Eureka 11.2020

www.eurekamagazine.co.uk November 2020

DESIGN | INNOVATE | ENGINEER

PRINTING
PROSTHETICS

AFFORDABILITY AND FLEXIBILITY
WITH ADDITIVE MANUFACTURING

IN THIS P14 P17 P21 P25
ISSUE THE FIGHT HIGH DRIVING REVOLUTIONISING
AGAINST FAKES TEMPERATURE IMPROVEMENTS LIQUID ANALYTICS



VOLUME 40 | NUMBER 11 NOVEMBER 2020 | EUREKA!

© Vladislav Ociacia - stock.adobe.com 17

21

10 25

10 COVER STORY 21 FASTENING & REGULARS 29 MOTORS
PRINTING ADHESIVES FROM F1 TO FARMING
PROSTHETICS EV BATTERIES: 05 COMMENT
DRIVING High-performance, high-
3D printing is not short of IMPROVEMENTS Remote working comes e�ciency, electric motors
applications, but one of the most with a range of pros and with their roots in motorsport
striking is in medical prosthetics, Sven Brehler, Engineering cons for the engineering are o�ering major bene�ts to
where it is already starting to Project Manager at TR sector, particularly when it farming vehicles.
revolutionise the provision of Fastenings, discusses the comes to training.
these vital pieces of equipment. need to ensure sustainability 32 POWER
in the design of electric vehicle 06 NEWS TRANSMISSION
14 ON THE TOPIC OF… batteries – one of the very AEROSPACE’S ZERO-
THE FIGHT AGAINST biggest challenges facing the ■ Renishaw shows EMISSION ELECTRIC
FAKES sector. how engineers can AXLES
#BeTheDi�erence
Counterfeit bearings can 25 SENSORS, TEST & A new product o�ering is
shorten the life of rolling MEASUREMENT ■ Ultra-e�cient UAV helping one company lead
bearings, leading to premature REVOLUTIONISING drive developed the charge into the future of
failure of machines, vehicles and LIQUID ANALYTICS commercial vehicle electric
other rotating equipment. ■ ‘Monster’ builds new propulsion.
The combination of complex limb!
17 ADDITIVE technical moulding and 34 COFFEE TIME
MANUFACTURING innovation in spectrometry ■ Modernised CHALLENGE
AM FOR HIGH has helped the creation of mechatronics factory A BUG’S DEATH
TEMPERATURE a concept that will prevent fully operational
cross-contamination of food & How can we e�ectively and
Will Dick-Cleland details drink, microbiological, chemical ■ Magnomatics secures ruthlessly rid ourselves of
how Honeywell Aerospace and forensic liquid laboratory o�shore wind funding the scourge of mosquitoes
assessed the use of a new high samples. while being completely
temperature alloy. ■ Collaborative robots to environmentally friendly?
help deliver vaccines
3
■ Knifemaker cuts
development time

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK

Invented in the 1800s. Optimised for today.

Visualisation of the von Mises stress distribution in the housing of
an induction motor by accounting for electromechanical effects.
In the 19th century, two scientists separately invented the AC
induction motor. Today, it’s a common component in robotics.
How did we get here and how can modern-day engineers
continue to improve the design?
The COMSOL Multiphysics® software is used for simulating
designs, devices and processes in all fields of engineering,
manufacturing and scientific research. See how you can apply it
to robotics design.
comsol.blog/induction-motor

EDITOR’S COMMENT

FAULHABER BXT SC

Power in new
dimensions

TOO REMOTE?

REMOTE WORKING IS something many instructional training videos that will o�er FAULHABER BXT SC Brushless
of us have had to get used to over the last step-by-step guides. But the question DC-Servomotors with Integrated
few months. In fact, many would argue remains whether these can or will ever be Speed Control
that this revolution in remote working substitutes for being there, keeping an eye
has been one of the few upsides of on someone and being physically available ■ High torque up to 92 mNm, continuous
the pandemic, meaning as it has the to be asked questions. output up to 60W
removal of some of the more irksome
aspects of one’s working life such as The whole workforce is having to ■ Compact design through complete
hours spent commuting, unnecessary address what their new reality is going integration
and time-consuming meetings or even to look like. There can be no doubt that it
irritating colleagues! throws up new challenges for all of us. ■ Stable and precise mechanical speed
Paul Fanning, Editor control from 200 – 10,000 rpm
Where remote working represents
more of a challenge, however, is in the MISSION ■ Ideal for pumps, handheld devices,
collaboration between colleagues that manufacturing, laboratory and industrial
is necessary to creativity and teamwork. STATEMENT automation
At the beginning of lockdown, many
assumed this would su�er, as workers left DESIGN | INNOVATE | ENGINEER www.faulhaber.com
in isolation failed to communicate with
their colleagues. In general, though, this Eureka! connects design NEW
has not proved to be the case – indeed, engineers with the UK’s
many businesses have reported that industrial heartbeat by WE CREATE MOTION
communication has in fact improved, as providing in-depth coverage
sta� members no longer exchange ideas on the very latest technology
with their immediate colleagues, but with developments and industry
colleagues from across the organisation. trends; keeping you inspired,
informed and innovative.
Technology has helped, of course, with
video conferencing becoming a key work
tool for so many of us. And perhaps in this
regard engineering has had an advantage,
having long been used to inter-company,
multi-site and multi-national projects
employing systems such as PLM systems
to bring the various parties together
virtually.

More challenging, though, is the
question of training. Of course it is
possible to have discussions with
individuals that explain to them how
processes work and telling them what
to do – and there is no shortage of

WWW.EUREKAMAGAZINE.CO.UK 5

NEWS | EUREKA!

Editor PAUL FANNING RENISHAW SHOWS
[email protected] HOW ENGINEERS CAN
#BETHEDIFFERENCE
Art Editor CHRIS CHARLES
[email protected] TO ENCOURAGE MORE Atendees will hear about life- “Showing real world
students to pursue engineering changing projects that Renishaw examples of how engineers make
ADVERTISING SALES 01322 221144 as a career, global engineering engineers have worked on, a difference in the world we live
technologies company, such as the manufacture of in gives students a real insight
Sales Director JEZ WALTERS Renishaw is hosting a webinar ventilators for the NHS to into how engineering can be an
[email protected] for school children and parents help COVID-19 patients and a exciting and rewarding career.”
as part of This is Engineering drug delivery system to treat
Sales Executive RAY GREEN Day on the 4th of November. Parkinson’s disease. This is Engineering Day was
[email protected] In support of the day, created first launched by the RAEng in
by the Royal Academy of “The current restrictions 2018 to encourage more young
Production CHLOE JEAKINS Engineering (RAEng), the mean that we can’t visit people, from all backgrounds, to
[email protected] webinar will give students and many schools in person, but consider a career in engineering.
their parents the opportunity we still want to engage with RAEng found that 60% of
Circulation Manager CHRIS JONES to find out more about the students as much as possible,” student attendees would
[email protected] opportunities in science, commented Rebecca Bound, consider a career in engineering,
technology, engineering and Education Outreach Officer at compared to just 36 per cent
Publisher PAUL FANNING maths (STEM) careers, hear Renishaw. “The webinar is an before launch of the campaign.
[email protected] from some of Renishaw’s opportunity to show students
younger engineers about their the diverse opportunities in the Renishaw’s education
ISSN 0261-2097 (Print) career journey and have the sector. We want to show how outreach programme supports
ISSN 2049-2324 (Online) opportunity to ask questions in engineers, from apprentices STEM curriculums in schools
an interactive Q&A session. to senior levels, played a part and colleges across Bristol,
Eureka! (incorporating Engineering Materials and Design in vital projects during the Gloucestershire and South
and Design News) is free to individuals who fulfil the The theme of this years’ pandemic, such as Ventilator Wales. Before the pandemic
publisher’s criteria. Annual subscriptions are £81 UK This is Engineering Day is Challenge UK. Some of our Renishaw hosted talks, hands-on
(£118 overseas or £153 airmail). #BeTheDifference. The young engineers also used workshops and events to
webinar, aimed for students in their skills to 3D print face encourage more students to
www.markallengroup.com Year 10 and above, will focus shields and use a laser cutter pursue engineering as a career.
on changing perceptions of to make plastic face mask clips To maintain its engagement
Eureka! is published by MA BUSINESS, Hawley Mill, engineering as a career and to provide comfort for staff levels it is now hosting virtual 3D
Hawley Road, Dartford, Kent, DA2 7TJ show how STEM careers can that had to wear them for long printing and coding workshops
Tel: 01322 221144 make a real difference in society. periods. for KS2 and KS3 children to teach
www.eurekamagazine.co.uk them new engineering skills.

MOVING ON? WWW.EUREKAMAGAZINE.CO.UK | NOVEMBER 2020
If you change jobs or your company moves to a new
location, please contact [email protected]
to continue receiving your free copy of Eureka!

© 2020. All rights reserved.

No part of Eureka! may be reproduced or transmitted in any
form, by any means, electronic or mechanical, including
photocopying, recording or any information storage or
retrieval s­ ystem, without permission in writing from the
Publisher. Please read our privacy policy, by visiting
http://privacypolicy.markallengroup.com. This will explain
how we process, use & safeguard your data The views
expressed do not necessarily represent those of the editor
of Eureka! Advertisements in the journal do not imply
endorsement of the products or services advertised.

Printed in UK by Pensord Press Ltd.

© 2020 MA Business

6

NEWS | EUREKA!

ULTRA-EFFICIENT Highest flow
UAV DRIVE DEVELOPED
on the coupling market
MOTOR SPECIALIST MAXON have been reached without controlled propulsion and
has collaborated with drone the excellent work of maxon,” steering mechanism with Safety has been CEJN’s top priority
startup Flybotix to develop said Samir Bouabdallah, CEO of two degrees of freedom. for many years, which led them to
performance-optimised Flybotix. “We are very excited “That gives the drones the develop eSafe: a compact one hand
brushless DC motors for a about this partnership and will aerodynamic performance of a operated, high flow coupling that vents
new kind of inspection drone. intensify it in order to advance helicopter and the mechanical downstream air before disconnection,
With the knowhow gained the industrialization of our reliability of a quadcopter.” eliminating the risk of hose whip.
from this and other projects, drone.” ASIO is surrounded by a eSafe is an innovative and patented
maxon is making inroads into protective cage, is collision- safety coupling offering the highest flow
the new UAV market, where Flybotix is a Swiss company proof, and allows access to on the coupling market, combined with
the reliability and quality of in the EPFL Innovation Park in tight spaces to carry out a low pressure drop. A low connecting
components are becoming Lausanne, which is also home inspections safely. An on- force and easy to grip design makes
more important. to one of maxon’s innovation board camera, combined with eSafe the natural choice when choosing
labs. CEO and founder Samir a high-quality display on the a safety product with top of the line
Two rotors instead of four Bouabdallah has 15 years remote control, allows pilots features. Contact Tom Parker Ltd for
was the approach used by of experience in developing to �y safely in hazardous areas more information on the eSafe range.
startup Flybotix to develop drone technology at the EPFL such as oil storage tanks,
the ASIO inspection drone, and at ETH Zurich. The drive underground mines or power Sales: 01772 255109 | Online: tom-parker.co.uk
which is set to conquer the system he developed with plants. Request a catalogue: [email protected]
market. This indoor drone his team is an algorithm-
for industrial facilities is built 7
around a patented drive
system powered by brushless
DC motors from maxon. maxon
worked closely with Flybotix to
develop electric motors that
are optimized for weight and
performance and speci�cally
adapted to this application.
These drives will allow the ASIO
to carry out long missions,
reach distant locations, and
save costs. “This world-class
level of performance could not

‘Monster’ builds new limb!

ONCE ONE OF the world’s race-ready prosthetic. medals at the 2018 Winter
top �ve snowmobile racers, Mike competed in The X Paralympics.
“Monster” Mike Schultz’s life
changed during what began as Games, an extreme sport Mike now has his own
an ordinary competition. After event for world champion- manufacturing company,
coming o� his snowmobile, standard athletes, with an BioDapt, which makes
Mike su�ered irreparable adaptive sports section. He prosthetic devices for users
damage to his lower leg, which won, and has since taken home that also require adaptable,
needed to be amputated below ten gold medals in
the knee. the Motocross, agile and capable
Snocross, and prosthetics.
Mike’s new prosthetic Snow Bike
device did not have the categories at
strength and agility for him to the X Games
compete again – ending his competition,
racing career. That was until as well
Mike took his own prosthetic as gold
limb designs to a machine shop and
and learned how to machine a silver

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK

NEWS | EUREKA!

MODERNISED MECHATRONICS
FACTORY FULLY OPERATIONAL

PRECISION DRIVE SYSTEM supplier, taken when designing the needs of EMS’s stakeholders. Magnomatics
Electro Mechanical Systems (EMS), production area. The highly As well as delivering innovative secures
has o�cially opened its modernised connected space with thoughtful o�shore
factory. The new space provides a equipment placement and new data products, EMS wanted its new wind funding
larger and more ergonomic work area connections has created a more facility to provide an impressive face
that will allow EMS to further expand e�cient manufacturing area that is for the business. With expanded and MAGNOMATICS HAS SECURED
its high quality precision o�ering. adapted to modern manufacturing modernised conference facilities over £300,000 in grant funding as part
methods. and an exclusive location adjacent of a £5 million UK government grant
Successful business to a nature reserve, Enterprise to develop and supply innovative
development drove the need for The design of the factory’s House o�ers an ideal venue for power electronics, machines and
more advanced facilities. EMS’s new production areas maximises hosting existing and potential new drives.
facility, Enterprise House, is located thermal stability to allow superior business.
in a private two acre site in Holton precision when manufacturing small The funding will be used for
Heath, Dorset. The 40,000 square and complex mechatronic systems. Environmental responsibility the Winder project, which will de-
foot facility provides enhanced The factory also provides enhanced was another important risk technology required for the
amenities, including an open plan research and development and consideration when designing the manufacture of large generators for
area for bespoke manufacturing. in-house testing facilities to deliver factory’s features, which include o�shore wind to the UK.
products that meet the precise solar panels on the roof and electric
Careful consideration was vehicle charging points in the Magnomatics Pseudo Direct
extended car park. Drive (PDD®) combines a magnetic
gear with a permanent magnet
“Despite unprecedented generator. The PDD is very e�cient
circumstances, opening our and extremely reliable with no
new factory and making it fully meshing gear teeth. Independent
operational remained a high analysis has shown this to provide
priority,” said Stewart Goulding, lower cost of energy.
managing director at EMS.
With recent government
“Now more than ever, delivering announcements showing
exceptional customer service investment support plans to make
is vital, and our new facility has the UK a world leader in o�shore
allowed us to streamline processes wind, it further emphasises
and invest in new technologies to Magnomatics’ leadership in the
continue delivering the highest �eld, as the company continues
quality products to our customers.” to develop and provide magnetic
gear technology to the wind sector
SOLUTION TO LAST MONTH’S across the world. Proving this
technology provides a credible
COFFEE TIME CHALLENGE route to UK construction of direct
drive generators for o�shore
The solution to last month’s Co�ee Briiv blends beautifully into your don’t have to estimate or worry wind leading to annual sales of
Time Challenge of how to design interior and sits perfectly alongside about when it’s time to change it. £1.2bn and dramatically increasing
an environmentally-friendly air plants or displayed as a centrepiece. the proportion of UK content in
puri�cation system comes in the Briiv will e�ectively improve o�shore wind farms.
form of the Briiv Air Filter. An intelligent app that tracks the air quality in a 36m² (387ft²)
your �lter usage as it runs, so you living space in just one hour. David Latimer, CEO of
Briiv uses 100% renewable and Magnomatics, said: “We are excited
natural materials to �lter the air in to have received this funding
your home or o�ce environment, and to embark on the project,
creating clean, safe air so you can which aligns perfectly with our
breathe as nature intended. experience in the O�shore Wind
Sector. Our technology is becoming
Using four fully biodegradable increasingly recognised across the
�lters, Briiv uses the natural world, not only for o�shore wind but
micro-structures of moss, for a multitude of applications.”
coconut, carbon and wool to �lter
air, the way nature intended. These
�lters are plastic-free and degrade
in a matter of months into
harmless soil.

8 WWW.EUREKAMAGAZINE.CO.UK | NOVEMBER 2020

NEWS | EUREKA!

Knifemaker cuts
development time

COLLABORATIVE ENGINEERS AT THE University of The Safety Knife Company products
ROBOTS TO HELP She�eld Advanced Manufacturing are a staple of warehouses around
DELIVER VACCINES Research Centre (AMRC) have saved the world and in 2015 Bill was awarded
a knife manufacturer valuable time an MBE in the Queen’s Birthday
WHEN OR IF an e�ective COVID- the environment around it and and wasted energy by simulating Honours.
19 vaccine is discovered, the next responds appropriately. The team the manufacturing process and
major challenge will be to scale up is also looking at ways of creating estimating the production costs of “The product we needed help with
its development, clinical trials and improved human interfaces, introducing additive manufacturing is called the ReAkta Knife which has
manufacture to unparalleled levels, which include wearables, and (AM) in its production process. a retractable blade. It was patented
says the Cambridge-based industrial technologies such as AI algorithms around 10 years ago, but we are yet to
design and product development to support the processing of a wide “We were given a de�nitive �nd a viable way of manufacturing the
partnership between Design range of reagents and cell culture answer,” said David Harris, General blade carrier,” said David.
Momentum and Plextek. consumables. Manager of Gloucester-based The
Safety Knife Company. “The answer “Originally we had the part
The two companies are working The human interface is vital as may have been that unit price was machined and more recently we have
together to develop technology connections such as feed and drain going to be prohibitive and that had them cast in aluminium; but both
for a new range of lab-based lines are made manually, and the we needed to look in a di�erent have meant an awful lot of quality
collaborative robots, bringing process of seeding and harvesting direction, but it stopped us wasting problems and the components need
together Design Momentum’s and the monitoring of overall cell our own time and money testing it. to be fettled manually to achieve
experience in life science health is overseen by cell culture the required �t. What we wanted
technology and Plextek’s sensor professionals. “We never would have got to from the AMRC was to research how
design capabilities and innovative that conclusive answer on our own viable it would be to use additive
use of micro-radar systems, to Design Momentum and without using the expertise of the manufacturing 3D printing to make
improve scale-up capabilities. Plextek are engaging with other AMRC.” this blade carrier part.”
biotechnology companies, including
Design Momentum and Clinical Research Organisations The Safety Knife Company was A team at the AMRC’s National
Plextek are developing technology (CROs) and Clinical Manufacturing formed in 1993 with a license from Bill Metals Technology Centre (NAMTEC)
that uses a multiple-sensor Organisations (CMOs), to Ireland who invented his pioneering conducted a feasibility study to
con�guration that monitors contribute to development. Fish Safety Knife after a chance determine whether Laser Powder
encounter with a farmer who had lost Bed Fusion (L-PBF) is a suitable
an eye when cutting a hay bale string. manufacturing process for the
aluminium alloy components
Bill, 84, was working as an required for the blade carrier.
engineer at Dowty Group at the
time and prototyped a knife with a
�sh-shaped handle which curves
around the blade making it
safer to use without
compromising
functionality.
Originally marketed as
a gardening product, now

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK 9

COVER STORY | ADDITIVE MANUFACTURING

PRINTING
PROSTHETICS

3D printing is not short of applications, but one of
the most striking is in medical prosthetics, where it
is already starting to revolutionise the production
and provision of these vital pieces of equipment.

T he additive manufacturing Bionics co-founders were recently strongest © Vladislav Ociacia - stock.adobe.com
(a.k.a. 3D printing) named as the 2018 Hottest Startup bre.
industry has been Founders in Europe, at The Europa
evolving rapidly over Awards. With the help of an Weight
the last few years and has broken awesome team and the support of is one of
into numerous industries and the limb different community, they the biggest
sectors. One of the most notable are pioneering a new bionic age reasons why
of these applications is the health inspired by science ction. people abandon
and medical industry in general. prosthetic arms,
Speci cally, one of 3D printing’s Engineered in Bristol, the Hero and that’s why the
most important contributions to Arm is a lightweight and affordable Hero Arm super
the eld of medicine has been 3D myoelectric prosthesis, available lightweight, with each
printed prosthetics. now in the USA, UK, Europe, full prosthesis weighing
Australia and New Zealand, for less than 1kg (2.2lbs).
The health and medical eld below elbow amputee adults and The bionic hand comes in
have been making use of 3D children aged eight and above. small, medium and large,
printing for over 20 years, but Grab, pinch, high- ve, st bump, and at 280g – 346g (0.62lbs
not to the extent that we are thumbs-up. – 0.76lbs), is by far the lightest
experiencing now. Industry is now multi-grip bionic hand on the
in a position where it is possible to The Hero Arm is durable market. The socket is exible and
use 3D printing to create anything and reliable. The prosthesis is breathable and it can be tightened
from dental applications to a medically certi ed and FDA or loosened with ease by simply
customisable prosthetics. registered Class 1 medical device. turning the BOA dial, giving your
All 3D-printed parts in the hand patients exceptional t and comfort
Perhaps the best-known are laser sintered from tough Nylon throughout the day.
example of 3D printed prosthetics 12, which has a tensile strength of
is found here in the UK, where 48 MPa, while the tendons in the Clearly this is an area where 3D
the Hero Arm, the world’s rst hand are made from the world’s printing plays a signi cant role,
clinically approved 3D-printed
bionic arm, with multi-grip Founders of Open
functionality and empowering Bionics Joel Gibbard
aesthetics was designed and built MBE and Samantha
by Open Bionics. Payne

Open Bionics was founded by
Joel Gibbard MBE, who began
tinkering with robotic hands
when he was 17 (and was the 2014
winner of the British Engineering
Excellence Awards Young Design
Engineer of the Year). There was
something about the movement
of a disembodied humanoid hand
that captured his imagination.
Hundreds of prototypes and many
crates of failures later, in 2014,
Joel co-founded Open Bionics
with Samantha Payne. The Open

10 W W W.EUREK AMAGAZINE .CO.UK | NOVEMBER 2020

The flexibility to according to Ben Folkes, managing
customise devices director of Shef eld-based
is a key advantage printing service 3D Folkes.
of 3D printing in He says: “Much like
the manufacture of traditional prosthetics,
prosthetics 3D printed
prosthetics are
made primarily of
plastic. Traditional
prosthetics make
use of an internal
structure called
a pylon that is
usually composed of
a strong but lightweight
material, such as titanium,
aluminium or carbon bre.
However, as 3D printing
technology improves, we are

beginning to have access to
printers which are compatible
with a range of new materials, such
as lightweight titanium. Titanium
provides greater durability and
strength than materials previously
used in 3D printed prosthetics.”

Flexibility is another key
advantage of the process in the

eld of prosthetics. This is because
each prosthetic must ideally t an
individual and therefore there is
no such thing as a ‘one size ts all’
solution.

Says Ben Folkes: “Every detail
needs to be custom made to suit
the wearer and before 3D printing
joined the scene, it could take
weeks, or even months, to make a
prosthetic limb that worked well
with a person. Not only are 3D
printed prosthetics more accurate,
but they take far less time to
produce.”

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK 11

COVER STORY | ADDITIVE MANUFACTURING

In fact Folkes claims, it won’t be colours, styles or with speci c apply only to children. Indeed, one
too long before creating precision designs – giving them even more the of the most obvious bene ts
prosthetics becomes even simpler appeal for children. of 3D printed prosthetics is the
than it is now. 3D scanning and cost. With traditional prosthetics
new body modelling technologies Another massive advantage costing at least $1,000 for
provide the option to 3D-scan limbs of 3D printing prosthetics for materials alone and up to $8,000
and then create prosthetics that are children is cost. Says Ben Folkes: in total, the far more affordable 3D
as accurate as possible. Not only “The reduced cost of 3D printed printed prosthetics create a more
will then result in prosthetics tting prosthetics can also greatly bene t accessible option.
better, but they will also look more children amputees. While the
lifelike. average lifespan of a prosthetic In comparison, an equivalent
is ve years, children grow so prosthetic arm created by 3D
This ability to customise rapidly that they often require new printing can cost as little as $50.
prosthetics is particularly vital prosthetics much more frequently. This reduced cost can signi cantly
when making them for children. The reduced cost of 3D printed help amputees in developing
As children grow, it is necessary prosthetics ensures that parents nations gain access to prosthetics to
to update their prosthetics on a of child amputees aren’t paying aid their mobility.
regular basis. 3D printing makes thousands of dollars every time
this process much easier. 3D they need to update their child’s According to Limbs
printing also makes it easy to prosthetic.” International, only 5% of the
customise prosthetics in particular approximate 30-40 million
But these cost bene ts do not amputees in the developing
world have access to any kind of
prosthetic device. A non-pro t
organisation called LifeNabled
is creating low-cost 3D printed
prosthetics in areas that previously
had little to no access to them.

The organisation was founded
by Brent Wright, who has been
working in the prosthetics eld
for over 20 years, and his wife
Meredith. It developed a new app,
DigiScan 3D, in an effort to simplify
and optimise its work, which is
mostly focused on the bi-annual
prosthetic clinics it runs in the Peten
region of Guatemala. DigiScan 3D
was built from scratch by Wright,
and is made to be compatible with
an iPad or iPhone, along with the

NEW PARTNERSHIP BREAKS GROUND ON PROSTHETICS

Essentium, a leading global at speed and scale. It also The Essentium + Vorum This programme’s give O&P practitioners more
provider of 3D printing provides a proven transition exclusive global partnership commitment to intentional time to focus on patient
solutions for manufacturing methodology including eliminates these barriers. and tailored goal-setting health, and patient access
industries, and Vorum, a proof of concept mapped to The partnership brings and tracking will help O&P to the most advanced O&P
world leader in CADCAM individual customer business together the Essentium practitioners make a swift devices available.
processes for the global O&P goals, design, deployment High-Speed Extrusion and successful transition
market this year announced path, training, installation 3D Printing Platform and from plaster-casting Carl Saunders, CEO
an exclusive global and support. materials with Vorum’s O&P methods to 3D printing and Founder, Vorum said:
partnership. The partnership CAD/CAM solutions and in any O&P production “Our partnership with
will deliver Essentium + Until now, the absence SurePath methodology. setting. It removes the risk, Essentium means we can
Vorum, a 3D Print Solution of a reliable 3D printing With 30 years of experience complexity and economic o�er O&P customers the
for Orthotics and Prosthetics platform and the lack of in O&P digital processes, barriers of transitioning con�dence that they will
(O&P) customers worldwide materials able to produce Vorum developed SurePath from legacy O&P production have the device they desire
that o�ers practitioners O&P devices of optimal to provide O&P clinicians to 3D production. By every time they print. We
a SurePath to success for strength and weight have with a proven approach for delivering the bene�ts of know that practitioners
the production of mass- been a major barrier to health 3D printing implementation, scale, speed, reliability and don’t want to waste their
customised O&P devices organisations establishing training and support. mass-customization, it will time with experimental
3D printing O&P devices. technology – they want to

12 W W W.EUREK AMAGAZINE .CO.UK | NOVEMBER 2020

Flexibility is

another key advantage prostheses. However, this

of the process in the will soon change. In the

�eld of prosthetics. This meantime, technology

is because each prosthetic is making cost-effective

must ideally �t an individual prosthetics a reality and

and therefore there encouraging creative
is no such thing as a people from all over the
world to participate in
‘one size �ts all’ their design.
solution Ben Folkes points to

another area where 3D printed

prostheses are making a big

difference. He says: “Thanks to

the rapid advances and reduced

costs of 3D printed prosthetics

even animals are now able to

enjoy prosthetics. We have all seen

the images of beakless eagles or

toucans having their independence

Structure 3D scanner. This allows prosthetics more affordable, but restored with 3D printed beaks.
3D images of potential prosthetic
users to be easily captured and so is the initial infrastructure. 3D People all over the world are
stored, even while of ine. This 3D
scanned mesh is then cleaned up printers are far more affordable rescuing badly injured animals and
and converted using the Remake
software. Finally, it can be opened than they once were, and much are using 3D printed prosthetics to
up in the cloud-based CAD
program Fusion 360, to connect the easier to use. In fact, creating a 3D restore their mobility.

nished project to the design for the model and printing the prosthetic is “Folkes sums up: “Not all
prosthetic itself, which will then be
3D printed to t the user’s body. no longer something only experts prosthetics are created equal and

LifeNabled can train nearly can do. 3D printed prosthetics won’t be
anyone to take a digital scan of an
amputee’s limb, send the le to a Today, people can create the answer to every amputee’s
be professionally modi ed by a
prosthetist (on the computer) and prosthetics from their own home or problem. While experts are still
then 3D printed for the exact shape
needed for the prosthesis. local 3D printer equipped centres, going to have to create some

Not only are 3D printed such as a university or hospital. prosthetics the traditional way, with

This easier access combined with 3D printing technology prosthetics

the lower cost means prosthetics are available at a fraction of the

will be available for those who cost and are quicker to make, more

might not have been able to afford versatile, and more comfortable.

one, or able to receive one if they In addition, as the technology

could. Most 3D printing materials continues to advance, you can

cannot yet replace the long-term expect to see further improvements

durability of traditionally-made in 3D printed prosthetics.” !

know that their investment printing platform combined
in a 3D print solution will with Vorum’s expertise
deliver the best devices will not only help O&P
for their patients. With customers embrace a faster,
our SurePath solution, we more e�cient method for
know that what Vorum can producing custom-made
provide in collaboration orthotics and prosthetics,
with Essentium is a trusted but the medical devices
end-to-end solution for will also be produced with
the digital design and high quality and durability.
manufacture of orthotics Together we are re-writing
and prosthetics that have the business and production
the ability to improve model for O&P professionals
people’s lives.” that bring profoundly
important mobility and
Blake Teipel, CEO and Co- independence to their
Founder of Essentium said: patients.”
“Our ground-breaking 3D

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK 13

ON THE TOPIC OF | COUNTERFEITING

THE FIGHT
AGAINST FAKES

Counterfeit bearings can shorten the life of rolling bearings, leading
to premature failure of machines, vehicles and other rotating
equipment. Technology can aid the fight against them.

C ounterfeit bearings are a either direct from the manufacturer counterfeit industrial products that
frequent cause of personal or via a certified distributor. These are relevant to safety such as rolling
injury and material damage methods guarantee that any technical bearings.”
to vehicles and industrial problems with the product can be
machines. The best way for buyers resolved quickly and efficiently. So why do some companies still
to protect themselves and their continue to purchase counterfeit
customers is to purchase only direct “Brand and product piracy is not a bearings? Cost is almost certainly
from the manufacturer or through a phenomenon that is limited to Asia or the overriding factor here.
certified distributor. South East Europe. It also takes place However, although the offer price
right on our doorstep,” says Ingrid for the bearings may initially
As a purchaser of bearings, you Bichelmeir-Böhn, leader of the Global look attractive, buyers must ask
need to be sure that the products Brand Protection Team at Schaeffler. themselves what the potential
you are buying are genuine and will “The German and European markets hidden costs are in terms of product
perform as the product datasheet are no longer only flooded with liability and credibility with their
states. Most don’t need to worry counterfeit luxury or consumer customers if the product turns
because they buy these products goods, there is also an increase in out to be counterfeit and things
inevitably start to go wrong. These
could, for example, be critical Fake bearings first
bearings on high value machinery seized in Spain in
in a production plant. The buyer 2010 could only
therefore needs to take into account finally be destroyed
the cost of any production downtime in December 2019
if the bearing fails early.

In addition to lost sales and
significant loss of image through
inferior-quality goods that may
affect future business, there have
been enormous costs arising from
the investigation, seizure and
professional disposal of counterfeit
bearings. The disposal requires tight
security, as only fully destroying the
counterfeits will eliminate the danger
for the consumer.

SPECTACULAR DESTRUCTION OF GOODS IN SPAIN ITALIAN CUSTOMS STOP COUNTERFEITS DESTINED FOR MOROCCO

During a raid that took the goods that had been At the start of January Once the BPT specialists Schaeffler rolling bearings
place in Spain in 2010, large seized could finally be 2020, the BPT received saw the photographs were on their way to
quantities of counterfeit destroyed. Those who
Schaeffler bearings were might have purchased an inquiry from the of highly suspicious Morocco. The BPT then
identified. The subsequent these counterfeit bearings
legal proceedings took were therefore saved from customs office in La goods submitted via the requested the seizure of
nine years to complete, both technical damage in Spezia, Italy, where a OriginCheck app, they the goods, thus setting
and it was not until potential applications and container of suspicious headed to La Spezia to proceedings in motion to
December 2019 that financial losses.
Schaeffler-branded check for themselves. Their ensure the destruction

rolling bearings had suspicions were confirmed: of the counterfeit rolling
been stopped in transit. 1,236 counterfeit bearings.

14 WWW.EUREKAMAGAZINE.CO.UK | NOVEMBER 2020

The German and

European markets are

no longer only flooded

with counterfeit luxury or

But the damage affects not only they can contact the consumer goods, there is case, please send
those companies that produce Brand Protection Team also an increase in counterfeit photographs of the
brand-name goods and invest (BPT) directly or via one suspect products to
heavily in research, development of Schaeffler’s national industrial products that Schaeffler, who can then
and quality assurance. It also affects companies. The BPT – are relevant to safety establish beyond doubt
those companies that install these the central department such as rolling whether the code in question
components. Rolling bearings are bearings
used in virtually every piece of
rotating plant and safety-critical responsible for inquiries related has been copied and used for
machinery and vehicles, from
machine tools, robots and wind to counterfeiting – can be contacted counterfeit products. Schaeffler
turbines, through to passenger cars,
trucks and rail vehicles. at [email protected] recommends using the OriginCheck

Whenever customers or sales The BPT receives many of these app to draw on the experience that the
partners have reason to believe
that a Schaeffler bearing they‘ve types of inquiries. In the last six Brand Protection Team is continuously
purchased may be a counterfeit,
months, the events below show that gathering to help you detect

counterfeit products are commonly suspicious and counterfeit goods.

found on a global scale. The OriginCheck app is available

free of charge for iOS and Android

HOW YOU CAN HELP? operating systems in German and

Should you come across a similar English. !

ONE DATA MATRIX CODE BUT SEVERAL CASES? A STRATEGIC APPROACH – THE FIRST CASE

Schaeffler sales partners an important role here. The first of these marked as a counterfeit in several countries including
regularly send inquiries Schaeffler has been able to duplicated DMCs was the system, all subsequent Greece, Brazil and Russia.
regarding suspicious identify duplicated codes identified by the BPT inquiries relating to It therefore became
products to the BPT, on counterfeit products at the end of 2019. This that code trigger a red clear that this code had
who thoroughly review that had originally code was immediately warning message. Soon been used worldwide
every single case. The been applied to original tagged in the system and after blocking the code, for different products.
data matrix code (DMC) Schaeffler products. reported as suspicious Schaeffler received The counterfeiters have
– a unique code for each These can of course only to the OriginCheck app’s inquiries regarding the clearly been at work – and
Schaeffler bearing – plays be counterfeits. users. Once a DMC is very same code from Schaeffler is investigating.

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK 15

32144_EUKA_WS2_Coatings 19/02/2019 16:03 Page 1

BE WISE WS2 Stops
galling of SS
WHEN YOU ADVERTISE and Titanium

Everyone wants to get what they paid for. Eureka is independently verified by Stainless Steels and Titanium are both prone to galling and
ABC, because we want our advertisers to know they’re getting the exposure seizing. WS2 is a very low friction dry lubricant surface
they’ve been promised. treatment, developed by NASA for use in deep space.
ABC. See it. Believe it. Trust it. It has been shown to provide a very cost effective
To advertise call Jez Walters on 01322 221144 solution, preventing both problems on threads and other
sliding surfaces.
www.abc.org.uk WS2 works well from -273° to 450° C and down to
10-14 Torr. WS2 has been applied to bearings and gears to
extend life.
Design out maintenance problems with WS2!

@: [email protected] &: 01430 861222

www.ws2.co.uk

Untitled-3 1 17/01/2020 12:28:57

RAL RAL RAL
9005 3015 9003
RAL
3018

For fast lead times and flexible, UK-based colour
compounding, contact [email protected]

Find your solution at:
www.distrupol.com

ADDITIVE MANUFACTURING | HIGH TEMPERATURE

AM FOR HIGH
TEMPERATURE
Will Dick-Cleland, Process Technology Team details how Honeywell
Aerospace assessed the use of a new high temperature alloy.

T he aerospace sector has traditional high temperature alloys
long been recognised as without compromising structural
an early adopter when it integrity while at the same time
comes to cutting-edge being compatible with AM. The
technology inventions, and as such it advantages of AM-compatible
is unsurprising that the use of additive alloys for high temperature
manufacturing (AM) as a production applications derive from the fact that
tool is relatively familiar in many of the components assembled in hot
the leading aerospace OEMS and sections of engines are usually some
their supply chains. of the most expensive, and due to the
harsh environment in which they work
It is fair to say that, to date, metal have short life-cycles. Using the L-PBF
AM processes have not performed process with high temperature alloys
well with the highest temperature offers manufacturers the opportunity
materials — that is to say, materials to bene t from better inventory
for components that operate at the management, reducing late penalties
top of the temperature range within due to tooling delays, and creating
jet turbines. In the aerospace sector more intricate shapes, often allowing
such applications would include, the integration of several components
but are not limited to the critical in a sub-assembly into one.
areas of a turbine engine such as
the back-end of the compressor, the It was to address this requirement
combustor, the high and low pressure that Alloyed worked with leading
turbine areas, and the exhaust. All aerospace OEM Honeywell to test a
parts in these areas of the engine are new high temperature nickel alloy
exposed to high temperatures and — ABD®900AM — with the L-PBF
higher levels of oxidation. process, to determine if it could
serve as a replacement for existing
For such high temperature high temperature casting alloys. The
applications, the aerospace purpose of this effort was to discover
sector typically uses nickel (Ni) at a high level if ABD®900AM
alloys such as IN738, IN713 and showed promise and warranted
MarM247. However, these alloys further development.
are incompatible with welding
techniques due to their chemistry, Honeywell rst engaged with
as they do not respond well to rapid metal AM processes in 2007 when the
thermal gradient changes and it is company had several prototype parts
virtually impossible to control the manufactured by external vendors.
amount of cracking during the weld Today, the Honeywell AM operations
process. Therefore, these alloys have have grown signi cantly in both size
historically been processed using and capacity and incorporate tensile,
casting methods where the cooling LCF, and creep testing equipment,
rates are relatively low. powder characterisation equipment,
and a vacuum furnace for stress
This is the conundrum facing users relief and heat treatment.
of metal AM within the aerospace In Arizona, more L-PBF
sector looking to capitalise on machines were added in
the advantages that the process 2020, and now the lab is fully
has to offer for high temperature equipped to manage end-to-
applications. It is this that has driven end powder and mechanical
further exploration of alternative characterisation,
materials that could replace

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK 17

ADDITIVE MANUFACTURING | HIGH TEMPERATURE

pre-production builds, and a full

range of R&D activities.

Honeywell is using the pilot-

production facility as a means to

either develop parts for production

that will be sent to a supplier for

manufacturing or working with

a supplier to cooperate in the

development of components for

production.

As an organisation, Honeywell

collaborates with universities and

companies around the world with

the intent of developing new

technology and exploring It was important

new technologies as they

emerge. After an initial to assess how the

introduction to Alloyed by alloy behaved when

a third party, Honeywell processed on a L-PBF

recognised the potential machine, and whether

of the Alloys By Design the welding operation project between Alloyed can affect the mechanical properties
(ABD) system brand involved would and Honeywell was the of the material and therefore, the
developed by highly assessment/qualification functionality of the part. To assess
respected metallurgists deleteriously effect of the ABD-900AM Ni- how ABD®-900AM behaved parts
from Oxford University and the integrity of the alloy powder for the next were subjected to vacuum heat
this stimulated further interest generation of additively treatment and Hot Isostatic Pressing
final part (HIP) often used on metal AM parts
to eliminate internal voids. There was
in the ABD®-900AM material manufactured high temperature no ‘post-weld’ cracking detected on
parts made from ABD-900AM.
and its potential for high temperature applications. Honeywell has
ASTM standard tensile tests were
aerospace applications as it was not undertaken a series of tests to confirm undertaken on the ABD®-900AM
parts measuring tensile strength,
prone to cracking. and optimise the properties of the breaking strength, maximum
elongation and reduction in area
The result of this initial alloy with some extremely positive between 427 oC and 927oC in both
build directions. The test showed
collaboration was a dedicated project results. good repeatability of test points,
with high temperature strength of
that would see Honeywell build a It was important to assess how the ABD®-900AM comparable with
“legacy” cast Nickel alloys which
limited number of test specimens in the alloy behaved when processed cannot be manufactured crack free
in AM.
its additive manufacturing laboratory on a L-PBF machine, and whether
Low cycle fatigue (LCF) is
located in Bangalore, India. the welding operation involved low-cycle endurance testing,
where components are subject to
Honeywell would build and test the — with all this implies in terms of mechanical cyclic plastic strains that
cause fatigue failure within a short
material to determine if the results rapid thermal gradients — would number of cycles. ABD®-900AM
was subjected to LCF testing at
merited continued investment and deleteriously effect the integrity of 650oC, the results showing that Non-
HIP-ed ABD®-900AM had superior
development. the final part. Various test geometries performance to HIP-ed alloy 718.

ABD-900AM is an age-hardenable, were trialled on an EOS metal system, The results of the work between
Alloyed and Honeywell show that
nickel-based superalloy designed and component scale testing was ABD®-900AM is an alloy that
demonstrates great potential for
specifically for use as feedstock in undertaken. It was found that there high temperature applications. The
material welds and fuses extremely
the L-PBF process. It is optimised for was no part distortion on cracking well, particularly when compared
with other high temperature nickel
environmental resistance and high- in the ‘as-printed’ condition, there alloys. !

temperature tensile strength, with was good surface finish, and a wide

a working temperature range up to processing window.

900°C (1652°F) in its age-hardened The ability to be able to re-use

state. unsintered material from build-

Exhibiting excellent creep to-build is obviously an important

strength, ABD-900AM has also factor when looking at the economics

demonstrated superior resistance of using metal AM processes.

to cracking during manufacture and Because of this, it was decided to

heat treatment, enabling complex manufacture and test parts made

part design. It is designed to be with ‘used’ powder, and it was found

free of solidification, liquidation and that there was no significant change

strain-age cracks, and showcases of properties in the parts made with

exceptional printability for a 40% γ’ used powder compared with virgin

-phase strengthened alloy. The ABD®-900AM powder.

ABD-900AM alloy also shows high as- It is often the case that parts must

printed part density of >99.9%. undergo a variety of post-processing

The scope of the collaborative activities after the AM build, which

18 W W W.EUREK AMAGAZINE .CO.UK | NOVEMBER 2020

BBeennddiittiguigsu®sd®rdyr-yte-tcehc®h..®..l.u. blurbicraictaiotnio-nfr-efreebeebaerainrginsgs
lliikkeeddrryylliinn®®

....d..rdyrliynl®inc®ucruvrevded
linleinaeraprrporfoilefisles

CurvCeudrvreadil praroilfpilreosfifloerstfhoer ethnetierendtireyldinr®ylin®
linealinr esayrstseymsteramngraenmgeadmeafdroemfrohmardhard
anoadnisoeddisaeldumaliunmiumini.uDmif.feDrieffnetrecnutrvceudrved
direcdtirioencstiopnossspiobsles.ibCleu.sCtoumstisoemdisperdojpecrotject
planpnlainngnsinegrvsiecrev.iIcdee.aIdl feoarlufsoer uinsceoinnctroonl trol
panpelasn, emlso,vminogvsincgresecnrse,eonrsm, oarcmhiancehainde- ad-
justmjusetnmtse.nTtsh.isThmisotmioontipolnasptilcas®ticasn®dand
furthfuertdhertadielstaaitlsigautsig.cuos..ucko/.cuukr/vceudrvraeidl rail

igusig® uCs®asCwaesllwReollaRdoad motmioontipolnasptlicas®ti.c..s®fo..r. lfoonrgloenr gliefer life
NorNthoarmthpatmonptNoNn 4N7NP4W7PW
Tel 0T1e6l 0041660747264707240
salessa@[email protected]

THE TAPE
ENGINEERING
EXPERTS

We Do More Than Sell Tape –
We Engineer Solutions

tesa double-sided tapes are suitable for bonding in manufacturing
industries using all major materials such as metal, plastics, wood
and rubber. They are lightweight, provide an immediate invisible
secure long-term bond and together with fast and easy
application mean, it is possible to move quickly to the next
production step. Saving time and improving process speed.
Each year, more than 100 new products are developed and for
many patent protection is obtained.
Talk to us and see how the ‘Experts in Tape Engineering’ can
help you.
tesa UK Ltd
Yeomans Drive Blakelands
Milton Keynes MK14 5LS
Tel: 01908 500 235
Email: [email protected]

tesa tesa.co.uk

MAXIMISE
PRODUCTION.
MINIMISE
DOWNTIME.

For over fifty years, Nylacast have helped and
assisted equipment manufacturers to enhance
machinery performance, e ciency and safety
through the design, manufacture and supply
of award-winning materials technology.
Manufacturing components from initial
chemistry to end product, Nylacast’s full
engineering solutions enhance performance
and reduce maintenance through their
corrosion resistance, low weight and
low friction.
How can you enhance your projects?
Speak to our engineering team today.

www.nylacast.com/industrial-equipment | [email protected]

FASTENING & ADHESIVES | ELECTRIC VEHICLES

EV BATTERIES:

DRIVING IMPROVEMENTS

Sven Brehler, Engineering Project Manager at TR Fastenings, discusses
the need to ensure sustainability in the design of electric vehicle
batteries – one of the biggest challenges facing the sector.

A s the new 70-plate cars EV waste but also profiting by The Faraday Institution - the
roll off garage forecourts importing and recycling EV waste UK’s independent institute for
across the UK, 2020 is from abroad. electrochemical energy storage
predicted to be another research - has suggested that
record-breaking year for electric In Japan, Nissan opened a recycled material could be a key
vehicles in this country. factory for the refurbishment of input for the eight Gigafactories
used EV batteries for repurposing it forecasts the UK will need by
A report by Statista published in electric cars as well as vehicles 2040 to meet domestic demand for
in May forecast that electric requiring less power, such as
vehicles will make up more forklifts and golf buggies, lithium ion batteries.
than 10% of new UK vehicle and in street lights.
registrations this year – up from Likewise, Toyota BATTERY LIFE
just 3.2% of vehicles in 2016. has linked units to
solar panels to provide Securing the
It is vital now that all of us power to shops in Japan. raw materials
involved in the EV industry work these factories
collaboratively to help the sector
grow in a sustainable way.

BATTERY LIFE

As electric vehicles become
more popular, the number of
EV batteries coming to the end
of their usefulness on the road
will soar. But whereas traditional
lead-based car batteries are
commonly recycled in the UK – so
much so that the majority of a new
lead-based battery is recycled
material – that is not the case for
EV batteries.

Last year a joint study published
by researchers from the University
of Birmingham, the University
of Newcastle and the University
of Leicester concluded that the
rise in popularity of EVs had not
been matched by a solution to the
problem of recycling the end of life
waste of their components.

The researchers argued that
there was an opportunity for the
UK to be at the forefront
of a new sector in the
recycling industry
to meet that
challenge –
potentially
not only
handling UK

NOVEMBER 2020 21

FASTENING & ADHESIVES | ELECTRIC VEHICLES

will need could be a mammoth

task in the face of a global rise in

demand, and the fact the mines

producing the minerals needed aren’t

exactly on our doorstep. Lithium and

manganese production is dominated

by Chile, Australia and China, but

the majority of cobalt comes from

less stable countries, in particular the

Democratic Republic of Congo.

Concerns have already been

raised by some experts that mining

output of some of these minerals

will not be able to keep pace with

the growth in demand for electric

vehicles.

While the Financial

Times reported recently “Putting Design
(6/9/20) that a number of for Manufacture at the
companies are investing heart of the system is key.
in Cornish mines in
Designers working with
the hope of sourcing the development of new product as efficient and effective
suppliers from the outset as possible, but still ensure its
low-cost lithium businesses to actually constituent parts can be quickly
and easily separated for recycling
domestically, a secure can reduce the number carry out the recycling when it runs out of juice?

supply from recycled of components in their process. CUTTING COMPONENTS

sources of the minerals product and increase All of us involved in Putting Design for Manufacture
at the heart of the system is key.
needed for EV battery their e�ciency“ the EV industry have a Designers working with suppliers
from the outset can reduce the
production in the UK would role to play in improving the number of components in their
product and increase their
provide assurance that sustainability of the market. efficiency.

output could continue no matter Some parts of a lithium ion At TR Fastenings, for example,
our specialist teams work closely
the political situation in other battery are already reusable as with our customers from the very
early stage of the design process,
countries. are the fasteners and components with our engineers able to develop,
test and put into production
within EV battery housings, innovative solutions to problems.

JOINT PROJECTS busbar assemblies and electrical TR Fastenings is a specialist
in the design, engineering,
Work is already underway on connectors within the battery, as manufacture and distribution of
a comprehensive range of high-
joint projects organised by the well as in the charging sockets and quality industrial fastenings and
assembly - particularly for the
Faraday Institute and involving facilities. automotive sector.

scientists and industry to increase The fasteners and components If we are to keep the cost of
replacing and recycling units
the efficiency of batteries and include silver plated copper down, we need to develop greater
standardisation of batteries so that
make them more environmentally or brass connector pins, brass a one size fits all system can be
created for end of life disposal of
friendly. inserts, stainless steel bolts, steel all of the constituent parts.

The aim of the ReLiB project self-drilling screws, aluminium In addition, unless there is a
sustained focus on tackling the
(Reuse & Recycling of Lithium connections and compression end of life situation for the current
generation of batteries, the green
Ion Batteries run by The Faraday limiters. benefits of the technology are at
risk of being undermined. !
Institution) is to secure the At the end of the battery’s

recycling of close to 100% of the functional life, these components

materials in lithium ion batteries should be easily removable for

in the automotive sector, by separation and recycled for use

identifying and removing the in other products, whilst allowing

technological, economic and easy recovery of the spent battery

legal obstacles to it. It includes cells.

developing new methods of But if we are to move to batteries

isolating the minerals used so that are near 100% recyclable, we

they can be recycled, identifying need to do more.

second life uses for the Those designing the next

components, reviewing the generation of EV batteries must

regulations on battery consider at the start of the

recycling to process - rather than as

ensure they are an afterthought, or not

fit for purpose at all - how units will

- and of course be disposed of. How

encouraging can we make the

22 W W W.EUREK AMAGAZINE .CO.UK | NOVEMBER 2020

New transparent

Grilamid TR HT 200

for Healthcare & Medical Applications

Steam Chemical & stress Overmolding
sterilisation crack resistance of LSR possible

Demand for tailor-made polymer materials optimised for specific uses is steadily growing. On the
downside, quantities of waste material to be disposed of has increased greatly due to the use of
disposable articles. To counteract this, EMS-GRIVORY has developed this new transparent high-
performance polymer which can be sterilised several hundred times and therefore, is reusable.

The new Grilamid TR HT 200 is greatly diversified due to its crystal-clear transparency, high mechanical
strength and toughness as well as its good resistance to chemicals and can be used for multiple
applications.

Your innovative development partner

EMS-CHEMIE (UK) Ltd. • Business Unit EMS-GRIVORY
Darfin House, Priestly Court • Staffordshire Technology Park
Stafford ST18 0LQ • Great Britain
Phone +44 (0) 1785 283 739 • Fax +44 (0) 1785 283 722
[email protected] • www.emsgrivory.com

MONTHLY E-NEWSLETTER + BI-MONTHLY MAGAZINE

Promoting
the success of
manufacturing
and engineering

in Ireland

COVER STORY COVER STORY 6,000

LCEOALLRANBINORGATIVE MANUFACTURING’S Manufacturing &
NEW NORMAL design sites
Collaborative robotics
revolutionises industry Has the pandemic changed digital 10,000
transformation forever? Key decision
makers
July 2020 • www.madein.ie 22 Medical 25 Design September 2020 • www.madein.ie 18 Profile 26 Automation 26/10/2020 17:20
How IMR’s work is The electronic Partners in green Cosmetic
19 Agri-Tech helping develop new apple improves 15 Motors power Cobots
New technology ventilators pick-and-place Beyond Industry
is driving 4.0
Agriculture 4.0

001_MADE_JULY20.indd 1 07/07/2020 01001:2_0MADE_SEPT20.indd 1 07/09/2020 12:44

If you are doing business in Ireland - or would like to be...

CONTACT [email protected] • Tel: +44 (0)1322 221 144

w w w. m a d e i n . i e

MADE HP AD house Add.indd 1

Expert Assembly Advice WWW.EUREKAMAGAZINE.CO.UK | NOVEMBER 2020
comes as standard with
all our Fastening and
Assembly Solutions

With over 40 years experience
serving British Industry Zygology
offers a unique, one-stop shop for
all your technical fastening needs.

We are, first and foremost,
engineering product specialists
who understand the practical
application of our fastening
solutions, offering friendly, expert
advice as and when our customers
need it.

Our technical expertise and our
ability to flex our service around
our customers’ requirements
gives us the unique ability to offer
a specialised service for each
application and each customer.

0808 123 1221
[email protected]

www.zygology.com

24

SENSORS TEST & MEASUREMENT | ANALYTICS

REVOLUTIONISING
LIQUID ANALYTICS
The combination of complex technical moulding and innovation in spectrometry
has helped the creation of a concept that will prevent cross-contamination of
food & drink, microbiological, chemical and forensic liquid laboratory samples.

From prototype to full scale and slide innovation. The unique Broanmain previously assisted
production, technical moulder Arrow concept comprises a puck Specac with its development
Broanmain Plastics has assisted and silicon wafer ATR consumable of a new ATR accessory for the
a lab testing spectrometer polypropylene slides featuring company’s high-spec offering to the
innovator to develop a unique puck overmoulded lids, allowing lab spectroscopy market.. This project’s
and slide concept that prevents scientists to batch test, save and success instilled so much con dence
cross contamination of food & drink, cross-compare chemical changes in in Specac’s team, they invited
microbiological, chemical and forensic samples over a period of time. Broanmain’s tooling and production
liquid laboratory samples. professionals - Kamil Stec and
Removing the need to clean the Thomas Catinat - to input into the full
Specac Ltd, a global provider of spectrometry puck between each development of this completely new
spectroscopic accessories used in individual lab sample has been ATR concept.
the laboratory analysis of specimens hailed by Specac and industry
in a wide range of scienti c and experts as a major scienti c Broanmain Plastics is a specialist
industrial settings, - from life breakthrough, as it safeguards family-owned technical trade
science research to polymers against sample cross contamination plastic moulder and one of only a
and plastics - recently unveiled as well as speeding up analysis. few UK plastic moulders to offer
its revolutionary ATR (Attenuated thermoplastic, thermosetting and
Total Re ection) consumable puck Technical tool developer and injection moulding from one
injection moulding specialist

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK 25

SENSORS TEST & MEASUREMENT | ANALYTICS

facility. Founded over 60 years
ago, Broanmain supports a wide
range of industries from aerospace,
electronics and defence through to
the science sectors and consumer
goods, and supports customers
with prototype development, tool
trials, right through to high volume
production runs.

TAKING ATR IN A NEW Ramsay explains more and why the
DIRECTION
Arrow ATR warranted a patent: “The
Specac’s original concept was to
create a disposable puck for high method of overmoulding the clipping
volume hazardous applications. Yet,
through the company’s collaborations mechanism on the slide and the
with Broanmain, the idea progressed
to the development of an aluminium process of removing slides from the
holding puck and disposable
recyclable silicon ATR slides, which spectrometry unit is very novel. From
used less material, so was less
wasteful. a productivity perspective, labs can

At the very rst meeting, now batch prepare and analyse over
suggestions for tooling and
material mouldability were made. 25 samples in less than 10 minutes,
Within a week Broanmain had
commissioned a specialist to build with no cleaning of the puck
the prototype Arrow™ aluminium
tooling for the slide with a built-in between tests.”
silicon wafer ATR crystal. As the
slide must create a liquid tight seal the puck, samples can be “It’s always Citing the importance of
between the well and ATR element
whilst also aligning the optical prepared in batches away our experience that analysing the composition
components accurately, design
precision was critical. The Broanmain from the spectrometry collaboration with a of food and drink
team also pooled their expertise in unit and analysed production partner like commodities and
overmoulding and material selection consecutively. Broanmain at the earliest ensuring samples are
for the development of the innovative stage results in the best not cross contaminated,
disposable Arrow™ slide, opting for To avoid the risk of product development Michael expands: “In
an acid resistant 100% recyclable cross contaminating the food supply chain,
polypropylene combined with samples or evaporation, and speeds up time brand integrity, authencity
elastomer. The result was a single a cap can be pressed to market.” and traceability is critical.
component, cleverly constructed to down over the well.
reduce part count and manufacturing
complexity. This enables scientists to Correct labelling of calori c

Specac’s Strategic Buyer Anthony archive samples or perform and nutritional content help
Gomme comments: “It’s always our
experience that collaboration with a long running tests using different consumers stay within recommended
production partner like Broanmain at
the earliest stage results in the best solution concentrations to observe limits. This requires accurate
product development and speeds up
time to market.” chemical changes in the samples. quanti cation of the composition

ELIMINATING Additionally, an overmoulded seal of food and drink to ensure full
CONTAMINATION RISKS
clips down to ensure long term compliance with local labelling
Just like a regular Quest diamond
puck, the Arrow’s ultra-thin silicon storage without risk of the sample regulations. Quality control is
wafer ATR can be used to analyse
forensic, microbiological, food and leaking past the silicon wafer. stringent. These food analysis tests
drink and paint coatings samples.
Yet more cost ef ciently. Rather Specac’s project leader Michael are typically performed in large
than placing samples directly onto
batches, where speed and accuracy

is critical.”

Launched in July 2020, Broanmain

has now scaled up into full production

of the Arrow puck and slides at its

state-of-the-art Dorking facility.

Operations Manager Thomas Catinat

comments: “It’s always exciting to

be involved in such a revolutionary

market development that has the

potential to reshape how scienti c

communities will perform sample

analysis in the future. As these

processes become increasingly

automated, innovations like the

Arrow ATR will yield more accurate

and reproducible results.” !

26 W W W.EUREK AMAGAZINE .CO.UK | NOVEMBER 2020

Leading Pan European Polymer Distribution Leading Pan European Polymer Distribution

POLYOLEFINS ENGINEERINGPOLYOLEFINS
LDPE • hLLDPE • mLLDPE • MDPE • HDPE • LDPE • hLLDPE • mLLDPE • MDPE • HDPE • Bimodal HDPE
Bimodal HDPE • UHMWPE • POLYPROPYLENE •
PP COMPOUNDS • EVA ABS - HUHiMgWhPHE •ePaOLtY, PFRROP,YPLElNaEta• PbPleCO, MTPrOaUnNDsSp•aErVeAnt • PC
POLYESTERS • PC-APlloOyLsYE•SPTBERTS• POM • PMMA • Nylon • PA6 •
PET • PETG • PCTG PA6.6 P•ERT •yPtEoTnG®• PCPTPG S • Radel® PPSU • Udel® PSU
ELASTOMERS • VeraEdLeAl®STPOEMSEURS• Vespel® • Selar® PA
Santoprene™ TPV • Lucene™ POE/POP •
Vistamaxx™ PBE • Exxelor™ MAH Santoprene™ TPV • Lucene™ POE/POP
STYRENICS
GPPS • ASA • SAN • SBC SILICOVisNtamEaxEx™LPABES•TEOxxeMlorE™RMASH
ABS - General Purpose HCR • SLTSYRRE•NRICTSV • Fluorosilicone • Fluorocarbon
CSiolimcopnoAGeuBPMnSPdS-aGs•sAet•nSeeACrrab•ulSaPsAuttNcroph•omsSeeBsSCilicone Compounds •

ENGINEERING

RECYACBSL-EHDigh &HeaBt, FIRO, PPlatOablLe,YTrMansEpaRreSnt
rPP • rANPCyBlo•SnPPC•A-A6rlHl•oPyIAsP6•S.P6BT • POM • PMMA
INZEARV®eyrtoaBndi®eol®PpPPoSElyS• UmRa•edVerels®sp•PelP®EScUo• zUedenl®®PSPUETG

SILICONE ELASTOMERS
HCR • LSR • RTV • Fluorosilicone

Fluorocarbon Compounds CMYK COLOR INFORMATION:
INDORAMA DARK BLUE: C100 | M80 | Y6 | K30 {PANTONE 288C)
Biesterfeld Petroplas Ltd, 6F ParkCuSstoqmuSialicornee ,CoMmpiolutnodsn Park, INDORAMA GREEN: C97 | M2 | Y98 | K12 (PANTONE 348C)
Abingdon, OxfordshireSOilicoXne1M4aste4rbRatcRhes INDORAMA LIGHT RED: C2 | M100 | Y82 | K6 (PANTONE 186C)

T: 01235 822 040 • F: 01235 833 155 • E: salrRePEPsC•@rYACBSbLE•irDeHIs&PStBeIOrfPeOlLdY-MpEeRStroplas.com
W: www.biesterfeldINZ.EcAo® mBiopolymers • Ecozen® PETG

Biesterfeld Petroplas Ltd T: 01235 822 040 • F: 01235 833 155
E: [email protected]
B6AieFbsiPntagerdkrofSenq,lduOaxrPfeoe,rMdtrsiolhtoiprnelaPsarkLtd
W: www.biesterfeld.com
OX14 4RR

BPFLYER - PRW May19.indd 1 03/05/2019 14:48:45

Biesterfeld Petroplas Ltd T: 01235 822 040 • F: 01235 833 155
E: [email protected]
BA6ieFbsiPntagerdkrofSenq,lduOaxrPfeoe,rMdtrsiolhtoiprnelaPsarkLtd
W: www.biesterfeld-petroplas.com
OX14 4RR
21/05/2019 11:45
32102_EUKA_BiesterfeldPetroplas_Layout 1.indd 1

Serving a World
of Industries

QUALITY STAMPINGS
& WASHERS

SINCE 1919

REQUEST
YOUR

FREE

CATALOGUE &
CALENDAR!

+16127299365

bokers.com

154 Hobart Street, Hackensack, NJ 07601, USA
+1.201.343.8983 ∙ main masterbond.com

Your UK supplier of choice for bespoke plastic Whether you are
injection moulding and tool manufacture looking to move
your existing Plastic
DESIGN Injection Moulding
DEVELOPMENT production or sourcing
a supplier for a new
MOULDING product, Pentagon will
TOOLING support you at every
stage of the process.
BEYOND THE MOULD
Delivering a full
turnkey solution
from one site of UK
Manufacture.

www.pentagonplastics.co.uk
[email protected]
Tel: +44 (0) 1403 264 397

MOTORS | AGRICULTURE

FROM F1
TO FARMING

High-performance, high-e�ciency
electric motors with their roots in
motorsport are o�ering major
bene�ts to farming vehicles.

It would be hard to imagine F1 season. The resulting hybrid
two sectors more different ywheel arrangement went on to
than agriculture and Formula
One, but technology transfer further success in endurance racing
exists even here in the form of with Porsche and Audi.

leading electri cation specialist, The high-speed ywheel
developed for the Williams
Equipmake, which has prepared a programme was effectively a
composite electric motor, Foley
range of high-performance yet cost- applying the expertise gained to
a new design: Equipmake’s APM
effective advanced electric motors INDUSTRY-LEADING range of ‘spoke’ electric motors.
These are permanent magnet
for agricultural use, bringing major The company’s APM motors, which motors that use a spoke architecture
(so-called because the magnets
bene ts to multiple types of farming incorporate many industry-leading are arranged like the spokes of
a wheel) to bring a major cooling
vehicles from better packaging innovations and are believed to advantage. Because the motor
can be kept cool, it can produce
to increased ef ciency and lower be the most power dense in global lots of power and torque, use
less expensive magnet materials
maintenance costs. series production, use technology and conventional manufacturing
methods, so can be made smaller,
Based in Norfolk, UK, Equipmake born out of Equipmake Managing lighter and more cost-effective.

primarily provides EV technology Director Ian Foley’s career in top- STEP CHANGE

to automotive OEMs and specialist level motorsport. Ian Foley, Managing Director,
Equipmake said: “From electric
supercar manufacturers, A former Lotus and Benetton buses to supercars, the APM range
of motors has made a step change
producing everything from A former Lotus F1 engineer, Foley’s to the ef ciency and performance
industry-leading electric and Benetton F1 research into electric of our automotive clients’ products.
motors to power electronic engineer, Foley’s research motors and ywheels Those same bene ts – high power
systems, all the way up to into electric motors and in the mid-2000s led density and light weight, combined
complete EV drivetrains, �ywheels in the mid- to him play a key role with an extremely compact package
while also operating 2000s led to him play a key in the development of that includes integrated components
across marine, off- role in the development Williams F1’s hybrid such as the inverter and gearbox –
highway, construction, of Williams F1’s hybrid system, used in the 2009 are just as relevant to the world of
mining and aerospace. system, used in the agriculture.”
2009 F1 season
With the world of Equipmake offers two compact,
agriculture following the power dense motors for agricultural
applications, which both use the
automotive sector in embracing company’s spoke architecture to
maximise cooling capability.
the bene ts of zero emission

powertrains, Equipmake sees many

advantages for its advanced motors

to be used by loaders, harvesters

and tractors, as well as smaller,

potentially robotic vehicles and

even drones too. The installation

of an electric powertrain can, for

example, offer durable running in a

rugged environment, require little

maintenance, increase payload,

slash emissions and noise, while

offering lower operating costs than

traditional fossil-fuel vehicles.

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK 29

MOTORS | AGRICULTURE

The APM 120 has peak power lower running costs. Our electric
of 125kW at 12,000rpm, continuous motors are extremely compact,
power of 75kW and peak torque of lightweight yet powerful, which
130Nm. Weighing just 14kg, it has a can play a huge role in improving
power density of just under 9kW per the payload of a farm vehicle too.
kg. With an integrated gearbox, it Factor in the lack of maintenance
measures just 200mm in length and required compared to traditional
170mm in diameter. diesel machinery, and it is not
hard to see why electri cation
The APM 200 has peak power makes so much sense. And, what’s
of 220kW at 10,000rpm, continuous more, Equipmake can work with
power of 110kW and peak torque of almost any agriculture machinery
450Nm. Weighing just 40kg, it has manufacturer to create an entire,
a power density of over 5kW per tailormade electric powertrain.”
kg. With an integrated gearbox, it
measures just 247mm in length and Late last year, Equipmake
318mm in diameter. opened an all-new factory in
Snetterton, Norfolk, where the
WITH OR WITHOUT Equipmake added: “We are company provides the complete
experiencing huge demand
Both motors can be speci ed with from the farming industry as electric mobility solution
or without an integrated gearbox manufacturers see the bene ts – whatever
and can be mounted horizontally that electri ed vehicles can bring, the sector –
or vertically. Equipmake also from reduced emissions and offering the
makes all supporting power noise to increased ef ciency and capability to
control electronics – including its design, test
own high-performance inverter and manufacture
which incorporates the latest
silicon carbide diode technology everything from
to improve power capability and motors to fully electri ed
enable the inverter to run at high platforms. It also sources and
switching frequencies. supplies the very latest lithium-ion
batteries, creating entire electric
Ian Foley, Managing Director, drivetrains for an increasingly
international customer base. !

WEG EXPANDS REMOTE TESTING

WEG has developed a new at the manufacturing plant, the inspection. attend the testing, meaning quality engineering and IT
testing procedure that allows and historically the customer More than just a video call, more people can participate manager at WEG Portugal.
customers to witness the or its representatives had to be remotely.
Factory Acceptance Test (FAT) present to conduct or witness the testing system takes Though some customers
process without travelling to the test. advantage of multiple cameras “The live remote testing will choose to return to the
a WEG manufacturing plant. and a dedicated IT system system further improves the factory for factory acceptance
Used in Portugal since March In March 2020, WEG to allow customers to get existing transparency and testing once social distancing
2020, the remote testing factories in Portugal introduced closer to the product and reliability of the manufacturing regulations and travel
system helps to keep projects a new remote testing system. simultaneously view a variety of and testing process, thanks restrictions are lifted, in the
on schedule despite social Customers connected to the testing aspects. to this potential increase in meantime, live remote testing
distancing regulations limiting factory site though a video customer representative o�ers a viable alternative in
factory visits. call and watched the testing Live remote factory numbers coupled with multiple order to maintain compliance
without travelling to the acceptance testing also camera views of the testing,” with testing requirements and
The factory acceptance test manufacturing plant, saving removes the limit on how many commented Rui Moura Guedes, keep projects on schedule.
is an inspection and testing time, money and resources by customer representatives can
process that con�rms whether eliminating travel costs.
a product is complete and
operating in accordance with The live remote tests follow
agreed design speci�cations. the same exact procedure
Once the Factory Acceptance as the traditional factory
Test has been passed, the acceptance tests. Customers
product or equipment can be can see the product working,
installed on site. The Factory and WEG’s expert testers are
Acceptance Test is performed there to answer questions and
provide support throughout

30 W W W.EUREK AMAGAZINE .CO.UK | NOVEMBER 2020

KEEPING YOUR 65 YEARS’
PROJECTS MOVING EXPERIENCE
MANUFACTURING
Essentra Components know how IN THE UK
important it is to establish and maintain
your processes in manufacturing which is FAST DESPATCH
why we have over 45,000 products
waiting for you. Manufacturing FREE SAMPLES
components in the UK and 11 other sites
globally, we combine the expertise and

exibility of a manufacturer with the
service and range of a distributor.

Looking for something? Get in touch today:

0845 758 5070

[email protected]

www.essentracomponents.co.uk MAKING IT EASIER

PRECISION MOTION CONTROL

As an advanced motion control NOVEL MOTION CONTROL TECHNOLOGY
technology distributor and
manufacturer, Mclennan supplies and From Allied Motion Inc., KinetiMax™ HPD series outer rotor
fully supports a wide range of precision brushless motors deliver a high torque-to-weight ratio and
motion control components from its excellent efficiency as a compact and frameless rotor/stator part-
distribution partners - and also has the set. Available in six frame sizes, the high power density motor
capability to combine these products offers a smooth, low cogging and continuously rated torque from
with its own design and build service 0.24 to 6.7 Nm with power output up to 1170 Watts.
for bespoke and turn-key motion
sub-systems - for applications across JVL’s HLMT series hollow shaft rotary actuators take a novel
industry and research. approach to decentralised precision positioning tasks where a
through aperture is required for routing services or maintaining
Servo motors & drives a clear line of site. The design features an offset motor mounting
in five model variants with clear through-hole diameters from 20
Stepper motors & drives to 30 mm and rated torque output of 5 to 142 Nm.

Synchronous AC motors AMP’s TSM14POE series is a Power over Ethernet
(PoE) enabled integrated miniature microstepping motor
Feedback devices package that combines a PoE linked closed-loop digital
drive, feedback encoder and an Ethernet-supported
Gearboxes motion controller as a single-cable motion control solution
based on AMP’s well proven StepSERVO™ technology.
Motion controllers & software
Call us or visit our website for more information
Mechanical components

Custom engineered motion systems

[email protected] www.mclennan.co.uk +44 (0)1252 531444

POWER TRANSMISSION LOW EMISSIONS

ZERO
EMISSION
ELECTRIC
AXLES

A new product o�ering is helping one

company lead the charge into the future of We are excited

commercial vehicle electric propulsion. to have this facility

A new series of fully gradeability, top speed that will provide our we continue to advance
integrated zero emission and ef ciency as well as customers and partners those products through
electric axles released an optional differential enhanced capabilities to collaborative validation
by Allison Transmissions lock. This ef ciency conduct full-vehicle testing programmes with
by replicating environments
looks set to revolutionise power advantage translates to leading truck original
transmission in medium and heavy- increased range capability and duty cycles all equipment manufacturers
duty trucks. or a reduction in battery pack in one centralised globally”, said Branden
size, optimising the economic Harbin, Managing Director
The eGen Power product location...

family, previously referred to as value the eGen Power electric of Global Marketing at Allison

AXE for trucks, will be the second axles deliver. Transmission. “Our promise to our

product offering under the recently These advantages are why Hino customers is to provide the most

announced Allison eGen portfolio Trucks and Hexagon Purus chose reliable and valued propulsion

of fully electric and electric hybrid to integrate the Allison eGen Power solutions in the world to enable

propulsion solutions. Allison will 100D into the Hino XL7 truck most our customers to work more

launch the eGen Power 100D, capable recently showcased during the ef ciently. We plan to continue to

of a 23,000 lb /10,400 kg gross axle October 5, 2020 “Project Z” zero be a propulsion solution provider of

weight ratio (GAWR), as the rst emission vehicle development choice, regardless of power source or

electric axle variant within the eGen programme announcement by Hino propulsion type.”

Power series of products. eGen Power Trucks. Allison Transmission is the world’s

electric axles will be manufactured in “Hino Trucks and Allison largest manufacturer of fully automatic

Allison’s recently completed 110,000 Transmission have a long-standing transmissions for medium- and

square foot electric axle development partnership, as evidenced by our heavy-duty commercial vehicles

and manufacturing facility in Auburn industry leading ve-year powertrain and medium- and heavy-tactical U.S.

Hills, Michigan. warranty and Allison’s standard defence vehicles, as well as a supplier

The eGen Power 100D is one of the position in all Hino conventional of commercial vehicle propulsion

most powerful and fully integrated trucks”, said Glenn Ellis, Senior Vice solutions, including electric hybrid

e-axle systems in the world for President of Customer Experience and fully electric propulsion systems.

medium- and heavy-duty trucks. It at Hino Trucks. “As we embark on Allison products are used in a wide

features two electric motors capable our ZEV development programme, variety of applications, including on-

of generating 200 kW of continuous Project Z, we are hopeful to highway trucks (distribution, refuse,

power each, or 400 kW in total, with incorporate Allison’s eGen Power construction, re and emergency),

a peak combined power of 550 kW. e-axle into our future product buses (school, transit and coach),

The eGen Power 100D also integrates offering.” motorhomes, off-highway vehicles

a two-speed transmission into the “Allison is continuing to build and equipment (energy, mining and

central housing. The two-speed our electri cation product portfolio construction applications) and defense

transmission facilitates a high starting under the Allison eGen brand, and vehicles (wheeled and tracked).

32 W W W.EUREK AMAGAZINE .CO.UK | NOVEMBER 2020

Transmission. “The VET center will centraliseddd location, allowing
facilitate rapid product development them to bring new and innovative
for conventional, alternative fuel and technology and vehicle systems to
electric vehicles, providing Allison market faster and more ef ciently. For
and our customers an ef cient and players in our industry this translates
effective tool for next generation into a competitive advantage, as
innovation and collaboration.” innovation drives the industry
forward,” said Rohan Barua, Vice
The 60,000-square-foot facility President of North America Sales for
houses a hot soak chamber, a cold Allison Transmission.
soak chamber, and two chassis
dyne-equipped environmental The VET facilitates immediate
chambers capable of simulating evaluation and responses to issues
under controlled conditions that
a broad range of duty cycles, ensure the desired operating
environmental conditions from environments can be isolated,
negative 54 degrees to tested, and replicated real time. This
125 degrees Fahrenheit, capability provides Allison and its
altitudes up to 18,000 feet, partners with a unique advantage in
simulated grades and other the development of new products.
on-road conditions. The VET The VET centre is equipped to help
centre can accommodate our engineers, our OEM partners,
most commercial on-highway, body builders, suppliers and eet
off-highway and wheeled owners innovate their vehicles,
defence vehicle applications, optimize performance and accelerate
supporting testing for a wide- time to market, by testing safely and
range of propulsion systems, con dently in a single, environment-
including conventional controlled and seasonally
powertrains, alternative fuel, independent location. !
electric hybrid, fully electric and
Founded in 1915, the company is
headquartered in Indianapolis, hydrogen fuel cell vehicles. It is
Indiana, USA. With a market presence located on the campus of Allison
in more than 80 countries, Allison Transmission’s global headquarters
has regional headquarters in the in Indianapolis, is the only one of
Netherlands, China and Brazil with its kind in the Midwest and is truly
manufacturing facilities in the U.S., unique in offering this range of
Hungary and India. Allison also has capabilities for public use.
approximately 1,500 independent
distributor and dealer locations “We are excited to have this facility
worldwide. For more information, visit that will provide our customers and
allisontransmission.com. partners enhanced capabilities to
conduct full-vehicle testing by
Allison recently opened its new replicating environments
Vehicle Environmental Test (VET) and duty cycles
centre to conduct year-round testing, all in one
replicating vehicle environments and
duty cycles, compressing product
development times and supporting
innovation for the industry.

“This facility is a direct re ection
of our commitment to advancing
new product development
technologies and reducing time
to market,” said Randy Kirk,
Senior Vice President, Product
Engineering and Program
Management at Allison

NOVEMBER 2020 | WWW.EUREKAMAGAZINE.CO.UK 33

COFFEE TIME CHALLENGE | SPONSORED BY MICRO-EPSILON

A BUG’S DEATH
Of all the potential threats man
faces from the animal kingdom,
one creature stands head and
shoulders above all others in terms
of its deadliness to mankind: the mosquito.

Even today, when modern medicine is able
to minimise the threat, more than 700,000
people each year fall victim to the mosquito
– usually via malaria, Yellow Fever or other
diseases. And even in this country where the
threat they pose is rarely deadly, the mosquito
is still a pest, leaving victims with swollen,
itchy bites that can easily become infected.

We have countermeasures, of course.
Besides mosquito nets, there are repellents,
which are effective, but smell unpleasant
and are likely not just to repel mosquitos.
Alternatively, one can burn candles or coils
that contain natural mosquito repellents and
keep them at bay.

But coils and candles don’t actually kill
mosquitos. They may be effective in a small
area, but they generally are not enough to
keep all of them at bay.

An electric bug zapper that draws the
insects in with UV light and then literally zaps
them with voltage is more effective because
it actually draws in the bugs and mosquitoes
and kills them with an electrical discharge.
They’re often seen in commercial buildings
and they’ve been around for many years. The
issue is that they can be expensive and are
not exactly portable.

THE CHALLENGE As ever we have an idea in mind that we will reveal in the December issue of Eureka! Until then,
why not let us know how you would tackle the problem by leaving your thoughts in the comments
The challenge, then, is to devise a means section of the Eureka! website or by emailing the editor: [email protected]
of attracting and killing mosquitos that is
chemical-free, portable, convenient and
effective. As ever we have a means in
mind, but we’re interested to see what you
come up with. !

Sensors tailored for your application

From this to this For this ...

Laser displacement sensors, powder bed monitoring in additive processes

WWW.EUREKAMAGAZINE.CO.UK Speak to our experts about your measurement requirement.

+44 151 355 6070 | [email protected]

www.micro-epsilon.co.uk 34

KN W
LEDGE

FREE ONLINE RESOURCE FOR THE
DISCERNING DESIGN ENGINEER

Eureka! Knowledge aims to provide useful content and tools to help make your designs
more e cient, cost-e ective and commercially successful.

Eureka! has teamed up with leading industry experts to explore a range of engineering
topics including motors, simulation and bonding & adhesives which are of integral
importance to a wide range of projects and industries.

NEWS ■ VIDEOS ■ WHITE PAPERS ■ EVENTS ■ BLOGS

INCREASE YOUR KNOWLEDGE

www.eurekaknowledge.co.uk

CONTENT
PARTNERS

THE BEST SOLIDWORKS

TRAINING LIVE ON

YOUR DESKTOP

Access the best remote, real
time training using the latest
version of SOLIDWORKS with
our ultra fast connection from
any machine in any location.

Interact live with • No pre-recorded sessions.
trainer & your peers • Practical exercises and case

No travel costs studies.
or time
• Up to date training delivered
The comfort of
your home by a certified instructor.

(Pets can join free) • Not your typical slow remote

desktop connection.

Call: 01926 333777
Visit: solidsolutions.co.uk

With our live Virtual Classroom Training, you don’t have to leave
the comfort of your couch, kitchen table or hammock!