Technology News

With Australia's high labour cost, most high-volume manufacturing has moved offshore. As a result, there has been a shift towards low-volume, high-value manufacturing, with Australian manufacturers adopting more advanced manufacturing methodologies such as additive manufacturing. This has necessitated a similar shift to advanced non-destructive testing for quality control, with computed tomography answering the call. Computed Tomography (CT) is a non-destructive 3D imaging technique analogous to CAT scans performed on humans. It is perfectly suited to inspecting manufactured components, especially those with complex geometries and internal structures. CT can be used to check dimensional accuracy (vs. CAD drawings), identify invisible defects beneath the surface to external inspection techniques, and investigate failures or process control and optimisation. Origins of CT Initially developed for medical applications in the 1970s, CT is now used more extensively in materials science, nondestructive testing (NDT), quality control, failure analysis, and geological materials investigation. In these applications, it is ideally suited to revealing subsurface defects and structures or checking manufacturing tolerances. Although CT has been used extensively in medical applications…

The metal forming industry relies heavily on precision, durability, and cost-efficiency. Traditional manufacturing methods, such as casting, milling, and forging, require extensive tooling, long lead times, and significant financial investments. 3D printing is revolutionising this space by enabling rapid prototyping, tooling production, and custom part fabrication at a fraction of the time and cost. The new Mingda industrial 3D printer range—featuring the MD-400D, MD-600D, and MD-1000D—is particularly well-suited to support businesses in the metal forming sector and the manufacturing industry. These printers offer large-format capabilities and exceptional material versatility, enabling companies to digitise their production workflows and minimise reliance on expensive traditional tooling. Key benefits Rapid Tooling Production: Print cost-effective tools, dies, and fixtures quickly for testing and small production runs. Large-Scale Prototyping: Create full-scale prototypes with massive build volumes, reducing lead times and costs. Support for Composite Tooling: Use advanced materials like carbon fibre-reinforced filaments for strong, lightweight tools. Customisation and Low-Volume Production: Produce bespoke parts and tools without additional tooling costs. Open-Material System: Experiment with various filaments to meet specific mechanical and thermal requirements. Cost and Time Savings:…

Manufacturers in Australia and worldwide are facing mounting pressure to boost profitability amid high inflation, rising interest rates, and escalating energy costs. To stay ahead, they must improve operational efficiency, optimise resources and meet increasingly demanding customer expectations, all while maintaining high product quality and tight delivery timelines. The key to overcoming these challenges lies in harnessing the power of Industry 4.0 technologies. However, to truly unlock their potential, manufacturers need a connectivity solution that is fast, reliable, and secure. That’s where Private Mobile Networks (PMNs) come in. A Private Mobile Network (PMN) is a dedicated, standalone cellular network designed exclusively for an organisation’s use, providing secure, reliable, and high-performance connectivity tailored to specific operational needs. It offers ultra-low latency, high-speed data transfer, and interference-free communication, making it ideal for demanding environments like manufacturing. With full control over the network, organisations can prioritise critical applications, safeguard sensitive data, and ensure seamless integration with advanced technologies such as IoT, robotics, and AI—unlocking new levels…

In a recent project highlighting the synergy between technology and industry, Automated Solutions Australia (ASA) collaborated with QuickAlly Access Solutions to upgrade their welding capabilities at their Brisbane facility. This project is a perfect example of how innovative automation solutions can enhance manufacturing processes, particularly for a company as committed to quality and safety as QuickAlly. QuickAlly Access Solutions is a key player in the Australian market and is known for its high-quality scaffolding and access platforms. As part of the G.James Group of Companies established in 1917, QuickAlly has a long-standing reputation for producing durable and reliable products that meet the highest safety standards. Their product range includes scaffolds, platforms, trestles & planks, stair treads and saw benches, all engineered to comply with Australian Standards. Additionally, QuickAlly specialises in creating customised work platforms for industries such as road, rail, aviation, marine, and industrial applications, further cementing their position as a leader in the field. The collaboration between ASA and QuickAlly focused on replacing an aging REIS welding robot with a new, state-of-the-art FANUC ArcMate 120iD/12L robot and 2x servo rotary positioners. This…

Rockwell Automation has launched Logix SIS, a cutting-edge safety instrumented system (SIS) designed to address the evolving needs of modern industrial environments. The introduction of the Logix SIS from Rockwell Automation provides a modern and integrated safety solution, offering both SIL 2 and SIL 3 certifications for enhanced process and hybrid safety. Logix SIS delivers all components of a safety instrumented system, including the process logic solver and I/O. The system is engineered to provide high availability with proven Rockwell Automation hardware, leveraging the latest 1756 controller, FLEX 5000® I/O platform, and Studio 5000 Logix Designer® application for a truly integrated user experience. "Logix SIS represents a significant step forward, offering exceptional flexibility for process and hybrid safety applications while leveraging our proven hardware to target the highest safety levels," said Dan DeYoung, vice president of product management at Rockwell Automation. "Its intuitive interface, consistent with our other solutions, minimises complexity and empowers partners to deliver high-level safety solutions." Key capabilities of Logix SIS: Modern SIL 2 and SIL 3 solutions deliver comprehensive safety across various industrial applications;…

Advanced Navigation, a world leader in navigation and autonomous systems, has announced the expansion of its versatile Certus range, with the new Mini series. Available in three variants, the Certus Mini series includes a GNSS-aided Certus Mini D and Certus Mini N inertial navigation system (INS), while Certus Mini A functions as an attitude and heading reference system (AHRS). Weighing no more than 55 grams, the series delivers impressive performance and cost-efficiency, defying expectations for its weight and size. Advanced Navigation CEO Chris Shaw said, “Manufacturers and system integrators often face trade-offs between performance, size, cost, and weight. The Certus Mini series is a testament that these attributes do not need to conflict. This value-driven breakthrough lowers the entry barrier to precise and reliable navigation for customers deploying land-based vehicles. It also unlocks new possibilities for lightweight airborne platforms, such as drones, where every gram counts towards flight efficiency and power consumption. Designed with flexibility in mind, the series is easily integrated into existing and new system builds with simple plug-and-play…

HVAC systems run almost constantly, leading to an increased risk of belt failure - and a potentially costly ripple effect on sensitive, temperature-controlled facilities. HVAC systems are often exposed to extreme ambient temperatures and environmental conditions, which can strain equipment. Maintaining your facility is already complex without adding in additional maintenance or unexpected part failure. Gates has engineered high-performance belt solutions that can withstand high temperatures, chemicals, and humidity without re-tensioning and at a lower upfront cost than comparable belts.   V-BELTS - TRI-POWER™ & QUAD-POWER™ 4 MOULDED NOTCH V-BELTS V-belts are essential power transmission components in industrial applications worldwide. Excessive belt slippage, stretching, and wear can result in big problems for facilities, with disproportionate resources spent re-tensioning, maintaining, and replacing underperforming belts. Gates offers high-performance v-belts engineered to save energy, minimise maintenance, and have a longer lifespan than competitive belts. Raw edge, moulded notch construction saves up to 3% on energy costs over wrapped belts. Specially designed moulded notches dissipate heat better than standard v-belts and are engineered to increase flexibility for improved energy efficiency. FEATURES: Innovative…

The Gaia EnviroTech business is the Bioenergy and Waste Management division of Gekko Systems, based in Ballarat, Victoria. The company has partnered with Jock Charles from the Berrybank Farm, who has successfully operated an Anaerobic Digester (AD) on piggery effluent in the Ballarat region for 30 years. The modular biodigester design was developed by Gaia EnviroTech and is manufactured onsite at their local facility. The expandable configuration is targeted to treat 5-20k tpa organic waste and upwards. Objectives The system in this case study was installed as a 12-month research and development project to establish the viability of an anaerobic digestion plant designed to convert dairy effluent to energy and minimise odour. The secondary objectives were to increase the nutrient value of the manure and ease handling constraints (e.g. allow longer-term storage). This was required to provide the dairy with a viable option for future herd expansion. The family-owned dairy houses cattle in a large shed and periodically takes them to pasture. In addition to milk production, potatoes are grown on-site and benefit from the nutrient value of the manure.…

Enel X is the only contracted party to provide 95MW of Demand Response firming capacity in NSW, to help meet the energy security target. With increasingly challenging grid conditions due to weather conditions, low wind and hydro output, coal outages, and spiking electricity prices, flexible demand is an increasingly critical resource for firming the grid and putting downward pressure on electricity prices for all consumers. Businesses and organisations in the greater Sydney region can provide flexible demand—the inherent ability to adjust when grid power is used—as part of Enel X’s Virtual Power Plant (VPP) to help ‘firm’ the grid and keep the lights on. Firming capacity helps the grid integrate renewable energy assets safely. Participants are paid both for committing to be available and for reducing grid energy consumption for set periods, generally only a few times a year. “Western Murray Irrigation has supported the grid across multiple Demand Response programs with Enel X’s VPP since 2020,” said Judith Damiani, Chief Executive of Western Murray Irrigation. “Participation is straightforward and works well for us. An automated system…

Pick-and-place robots are increasingly important in automated processes, such as assembly lines. With its EXPT, the automation specialist Festo offers an exact and dynamic solution for this. Operating at up to 150 picks per minute, the robot works continuously. For this, safe and gentle feeding of the cables to the gripper had to be guaranteed. The unique feature—a rotating additional axis—led to increased wear of the cables. With a unique energy chain for tight installation spaces and dynamic applications, including a rotation module, the cables are now safely guided at high rotation angles Problem Festo SE & Co. KG is a leading provider of automation solutions for processes and entire production plants. The manufacturer also includes its universal parallel robot, "EXPT," in its extensive product portfolio. The tripod-based pick-and-place robot works with high performance and precision and manages up to 150 picks per minute. Its design and control system enable flexible and cross-application use, enabling convenient implementation in applications with several robots in the production line. An A5 axis was to be implemented at the lower end…

Servo systems are increasingly finding their way into applications used by industry; everything from simple vertical filling machines to high-speed printing presses are using servos to improve their output. Harry Mulder, Product Specialist for Motion Products at Beckhoff Automation, explains that while some believe all servos are the same, there are, in fact, some clear differentiators. “It’s these differences that yield big benefits.” What sets Beckhoff apart from the rest, according to Mulder, is its wide selection of motors and matching gearboxes. “Each motor offers a range of feedback options - everything from resolvers for harsh environments to 24-bit multi-turn absolute encoders with SIL 2-rated safety. Beckhoff also supports EnDat, SSI, BiSS and other protocols, as well as providing input for secondary feedback systems.” One feature that rates very highly among end users is a single connecting cable between the motor and the drive, commonly known as One Cable Technology or “OCT”. “Using just one cable to carry power, braking and encoder signals is more cost-effective and so much more convenient than running separate cables. In addition, not having a…

Aluminium remains a key structural material used in multiple industries worldwide, and Tiwai Point is New Zealand’s only smelter. A significant investment in new robot welding equipment shows that Rio Tinto is firmly committed to a future in the Deep South. According to long-serving staff member Paul Cavanagh, Rio Tinto’s Tiwai Point has always been about its people, and that’s the driving factor in a recent upgrade and doubling of its robotic welding equipment. "It’s about keeping people away from the load. People and safety first,” he said. Tiwai Point has used robotic welding since 1995, and this is the second upgrade since 2008 – but this time, the number of robots has doubled, along with the addition of an extra robot for loading heavy steel pins, a previously manual task. Cavanagh, the crew leader for the rodding process, says recent uncertainty was in the rear-view mirror, with the smelter securing a 20-year deal for electricity supply. For some time, it was clear that the old system used to weld anode rods in aluminium production—around 550 are…

Hydraulic tooling and bolt tensioning specialist, Technofast is adding a new pipe fitting technology to its range as the exclusive distributor for HAELOK® in Australia and New Zealand. Swiss-engineered HAELOK® pipe fittings can be swiftly installed in under a minute, providing a secure metal-to-metal gastight connection without sealing elements and welding, which add time and cost to the process. Proven in service for more than 20 years in major European markets, the durable and efficient HAELOK® fittings apply to a broad range of applications, including power stations, high-pressure hydraulic lines up to 1270 bar for smaller sizes (up to four-inches at 250 bar), oil, gas, and petrochemical refineries (including offshore), navy, marine, and defence, acidic environments, heavy mine sites, steam and biogas lines in sugar mills, and hydrogen piping. “The HAELOK® range is a natural extension of our Technofast range, which is already focused on saving downtime by efficient bolt tensioning technologies applicable to similar industries,” said Technofast Founder and CEO, John Bucknell. A better connection HAELOK® fittings function using an axial crimp. They have a tapered press…