans up your systems and your business,” says Cole.

This is important given current market conditions. “The biggest challenge right now is that the economy’s taken a downturn. We’re in a period of artificial inflation, and right now, manufacturing’s in a bit of a lull,” says Cole.

Think-PLC has adjusted by becoming more strategic in its marketing efforts. If sales are dropping in one area, the team pivots and invests marketing dollars in sectors that are doing well, such as “defense and datacom.”

Stepping into the future
He expects the overall economy to improve and is bullish about the company’s future. In this regard, Think-PLC staff recently utilized the EOS to create a document enumerating steps designed to help the business grow. These steps include the full implementation of a new Enterprise Resource Planning (ERP) system, purchasing its 30,000-square-foot facility (as opposed to leasing sites, the company’s present practice), more philanthropy and community involvement, a drive for more awards and recognition, and establishing new satellite offices.

Basic tenets that have always governed the company’s efforts, such as keeping customers and employees happy, are not forgotten but meticulously annotated on the master list for this rapidly expanding company.

Asked where he sees the company in five years, Cole says the goal is to “be the largest systems integrator in North Carolina,” and it’s clear that the company is well on the way to achieving this milestone. Think-PLC was ranked at number 24 in the Triad Business Journal’s 2025 Fast 50, and Cole was honored with the Journal’s 2022 40 Under 40 award and a 2024 C-Suite Award.

Presently, the company is building up its workforce to 55 employees, says Cole, and methodically instituting the full array of resolutions from the EOS document aimed at guiding the company to the top tier of systems integrators

Buoyed by its expanding team, its growing footprint, and its impressive roster of clients ranging from craft breweries to defense contractors, Think-PLC is proving itself a versatile and trusted systems integrator. The company’s ability to blend technical expertise with practical, customer-focused solutions has not only earned it a reputation for reliability but also positioned it for continued success in volatile markets. Guided by a clear strategic framework and ambitious yet mindful growth plans, Think-PLC is charting a course toward industry leadership, with a blend of innovation, discipline, and partnership that will keep it at the forefront of automation and integration.

The post This Industrial Controls Firm Stars in Its New Role of Systems Integrator<p class="company">Think-PLC</p> appeared first on Manufacturing In Focus.

“It is something really special, and not lost on us,” says Ana Lopes, Vice President of Sales and Marketing, Beacon Design. “And our customers see tremendous value in U.S.-made products.”

The company’s slogan, “Where Quality Drive meets the New England Way,” says it all. For ChemArt’s many customers, there are countless benefits that come from working with a proud New England company. “Made in the USA means quality craftsmanship, dependability, and our ability to react to demand,” says Lopes. “And it gives you outstanding service, because you’re not having to deal with lag time from working with somebody overseas. There is comfort in knowing you can execute a project on time, on budget, and with consistent communication along the way.”

Investing in people and products
ChemArt has come a long way since it was founded by research chemist Richard Beaupre. Serving in the Navy in the 1950s, he earned his BS degree in Chemistry from the University of Rhode Island in 1962, which fueled his passion for innovation. Soon, Beaupre worked for several companies, including Dynachem Corporation. Highly inventive, he developed and patented several unique core chemistry processes, including dry film resist polymers, still in use today. Created under a work-for-hire arrangement, Beaupre didn’t get into the royalty stream, but is listed on the patent; when he left Dynachem, he received a check as a gesture of appreciation. This became the seed money for ChemArt, which he created with his wife, Barbara, in 1976.

“When ChemArt first launched, it wasn’t a big company,” says Nick Jones, Vice President of Operations. “It was a small location in an old ice cream shop.” Within two years, Beaupre moved the business to its current Lincoln, Rhode Island site, and in 1998 created an additional building. ChemArt was profitable in its first year and every year since, allowing it to grow entirely on internally generated cash flow, which meant there was no outside funding. “This is a very rare accomplishment,” notes company CEO Hamilton Davison.

Planning for the future, Beaupre saw the benefits for the company and its customers of having everything—from initial concept to manufacturing and packaging—under one roof. This allows control over entire projects, from the initial phone call to getting products out the door. “That’s important to our customers,” says Lopes. “It allows us to meet emerging trends, optimize inventories without risk of shortage, and ensure consistent quality.”

ChemArt’s customers include government agencies, military, and historical organizations, as well as medical and aerospace, and for these clients and others, working with a well-established, U.S.-based business has its advantages; Beaupre developed many of the company’s innovations, such as dry film technology, plating recipes were internally created, and the company was vertically integrated long before its competitors. A trusted list of local suppliers and vendors from area companies completes ChemArt’s capabilities to allow the company to make most anything fathomable out of metal, finished in 24 karat gold or other finishes, then hand assembled and packaged in stock or custom boxes.

“Even today, we continue to innovate,” says Jones. Before he passed in 2018, Beaupre realized the importance of investing in technology to produce high-quality products at a reasonable cost. “A Christmas ornament only sells at a certain price point, so we have to figure out how to keep making it for less, given our price point and increasing cost inputs,” Jones explains. “So we’ve combined 3D printing as a form of tooling, rather than paying for traditional hard tooling, and use 3D printers in some of our processes. We’ve added automated cutters instead of hand-cutting, and digital printing instead of just screen printing. And we’ve automated basically through micro-controllers that allow data gathering, improved safety, robotics, and automated press forming, among other advances.”

Along with incorporating robots and updating equipment, the company has also improved its wastewater treatment facility, which has an excellent record. Protecting the planet is important to the company and its clients alike, who value ChemArt’s commitment to the environment compared to more far-flung manufacturing locales.

“Since everything ultimately drains to the Atlantic Ocean, there are very stringent discharge requirements imposed on all companies in this area, especially regarding metals, and we continuously monitor our discharge, sample it, and send it off weekly for chemical analysis,” says Davison. Occasionally, members of the Narragansett Bay Commission, the regional wastewater operator, show up unannounced, take samples, conduct their own analysis, and compare the two to ensure accuracy. In 2023, ChemArt had a perfect record; in 2024, it had just a single incident, due to employee error. “We take employee health and safety and environmental stewardship very seriously,” adds Davison. “We’ve got a great track record, and that’s something we’re very proud of.”

Constantly refining its processes and procedures, ChemArt continues to improve efficiencies and reduce waste and setup times. In the two years he has been with the company, Davison has seen significant improvements. “By being vertically integrated, we can bring different disciplines together to ideate and problem-solve in a way you don’t find in other non-vertically integrated shops,” he states. “They just have a piece of the process; we can look holistically across the whole production flow and optimize the entirety, not just individual pieces.”

“Three brands. One legacy. Made in the USA.”
ChemArt is proud of its three brands, which focus on distinct market segments. Beacon Design is centered on creating custom brass ornaments for clients including religious organizations, universities, non-profits, and fundraising programs across America. B Luxe creates tags, wraps, labels, and other custom luxury packaging solutions “designed to elevate high-end retail presentation.” And ChemTecUSA manufactures precision metal components for industrial and aerospace applications.

“Most of the products we make at Beacon Design support missions of non-profits, by giving them program income while deepening their donor basis allegiance and affiliation with the charity,” Davison explains. “That’s really the lion’s share of our business.” In fact, most of the company’s products are for non-profits. This includes educational and religious institutions as well as local and municipal government agencies and entities.

“The idea with Beacon Design is that we are creating products that reflect the missions of the organizations we are working with to create sustainable annual programs where they are turning their supporters and donors into lifelong collectors,” says Lopes. One of the company’s many long-time relationships is with the White House Historical Association, which furthers its mission to promote a deeper understanding of the Executive Mansion through millions of dollars annually in proceeds from the ornament.

ChemTecUSA, the company’s precision division, sells very tight tolerance parts to industrial clients that are used in subassemblies in medical, energy, transportation, defense, aerospace, and oil & gas. Products include filters, flow measuring components, connectors, springs, sharps, encoder disks, and critical components. B Luxe, meanwhile, uses its capabilities to make luxury attachments and accessories, which helps elevate and differentiate brands in the crowded consumer marketplace and create shelf awareness in retail spaces. Made of metal, these attachments and accessories can be configured to be attached to a box, handbag, perfume bottle, or other containers.

America’s jewelry state
Known as the ‘Ocean State,’ Rhode Island is famous for its striking coastline, rich history, Newport mansions, seafood restaurants, thriving arts scene, and jewelry industry. A leader in the state, ChemArt has made more than 70,000 unique projects in the past 20 years and has some 400 SKUs representing everyday items sold through its open line for retail.

Averaging about 120 full-time staff, the team expands leading up to Christmas, with its increased ornament production. “We can be at over 200 employees at peak season,” says Jones of the company’s roster, which includes manufacturers, assemblers, designers, engineers, and sales. In addition, it has about 150 independent field representatives supported by Beacon Design. These talented staff members, and a commitment to quality and service, continue to put the company ahead of the competition.

“We are lucky to have a highly skilled, collaborative workforce on projects both big and small,” says Lopes. “All those pieces of the puzzle are really important. And to say we have the largest output in the country, being the smallest state, is super impressive.”

CEO Davison joined the company about two years ago. Today, ChemArt’s former CEO remains active as head of the retail division. The transition brought an influx of strategic investments as well as experience and increased sophistication in certain areas.

“Having been through these sorts of transitions in the past, I can honestly say this has been one of the best—maybe the best—I’ve seen in terms of combining incredible history and capabilities with new ideas and technology in a seamless, productive way,” says Davison. “We have not lost any of our executives or managers in that process. There has been a great transition and melding of capabilities, which has been a lot of fun.”

When Davison arrived, he saw the company’s 17 distinct manufacturing steps and how they were precisely sewn together. “I was full of wonder and amazement—and I still am—on a daily basis here,” he says. “And I realized how hard it is to do, to come up with a quality product; maybe we are the only people silly enough to try it? It is really hard!”

When customers and others visit the company, they are often in awe of ChemArt’s dedication to quality and the intricacy involved in the products it produces. “I think for anyone trying to recreate this, the barrier to entry would be huge,” says Davison.

The manufacturing process varies depending on the project: the shortest time from initial conversation to production can be as little as six weeks, while high-volume, large-scale projects with many components can take months or more. Many clients do projects with the company year after year.

Although potential customers can choose to deal with cheaper offshore companies, ChemArt’s clients prefer consistent American quality, accountability, and timely turnaround. This is especially crucial during peak seasons, when customers can’t wait weeks or months for shipping from overseas. “And buying locally allows customers to purchase from us and not have to hold large inventories,” says Lopes.

The ChemArt advantage
Offering design, cutting, plating, advanced manufacturing, assembly, and packaging all in-house, ChemArt continues to attract new clients. “There are other companies that do everything we do—they just don’t do all of what we do,” says Davison. “If you were to go elsewhere, you would be paying three, four, maybe five companies, plus an artist or engineer. And each one of those companies or contractors would have their costs, plus their markup, whereas we just have one markup at the end, so that also keeps us competitive. And because we are vertically integrated, if something goes wrong, you don’t have people pointing the finger at each other, and saying, ‘that wasn’t me, that was your other supplier.’ We take a lot of pride in our quality here, so everyone views themselves as an inspector. When it shows up at their department, they make sure it looks like it’s supposed to look.”

Experienced in running plants in the U.S. and one in Canada before coming to ChemArt, CEO Davison says, “I would put the Northern Rhode Island workforce up against any that I’ve worked with. There is such a sense of craftsmanship, pride, and commitment to quality here, and it’s multi-generational. It’s really cool, and a great asset.”

Lopes, meanwhile, has been with the company for 26 years, and is continually impressed by the company and its staff’s dedication to their craft. “We take great pride in our ability to produce beautiful ornaments and keepsakes all year long for our customers,” she says.

“When you walk out on the assembly floor it’s like walking into Santa’s workshop. The joy and amazement you see in our employees while they handcraft beautiful product for our customers is inspiring.”

The post Crafting Ornaments, Luxury Packaging Accents, and Precision Components Since 1976<p class="company">ChemArt</p> appeared first on Manufacturing In Focus.

From its 140,000-square-foot facility, the team at Countryside Cabinets gives customers the opportunity to customize their choices based on wood type, finish, and accessories, all of which will set any project apart. And, with a new catalogue on the way as part of its 50^th anniversary celebrations—complete with its new Slim Shaker doors and the ever popular Quartersawn White Oak offering—the company looks to bring its offerings into new markets, ensuring that there is something for every room, style, and budget.

Rooted in family
Over its long history, Countryside Cabinets has made great effort to simplify the design and manufacturing process while strengthening its own internal culture. From its catalogue to its pricing structure and the level of service it provides, these efforts have been a major point of differentiation in the market.

“We’ve eliminated complex pricing structures in our catalogue and essentially put all our offerings into one single cabinet line,” says Marketing and Product Manager Anna Harteau of Countryside’s a la carte offering. “Designers don’t have to jump catalogues or cabinet lines to upgrade the product; we offer all architectural styles at each price point so customers can make decisions based on their preference instead of their budget.”

With the motto “Custom made simple,” Countryside Cabinets seeks to be the go-to source for cabinets on the basis of quality, aesthetic, function, and simplicity, taking the guess work out of cabinetry and becoming a true partner in the process. This approach can be attributed to the company’s founding. Countryside Cabinets was established as a family business in 1975 and grew throughout the years, doing so on a firm foundation of family values and open lines of communication entrenched in the company culture.

When the company was sold in 2020, that same commitment to its values carried forth—all that changed was a renewed sense of energy and the adoption of a growth mindset that would position the company to grow in the Midwest and beyond.

Currently, its sights are set on the Northeast, as Harteau explains. “We have outside sales teams in each region that do a great job of being our eyes and ears in the field,” she says. “We are still able to deliver the majority of our product on our own trucks,” though future growth could necessitate the use of third-party logistics.

Customer-led growth
Much of Countryside Cabinets’ growth has come about organically in response to demand, and customer feedback has informed the expansion of its catalogue as well as how the company operates.

As Harteau notes, “We really listen to what our dealers and designers are asking for, not only in the fashion aspect of our cabinetry line but in the function and quality as well. Our catalogue was built on dealer requests. Because we can do these custom requests, we’ll take what people have been asking for repeatedly and bring it into our line as standard.”

In the 1990s, the business invested in acquiring machinery to produce stock cabinetry to support the burgeoning multi-unit construction market, though it maintained the ability to manufacture simple modifications, which served it well as the market evolved. In the 2000s, there was growth in the single family home market and the demand for customization grew—and so too did Countryside Cabinets. From 30 employees to 300, and 75 pages to 500 pages in the catalogue, the company has come a long way over the last half century, but it remains committed to the values and the relationships it has built along the way.

Customer feedback has not only impacted the breadth of the company’s offerings; it has also led Countryside Cabinets to become a certified partner in sustainability. Recognizing that many of its processes were already “green,” a customer inquiry took it to the next level. “15 years ago, we had a builder reach out asking if we had an environmental certification that was required for a project of his and at the time we didn’t, but when we started looking into it, we realized that a lot of our practices were already aligned with that,” Harteau shares. “We were already purchasing hardwood materials locally whenever possible. We recycled. We eliminated process wastes as much as we could. Our sawdust is actually collected and used as animal bedding at local farms and any extra product that we have, we donate to Habitat for Humanity.”

For 12 years now, Countryside Cabinets has been certified under the Kitchen Cabinet Manufacturers Association (KCMA) Environmental Stewardship Program (ESP), which has guided its sustainability practices and continuous improvement efforts.

“As our manufacturing plant has grown and as our processes have needed to change, it played a really large part in us switching to water-based stains and paints. I think we’re a leader on that point. It’s very difficult to work with water-based and it took a lot of work internally, but we’ve been running that since 2014 and it’s been great for the environment and also for our employees’ health,” Harteau explains.

Collaborative success
At Countryside Cabinets, quality and safety go hand in hand, and these elements are embodied in the culture of the company. A healthy work-life balance is encouraged and as the company has grown, so has its commitment to open lines of communication. Feedback loops with customers and employees alike are a key part of Countryside’s continuous improvement strategy.

With standard quarterly meetings of the representative safety committee and continuous improvement team, everyone has a stake and their efforts are appreciated. “Our production moved shifts to four 10-hour days and that really helps with work-life balance—if we do have overtime requirements, our employees are still keeping their weekends,” says Harteau of the effort to ensure that work-life balance is a priority even when the going gets tough.

She also notes that there is a large Hispanic population in the region, many of whom are employed by Countryside Cabinets, so efforts have been made to create bilingual resources to ensure that everyone can communicate effectively and operate as a collective in the interest of quality and safety.

The company also hosts monthly birthday lunches which give employees an opportunity to meet with the president, director of operations, human resources, and their team supervisors, creating an additional line of communication between employees and decision makers. Harteau refers to it as, “an hour of face time where you can share an update on the company and tell people what’s going on and they get to give feedback on their own experiences and day-to-day life in the shop.” These insights, she says, are invaluable to the company’s leadership.

This year, given the company’s milestone 50^th anniversary, there is even greater cause to celebrate. Countryside Cabinets has hosted company picnics (one for each shift to ensure that everyone has an opportunity to participate) and other fun events to reflect on the long tenure of the company as well as its bright future.

To 50 more
The success of Countryside Cabinets is unmistakably connected to its culture, including its commitment to continuous improvement and its ability to consider and internalize feedback from its customers and employees. This is why its relationships, like the cabinets it designs and manufactures, are built to last.

For Harteau, the goal is clear: “We want to produce a product driven by quality and focused on value. We want to continue to exceed industry standards for semi-custom cabinetry and maintain relationships with the same family values that got us here.”

This principled approach will continue to serve Countryside Cabinets well as it looks to new markets across the U.S. Backed by a long tenured history and solid reputation, its semi-custom cabinet solutions will satisfy design and function requirements at every price point and its service delivery is sure to impress.

The post Made to Order. Built to Last.<p class="company">Countryside Cabinets</p> appeared first on Manufacturing In Focus.

“We are focused 100 percent on precision dispensing,” notes company Founder, Chair, and CEO, Dwight Carlson.

Consistency, perfection, precision
Coherix’s systems, sensors, and software are used to monitor and inspect industrial dispensing processes to ensure “consistency, perfection, and precision” are maintained—even in advanced applications like cutting-edge “lights out” fabrication. And impressive as Coherix’s products are, the company hasn’t forgotten the importance of the human element. Since our previous profile, Coherix has launched new training programs, workshops, and academic initiatives.

The company primarily serves the automotive and electronics industries (the company counts roughly 150 auto OEMs and Tier 1 suppliers as clients), as well as dispensing equipment manufacturers and system integrators. At present, Coherix is preparing to relocate to a larger facility in its hometown, expanding its footprint from 15,000 to upwards of 25,000 square feet. If all goes to plan, the Coherix Innovation Center, a space featuring an array of robotic systems and dispensing equipment for training and research, will triple in size following the move.

“We provide a tremendous amount of value by having the major robot manufacturers and all the dispenser manufacturers bringing in new things, testing them, and then briefing the industry on what’s what,” says Carlson. “We gain a lot of credibility. We’ve got the best team in the world in terms of dispensing systems engineers.”

When our previous profile appeared, the company was preparing to launch the Coherix 3D Mini, designed for use with mini-dispensing machines. This cutting-edge inspection/process control system can examine and report on the width, height, volume, and location of mini-beads as small as 0.2 to 3.5 mm. Newer products from the team include third-generation Coherix 3D sensors, which provide adaptive bead path monitoring during dispensing processes, real-time defect correction, and the processing power to enable AI-backed analytics. They have four times more physical memory than Gen 1 Predator3D sensors, resulting in faster processing, and boast protective hardware that reduces wear and tear while safeguarding sensors from splatter from materials. Storage has been increased tenfold so users can save more data from 3D scans.

“Now we can write the kind of algorithms that can really make this sing for the customer,” says Carlson of the new and improved Gen 3 sensors.

Service as value
Coherix backs all of these solutions with a strong commitment to customer service. “A lot of inspection products go into plants and don’t provide value… We don’t want our product in a plant if it’s not providing value,” Carlson says.

To achieve this, the team runs a comprehensive support program called Coherix CARES to ensure its products provide value to customers. Under the terms of this program, Coherix staff make quarterly visits to client worksites. Once on site, Coherix personnel test equipment and train staff, aiming to enhance plant efficiency, maintain consistency during dispensing operations, and reduce waste. Videos are made and presented to the client to highlight any dispensing variances.

“If you’re not getting any variation, no problem. If the bead is exactly in the right place every time, you don’t need anything else,” Carlson explains. On the other hand, if “the volume starts varying, and we can see it in these dynamic videos, we say, ‘Okay. We can fix that for you.’ We can put in our volume adaptive control. We can adjust the dispenser to make sure that the volume doesn’t vary, the process doesn’t vary outside the control limits.”

Coherix uses Adaptive Process Control (APC) technology to help establish these control limits. APC automates the control of industrial processes and adjusts parameters when necessary to ensure consistency and precision. Coherix 3D Lateral Tracking is an APC-enabled software solution that monitors and corrects bead position in dispensing operations. The product also offers feedback and can be integrated within an existing robotic dispensing system.

“Our target is to eliminate 90 percent of the dispensing downtime—we’d say 100 percent, but we want to be conservative,” says Carlson.

In addition to Coherix CARES, the company hosts regular workshops and training sessions. Total Dispensing System Engineering (TDSE) workshops led by moderator/engineer Terry Taylor are held at the current Coherix Innovation Center. Attendees come from robotics firms, dispensing equipment manufacturers, systems integrators, OEMs, Tiers, and the like. In a typical workshop, Taylor outlines technological developments and industry trends and discusses solutions to adhesive and sealant dispensing issues. TDSE workshops offer “very high-value information. We talk about how you can get to autonomous dispensing,” Carlson shares.

Open training sessions
While TDSE events cover the industry in a general way, Coherix also holds Open Training Sessions that are specifically focused on its own solutions. Clients attending these sessions receive instruction on everything from generating 3D adhesive bead renderings to establishing inspection paths for total coverage, loading and backing up projects, adding templates, and importing scan data.

“In these Open Training Sessions, people come in and learn about our systems. Engineers can come in. Usually, we charge for training like this, but we’re offering it for free to build those relationships,” explains Josh Anton, Marketing Communications Manager at Coherix.

For instance, Coherix has formed a partnership with the GameAbove College of Engineering and Technology at Eastern Michigan University (EMU) to spread knowledge about dispensing solutions. In a joint initiative, EMU mechanical engineering students will undertake intensive training in a university facility stocked with equipment provided by Coherix, Sames, Kawasaki Robotics, and Gonzalez Group. “When these kids graduate, they want a job; they want to be engineers and get their hands dirty. It works out great for us and other members of the EMA,” says Carlson.

The EMA is the Engineering and Manufacturing Alliance, a “not-for-profit corporation that promotes, facilitates, and enables research and education of dispensing systems engineering,” according to the group’s LinkedIn profile. Coherix is a strong backer of the EMA, with some of its staff playing important roles in the Alliance.

Artificial Intelligence represents a trend that engineers and manufacturers alike are watching very closely, and Coherix has been experimenting with AI, primarily with regard to machine learning. Carlson explains AI could help take factories to a level where skilled workers aren’t so essential. This could be a boon, given that existing workers in skilled professions are approaching retirement age and young people aren’t clamoring to replace them.

“What you’re shooting for is autonomous dispensing in lights-out conditions,” he says. “That’s the way we see it. We’ve got to get these plants fitted with AI-enabled automation. Any leader in automation manufacturing knows you have to get this stuff AI-enabled.”

Global presence
An international corporation, Coherix maintains operations in China, Japan, Europe, Mexico, and the Asia Pacific. And with an eye to the future, the company has already selected new regions for possible expansion. “We have Brazil, India, and Korea right on our radar. We’re doing business there, but we haven’t formed a wholly owned subsidiary,” says Carlson.

Despite its global presence, Coherix is still a relatively small company and thanks to its diminutive size, is nimbler and more adaptable than most high-tech giants, says Carlson. “With 85 to 90 people, you can really focus and move the ball fast,” he notes.

This does not entail broadening the company’s reach into brand-new markets, however. Some Coherix channel partners have implemented the company’s technology in sectors as diverse as residential glass and military supplies, but for its part, Coherix is sticking closely to the automotive and electronics markets.

Of course, the auto sector, along with the broader economy, has experienced some turbulence recently. “First of all, there came COVID. Then came the collapse of the electric vehicle in America. And now we have the Trump tariffs,” says Carlson, in response to a question about challenges facing the firm.

Agile, flexible, and tough
So far, Coherix has made it through, with the team able to source sufficient supplies of scarce semiconductor chips during the pandemic and benefiting from increased EV sales in Europe, even as electric vehicles lost popularity in America.

“You really have to be agile and flexible and tough,” notes Carlson, displaying the kind of attitude that will no doubt help steer the business through current economic maelstroms.

In fact, Carlson envisions a bright future: “We expect a 25 percent revenue increase this year. In 2029, we plan to be a little over $100 to $103 million,” he says. It’s not all about money, however: “Some exciting things are going on in the industry. And we’re going to get to lights-out automation,” he adds, with some obvious excitement himself.

The post Ensuring Precision, Even in the Dark<p class="company">Coherix</p> appeared first on Manufacturing In Focus.

“Since 1991, METALCON has been the only global event dedicated exclusively to the application of metal in building design and construction,” says Judy Geller, METALCON Vice President. “Each year, we bring together contractors, architects, developers, owners, installers, manufacturers, fabricators, and suppliers from more than 50 countries. With over 250 leading companies showcasing cutting-edge products, solutions, and game-changing technologies, METALCON is where the global metal construction community connects, learns, and grows.”

Produced by PSMJ Resources, Inc. in partnership with the Metal Construction Association, METALCON thrives on a dynamic exhibit hall, extensive education, hands-on training programs, and one-stop access to the industry’s most comprehensive range of products, tools, solutions, and opportunities in metal construction and design.

Something for everyone
There are many reasons attendees return to METALCON year after year, and one of the biggest is networking. Business in the metal sector is often face-to-face, and METALCON provides plenty of opportunities to meet up with old friends and make new connections. Since this dynamic industry is so widespread, METALCON draws builders, architects, contractors, designers, developers, owners, engineers, roofers, suppliers, and many others in renewable energy, environmental engineering, finance, and other areas.

“While METALCON doesn’t adhere to a single defined theme, our focus is clear: build better, build smarter—with metal,” comments Geller. “It’s a message that resonates across the entire built environment and speaks directly to those striving for greater performance, sustainability, and innovation in their projects.”

Over two and a half days, attendees can take advantage of education sessions designed to deliver practical insights and real-world solutions (excluding workshops, all education sessions are included with registration). Among the many free learning sessions are timely topics such as ‘Steel Pricing: Where Could it Go Next?,’ ‘The Value of Metal Composite Materials: How Durability and Design Flexibility Affect Cost vs. Value,’ ‘Improving Utilization and Revenue Through AI,’ and ‘Cold Formed Buildings: An Introduction to a Growing Movement,’ to name a few. “Additionally, we also host METALCON Online, which are industry-related webinars that take place year-round, with the opportunity to earn AIA credits whether you watch live or on-demand on our YouTube channel,” adds Geller.

Highlights and on-site demonstrations
Behind the scenes, a year of planning goes into making METALCON the premier event for the metal construction and design industry. The result is a show floor that is packed with unforgettable experiences—including a full-scale live build, new Masterclasses, Morning Kick-Off Sessions, Keynotes, the Design District, and much more.

One of the most exciting demonstrations will be The Eagles Landing Barndominium Build. To be erected on the show floor, the 2,500-plus-square-foot steel barndominium frame will later be moved, completed and turned into a permanent retreat for veterans in Hall, Montana. Partners for this remarkable project include Military Warriors Support Foundation, Scottsdale Construction Systems, The Barndominium Company, and numerous METALCON exhibitors.

“METALCON takes pride in helping our veterans,” says Geller. Anyone wishing to check out the build’s progress and help support the cause in materials, funds, or both, can visit www.metalcon.com/barndo. “Additionally, we have also partnered with Semper Fi & America’s Fund to collect donations for Las Vegas-based veterans, a non-profit organization we have worked with consistently.”

Contractors, remodelers, and other industry pros can upskill in real time with hands-on demonstrations and education using a variety of mock-ups, materials like aluminum, copper, and painted steel, and tools at the METALCON Training Zone. Delivered in English and Spanish, the Training Zone is sponsored by Sherwin Williams/MetalVue, and tools will be available to the audience for testing and purchase.

Presented by the Metal Construction Association (MCA) and the Metal Roofing Alliance (MRA), MCA’s Metal Mastery Clinics will offer expert training and industry best practices from the MCA and the MRA. Some of the demonstrations will include standing seam roofing panel installation, metal shingle application, retrofit systems, and proper techniques for on-site roll forming and machine maintenance.

Billed as “Where resilient design meets bold vision,” the Design District @ METALCON is an immersive hub featuring exclusive educational offerings and presentations from industry leaders. “Work in architecture, design, or engineering?” asks Amanda Carlow, Marketing + Event Coordinator. “Discover how metal can help you solve your toughest structural, environmental, and building performance challenges with exclusive education, networking, and innovations sure to inform and inspire your future designs.”

Sponsored by PPG, The Design District @ METALCON is a dedicated destination for architects, designers, specifiers, and engineers. “Architects and design professionals have access to AIA-accredited education, exclusive networking, and innovations reshaping the future of architecture and construction,” says Carlow. Features include curated morning kickoff sessions, an exclusive Design District hub, and the opportunity to learn and network with industry experts. “Whether you’re designing with performance, sustainability, or innovation in mind, the Design District @ METALCON is your gateway to metal’s full design potential.”

Another highlight of this year’s METALCON is the Stock Car Pit Crew Challenge. Sponsored by METALFORMING, the Challenge is all about speed, skill, and teamwork. “You don’t need to be a racing fan to test your skills or cheer on your colleagues in this fun and fast-paced competition,” says Geller.

And now in its fifth year, the Top Product Awards were created to highlight new, cutting-edge products in the metal construction and design industry. Products that were brought to market on or after January 1^st, 2024 are nominated in one of 15 categories and then voted on. The top three products are then announced and awarded at METALCON on October 22^nd, 2025 2:30 PM at The Deck.

Making connections
“METALCON is the only event dedicated entirely to metal in construction and design,” says Carlow. “While other events might treat metal as a side topic, at METALCON it’s the main event and everything either a seasoned pro or a newcomer needs is right here: hands-on demonstrations, expert-led education, direct access to cutting-edge products and innovations, and unmatched networking opportunities. There’s no better place to build face-to-face relationships, discover the latest products and innovations, and immerse yourself in what’s next for metal design and construction.”

Indeed, for more than 30 years, METALCON has fostered a longstanding reputation for relationship building, peer-to-peer networking, and access to expert insight. These factors, and many others, truly set METALCON apart from other industry events.

“Because METALCON brings the entire metal construction and design community together under one roof for two and a half concentrated days, it creates the perfect environment to connect with industry leaders, innovators, and decision-makers,” states Geller. “From structured events to casual meetups, METALCON offers a variety of networking opportunities designed to spark conversation, collaboration, and long-term relationships.”

Some of the scheduled networking activities at this year’s METALCON include the Valley of Fire Tour: Monday, October 20 | 7:00 AM – 1:00 PM (Off-Site), where participants can explore the Valley of Fire, led by U.S. Marine Corps veteran Adam Bautz. Women in the industry are invited to a breakfast focused on connection, insight, inspiration, and networking at Metal and Mimosas: Tuesday, October 21 | 7:00 – 9:00 AM (registration required). Speed Networking: Tuesday, October 21 | 3:00 – 4:00 PM is an opportunity to meet professionals in a dynamic, fast-paced environment. Attendees on the show floor can enjoy METALCON’S Welcome Party: Tuesday, October 21 | 4:00 PM – 5:30 PM, while the Future Leaders Happy Hour: Wednesday, October 22 | 4:00 PM will be held in The Backyard.

From in-depth workshops to educational sessions and more, METALCON is the place to experience the high-performance power of metal in design and construction, and the only event devoted exclusively to this rapidly evolving industry. Says Geller: “Now is the chance to learn from industry experts, network with the Who’s Who in the metal construction industry, and witness all the newest technologies and products related to metal. Thousands of attendees from all around the world will be under one roof and you should be, too. It’s a can’t-miss experience!”

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“Everything that was possible in internal combustion is now possible with Hangcha in an electric version,” says Louanne Rioux, Sales and Marketing Director at Hangcha Forklift Canada Inc.

While the company still offers internal combustion forklifts, Hangcha is seeing tremendous growth with its XC and XE Series and the high voltage lithium ion XH Series of forklifts. Presenting customers with alternatives to propane or diesel-powered forklifts—for use inside a warehouse or factory, or outdoors on rough terrain—Hangcha has options and add-ons to meet every need.

Pioneers in lithium technology
Customers in sectors as diverse as transportation, automotive, lithium battery development, steel and wire manufacturing, fruit growing, wood products, and many more come to Hangcha Forklift Canada for its range of electric forklifts, from sitdown forklifts, narrow aisle trucks, and warehouse equipment such as pallet jacks and stackers to tow tractors and rough terrain forklifts.

Depending on the model, capacities range from 1,000kg (2,200lbs) to 48,000kg (105,000lbs), with the Electric Lithium-ion Forklifts, to the Electric Tow Tractor, which handles up to 32,000kg (70,000lbs).

“Our full lineup is essentially complete now on the electric side—even the big capacities,” says Rioux. “We have a 36,000-pound (16,329 kg) version available in lithium and go up to 27 tons (23,586 kg). Being pioneers in lithium technology definitely sets us apart.”

Selling forklifts Canada-wide, Hangcha is seeing much of its growth in the province of Ontario, including the city of Mississauga, home to its Greater Toronto Area (GTA) warehouse. “Roughly half the trucks sold in Canada are coming out of Ontario,” says John Sedlacek, Hangcha’s National Sales Director. “We are targeting a lot of major users here.”

The reason, he says, is the province’s established automotive sector and the rise of new lithium battery developments in Windsor for the electric vehicle (EV) market. Another prominent sector for Hangcha is transportation, since it operates coast-to-coast, “and we have good trucks for them,” says Sedlacek.

The Hangcha story
Over the past quarter of a century, Sedlacek has seen firsthand the transition from internal combustion diesel and propane-powered forklifts to electric, alongside the shift in customer acceptance of lithium-ion battery technology. But for years, the return on investment just hadn’t been there. This was what prompted Hangcha to turn the forklift industry on its head, becoming the first manufacturer to build a truck from the battery up and bring affordable lithium to the market.

“As far as high-voltage goes, everything is going 80-volt or higher; the higher the voltage, the faster the charge time, the longer the runtime, and there’s less stress on the componentry,” he says. “We’ve had some great success stories selling high-voltage, which I didn’t think would sell that fast, but there it is—people are willing to take the gamble.”

Sedlacek is training and encouraging his team to promote the Hangcha story across the country. This includes the founding of the parent company in 1956 as the Hangzhou Mechanical Repair Factory in Hangzhou, Zhejiang, China; how the company shifted entirely to forklifts in 1974; the creation of Hangcha America in 2017; and the launch of Hangcha Forklift Canada in 2019. Today, Hangcha is among the top eight forklift manufacturers in the world. In just the past five years, the company has established locations in the Netherlands, Thailand, Australia, Brazil, Mexico, Indonesia, Japan, Malaysia, Vietnam, and France.

Along with over 5,000 employees globally, Hangcha has a strong dealer network, selling over 200,000 forklifts every year, many of them to repeat customers. “It’s interesting how the sales cycle is going,” notes Sedlacek. “It’s a different story now—what I’m selling and how I’m training my people across Canada… We have affordable lithium now for the first time in the marketplace.”

Why lithium-ion?
There are many advantages to lithium-ion technology, including faster run times, the ability to handle 24/7 operations, and, in some cases, more power, greater torque, and more speed.

As if those factors weren’t enough, one of the most significant in everyone’s eyes is cost. The ROI is so high that—depending on how many hours the forklift is in use—every third truck is essentially free. “The more you use it, the more you’re saving,” says Sedlacek. “That’s how it works.”

Apart from cost savings, there are also environmental and safety benefits to lithium-ion. The team has received plenty of positive feedback from customers praising Hangcha’s lithium-ion forklifts, including one who said his building couldn’t handle emissions from propane-powered forklifts. The client had invested tens of thousands of dollars in an air exchange system, which produced a lot of heat. By investing in lithium-powered trucks, the client—although continuing to use propane in some cases—saw his fuel costs cut in half.

For forklift operators, there are many benefits of lithium-ion compared to internal combustion engines. It is easier to adjust speeds with lithium-ion trucks—which are fully programmable—and the trucks are cooler to operate. Another consideration is that there is no need for a battery room with lithium-ion, as is the case with heavy, lead-acid “wet cell” batteries, which can be dangerous when charging.

“That’s another advantage of going with lithium,” says Yan Lamontagne, After-sales Director at Hangcha Forklift Canada. “There’s less pollution, and it’s an advantage over lead-acid. You don’t need to have water, and it’s safe. Compared to the internal combustion trucks, there is also less noise.”

A dynamic and durable fleet
Quality, customer service, and selection are just some reasons customers keep choosing Hangcha. Continually innovating, the company is proud of all its trucks.

The XH Series High-Voltage Telehandler has a capacity of 2,500 to 3,500 kg. Its many benefits include permanent magnet synchronous motor (PMSM) technology, able to reach a 25/km/h drive speed (no load), and a maximum grade ability of 45 percent. With three steering modes and two driving modes, the XH Series High-Voltage Telehandler is a highly maneuverable 5-ton, comfortable to operate with a driver assistance system, and options including air conditioning, radio, USB charging port, and more. With its lithium iron phosphate battery pack, LED lights, and overload monitoring system, it’s safe and reliable.

Other innovative lithium-ion products in the company’s XE Series are manufactured to replace outdoor trucks and come in 1.5-ton to 5-ton versions. “The XE Series is really one of those,” says Rioux.

Hangcha is also seeing growing demand for forklifts in its lithium-ion XC Series. A four-wheel cushion tire forklift, it has a capacity of 4,000 to 6,500 pounds. With a lightweight design, faster travelling and lifting speeds, and optional energy-efficient management, the Hangcha XC Series 4W cushion tire forklift “draws on the design concepts and technological innovations of 4W forklift trucks with lithium-ion technology and cushion tires to build a lithium-ion dedicated platform for cushion tire forklift with lithium-ion technology,” says the company.

At Hangcha, innovation comes hand-in-hand with safety and efficiency, and this includes the company’s Fleet Intelligent Management System. Hangcha FIMS provides valuable real-time information and data collection about forklifts and drivers, be it a single lift or even hundreds across multiple sites. Just some benefits of 24/7 GPS monitoring include safety, preventative maintenance, lower costs, and increased productivity, as trucks are analyzed for vibration, overspeed, abnormal operation, and more.

Meanwhile, the innovative Hangcha ADAS (Advanced Driver Assistance System) provides early warning of potential hazards. With a high-precision detection rate of about 98 percent, the ADAS offers 360-degree surround sensing, lightning-fast response with monitoring every 25 milliseconds, GPS tracking, route history, AI machine learning technology, and other unique safety features.

Powering what’s next
For years, Hangcha has been renowned for its positive and supportive company culture, which means investing in its employees. “It’s part of our work-life balance,” says Lamontagne. “We don’t have a high employee turnover, and have several staff members who have been here a very long time.” Expressions of employee appreciation, including coffee breaks, free snacks in the cafeteria, team barbecues, and welcoming out-of-town guests, mean a lot. “We do spend eight hours a day together, so we try to make it an interesting environment for people to feel welcomed.”

With a focus on quality and a team whose members are all pulling in the same direction, Hangcha Forklift Canada sees a bright future, both for the business and for lithium-ion technology. Sedlacek foresees growth in sectors such as mining and continued success in the lumber sector. “Wood is becoming a huge target for us; we’ve had some great success stories,” he says, adding that Hangcha is working with a well-known pallet company and recently made a deal with a business in Vancouver’s fruit belt. “Anything that grows in the ground seems to attract our trucks.”

As industries across Canada continue shifting toward cleaner, more efficient operations, Hangcha Forklift Canada is well-positioned to lead the way. With its proven track record, commitment to innovation, and a comprehensive lineup of lithium-ion solutions, the company is redefining what forklifts can do while helping its customers achieve long-term savings and sustainability. For Hangcha, the future isn’t just electric—it’s here.

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