Machine Design Leaders

WHERE TO FIND
ENGINEERING
TALENT P. 24
3D PRINTING GOES
BIG TIME FOR SHORT
PRODUCTION RUNS p. 42
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2014 LEA
2
LEADERS
AD
ADERS
PROFIL
PROFILE
LE
LE
ALTECH CORP.
http://www.altechcorp.com
info@altechcorp.com
TEL | 908.806.9400
FAX | 908.806.9490
35 Royal Road
Flemington, NJ 08822
WEB |
EMAIL |
ltech Corporation is an established

United States supplier of components
and devices used in industrial control,
instrumentation, medical, and automation
applications. Altech provides a very broad line
of products such as miniature circuit breakers,
busbars, DIN rail terminal blocks, printed circuit
board terminal blocks, contactors, motor
disconnect switches, digital panel meters, pin &
sleeve devices, receptacles, foot switches, relay
modules, safety relays, slim-line relays, push
buttons & pilot lights, metal-detection systems,
ferrules, marking & engraving systems, fuses,
power distribution blocks, power supplies,
corrugated tubes, liquid tight strain reliefs,
programmable relays, digital multi-timer, safety
switches, test & measurement, tower lights &
wire ducts.
ALTECHS PRODUCTS MEET UL and international
standards and all are RoHS and REACH compliant. Altechs
commitment to quality and continuous quality management
was recognized on May 27, 1999, when they were awarded
the prestigious honor of ISO 9001 certification. Since then,
Altech has successfully gone through the recertification
process and still maintains this ISO 9001:2000 certification.
One of benefits that Altech provides is the ability to successfully perform a multitude of services for customers. This
starts with its employees where Product Managers provide
technical support and partner with customers in design
assistance, ensuring the best solution for the application.
Next, an efficient Customer Service Department ensures that
customers are informed with complete order information. De-
2 TO MACHINEDESIGN.COM
GO
pending on the product, the versatile Assembly Department provides manufacturing, value-added, or customization services to
expedite delivery. Altechs dedicated warehouse staff receives and
stocks up to 5 tons of freight every week and ships most orders
within a day. Altechs Marketing Department has been highly recognized for its catalogs, advertising, and website designs, while
the Sales Department motivates over 20 manufacturer representative companies and 120 distributors throughout North America,
ensuring product information is current and complete.
ALTECH CORP.S COMPANY POLICY REMAINS:

ALTECH SATISFIES ITS customers requirements through
distribution and direct sales. Our sales channels provides

quality products that are adequately stocked at competitive
prices. Superior customer service and delivery are maintained
through Quality Management System and continuous
process improvement. We perform these services with
honesty and integrity. All Altech employees are trained in
Quality Management Systems and as a team are committed
to achieve these goals.
MACHINE DESIGN
2
2014
2
In OEM
FEATURES
24
Our panel of industry leaders

discusses where and how they
nd technical employees.
42
24
58
Moving
arm
Arm motion
e clamp
68
Blocks
Weight
Cable
under
test
58
3D PRINTING GOES
BIG-TIME FOR SHORT
PRODUCTION RUNS
Increasingly sophisticated 3D
printers and materials are
changing industries by letting
OEMs make end-use plastic
parts on demand, before
traditional tooling gets set up.
TICK-TOCK
CABLE
TEST
TICK-TOCK
CABLE
TEST
Continuity
check
WHERE DO COMPANIES
FIND ENGINEERING
TALENT?
WHEN FLEXIBLE
CABLE DOESNT
FLEX FOR LONG
Its easy to get confused by
terms thrown around for cables
meant to last a long time on
moving, automated machinery.
ELECTRONIC
CONTROLS
BOOST HYDRAULIC
EFFICIENCY
A new generation of hydraulicpump controls is rapidly gaining acceptance for mobile and
industrial applications.
COLUMNS
4
EDITORIAL
80
AD INDEX
42
68
MACHINE DESIGN
Now simply CLICK for analog

The best little PLC keeps getting better
Level
Pressure
Temperature
Variable Speed Control
Flow Control
Shown at actual size
Current
$29.00
(C0-00AC)
$69.00
(C0-00DD1-D)
Connect to lots of process devices

with analog I/O modules for the
CLICK PLC
The CLICK PLC now has more ways to help you with
simple control applications. Monitor pressure, level,
current, even thermocouples and RTDs directly.
Perform simple variable control* with analog outputs
connected to devices such as drives. These highresolution modules offer fast setup (no DIP switches)
with software scaling to make your life (and program)
easier. Choose from:
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Order Today, Ships Today!

* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
$89.00
(C0-04AD-1)
$149.00
(C0-04THM)
$119.00
(C0-04DA-1)
Mighty as a stand-alone unit, or expand to 142 total I/O

With CLICK PLCs, you get a lot of application control in
a small package. You can replace even just a few relays
cost-effectively, but do a whole lot more with
the easy-to-understand instruction set.
An 8-input / 6-output base unit with
built-in serial ports can stand alone
(starting at just $69), or add any
combination of up to 8 discrete and
analog I/O modules. Simple!
And with FREE programming
software, weve made it even easier
to give CLICK a try.
Download the free software so you

can see just how simple control can be.
Configure, price, and buy at:
www.automationdirect.com/click-plc
1-800-633-0405
the #1 value in automation
LEADERS
IN OEM
Editorial
NANCY FRIEDRICH | Content Director
The Secret to Success
elcome to our second annual Leaders in OEM issue. This issue gives us the
opportunity to partner with some of our sponsors to profile todays brightest
movers and shakers. Although all good leaders inspire and motivate their teams
and companies, those heading the charge in the design-engineering universe
must do so in an extremely dynamic environment. Here, constant change is normal. Technology is evermore-rapidly changing before our eyes. As it does, design practices, product requirements, materials, and
more must adapt to each fresh wave of changes.
Rather than tout their remarkable gifts, however, the leaders profiled here are a largely humble bunch.
Repeatedly, they point to the hard work of everyone in the organization and credit them for their success.
They recognize that the success of an organization depends not just on its leadership, but on the people
who help to build and maintain a creative and effective environment.
Across the design-engineering realm, there are countless stories of great design ideas and how they
came to be. Occasionally, a tale is told of a failed idea that was ahead of its time in terms of execution or
whether the market was ready to adopt it. Or maybe it got replaced by a competing technology before
it reached any success. Yet those stories are dwarfed by the many instances in which a good ideathe
brainchild of a visionary design engineeris generated at precisely the moment when the need for it is
recognized. It is that timing that eventually turns an idea into a successful product or technology offering.
Yet the success of an idea also depends on the level of support and openness within the organization.
It sounds simple, but such successes require that employees be invested in their jobs. They have to care
enough about solving customer and other problems to be inspired to brainstorm ideas. Beyond this motivation, career coaches everywhere underscore the need for autonomy. In other words, employees have
to feel that they can reasonably make decisions and take responsibility for driving something forward
without being micromanaged.
Finally, we come to the crucial concept of teamwork. The design engineer must have the trust and support of his or her employer, team members, and other contributors to bring it to fruition. This plays into
the autonomy angle, but it also underscores the environment of the company itself. For design engineers
and their team members, a new project requires countless extra hours that are often added to the regular
workloadmeetings and coordination with anyone taking part in the process, searching and procuring
parts, running simulations, and more. A positive environment in which everyone feels valued and appreciated will inspire all team members to put their best efforts forward and make time as needed.
A great leader is inspiring, motivating, trusting of his or her employees, and committed to building an
effective environment. By taking this type of approach, such a leader builds a company environment in
which teamwork and brainstorming are supported and happen quite naturally. Yet as many of the leaders
in these pages emphasize, those at the top can only carry their message so far. It is then up to the employees in the company to truly bring design-engineering projects and the company to continued success.
MACHINE DESIGN
2014 LEADERS PROFIL

2
PROFILE
LE
PARKER HOSE
PRODUCTS DIVISION
WEB |
TEL |
FAX |
www.parkerglobalcore.com
440.943.5700
440.943.3129
30240 Lakeland Blvd.

Wickliffe, OH 44092
FIVE HOSES. TWO

FITTINGS. ONE SOLUTION
ou know Parker as the global leader in

providing unprecedented performance
and value for hydraulic systems with
high-pressure applications. With our GlobalCore
solution, you can significantly reduce your
inventory and part-number complexity by using
just five hoses and two fittings.
Designed, built, and tested to twice the ISO 18752
specification, GlobalCore reduces engineering and
service complexity by providing the first comprehensive product family across the most commonly
used constant working pressure classes.
The high-performance standards designed, engineered, and manufactured into GlobalCore provide
the longest service life possibleeven in the tough
conditions of your work environment. GlobalCore
hoses are manufactured in the major regions of the
worldNorth America, Europe and Asiasupporting the equipment they serve, regardless of where it
was originally manufactured, or where it is today.
ADDITIONAL VALUE is
realized through:
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GlobalCore expands our range of ISO 18752 hoses and

provides options for the most critical sizes and pressure
ranges3,000 psi to 6,000 psi in sizes -4 through -32.
GO TO MACHINEDESIGN.COM
LEADERS
IN OEM
EDITORIAL
EXECUTIVE EDITOR: KENNETH J. KORANE ken.korane@penton.com
SENIOR EDITOR: STEPHEN J. MRAZ stephen.mraz@penton.com
CONTENT PRODUCTION DIRECTOR: MICHAEL BROWNE michael.browne@penton.com
CONTENT PRODUCTION SPECIALIST: ROGER ENGELKE roger.engelke@penton.com
PRODUCTION EDITOR: JEREMY COHEN jeremy.cohen@penton.com
ASSOCIATE CONTENT PRODUCER: ILIZA SOKOL iliza.sokol@penton.com
INDUSTRY COVERAGE:
AUTOMOTIVE, FASTENING & JOINING, PACKAGING, MATERIALS, MEDICAL STEPHEN J. MRAZ
CAD/CAM, FLUID POWER, MANUFACTURING, MECHANICAL KENNETH J. KORANE
ART DEPARTMENT
ART DIRECTOR: RANDALL L. RUBENKING randall.rubenking@penton.com
GROUP DESIGN DIRECTOR: ANTHONY VITOLO tony.vitolo@penton.com
SENIOR ARTIST: JIM MILLER jim.miller@penton.com
PRODUCTION
GROUP PRODUCTION DIRECTOR: CAREY SWEETEN carey.sweeten@penton.com
PRODUCTION COORDINATOR: COURTNEY DENISON courtney.denison@penton.com
AUDIENCE MARKETING
USER MARKETING DIRECTOR: BRENDA ROODE brenda.roode@penton.com
USER MARKETING MANAGER: DEBBIE BRADY debbie.brady@penton.com
MARKETING AUTOMATION SPECIALIST: DAN KRAFT dan.kraft@penton.com
FREE SUBSCRIPTION/STATUS OF SUBSCRIPTION/ADDRESS CHANGE/MISSING BACK ISSUES:
HALLMARK DATA T | 847.763.9670 F | 847.763.9673 machinedesign@halldata.com
ONLINE
COMMUNITY LEADER: RYAN MALEC ryan.malec@penton.com
CONTENT OPTIMIZATION SPECIALIST: MATT LEE matt.lee@penton.com
CLIENT SERVICES COORDINATOR: JOANN MARTIN joann.martin@penton.com
SALES & MARKETING
MANAGING DIRECTOR: TRACY SMITH T | 913.967.1324 F | 913.514.6881 tracy.smith@penton.com
REGIONAL SALES REPRESENTATIVES
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PAUL MILNAMOW paul.milnamow@penton.com T|312.840.8462 F|913.514.3957
DC, DE, MD, NC, NJ, NY, OH, PA, SC, VA, WV:
BRANDY BISSELL brandy.bissell@penton.com T|234.678.8401 F|913.514.6357
CT, MA, ME, NH, RI, VT, EASTERN CANADA:
LIZ STOTT, liz.stott@penton.com T|857.636.9737 F|913.514.6914
IL, IN, MI, CENTRAL CANADA:
MARTY McCLELLAN marty.mcclellan@penton.com T | 312.840.8488 M | 312.343.9278
AL, AR, FL, GA, KS, LA, MO, MS, NC, NM, OK, SC, TX:
CARRIE HALBROOK carrie.halbrook@penton.com T|317.358.9965 F|913.514.3965
INTERNATIONAL SALES REPRESENTATIVES
BELGIUM, FRANCE, LUXEMBURG, NETHERLANDS, PORTUGAL, SCANDINAVIA, SPAIN, UNITED KINGDOM: RACHEL DISANTO
rachel.disanto@husonmedia.com T|011.44.1625.876622 M|011.44.7794.366887
GERMANY, AUSTRIA, AND SWITZERLAND: CHRISTIAN HOELSCHER, christian.hoelscher@husonmedia.com
T|011.49.89.95002778 F|011.49.89.95002779
ITALY: CESARE CASIRAGHI cesare@casiraghi,info T|011.390.31.261407 F|011.390.31.261380
JAPAN, ASIA: HELEN LAI helen@twoway-com.com T|866.2.2727.7799 F|866.2.2727.3686
DESIGN ENGINEERING & SOURCING GROUP
VICE PRESIDENT & MARKET LEADER: BILL BAUMANN
GROUP DIRECTOR OF EDITORIAL CONTENT AND USER ENGAGEMENT: NANCY FRIEDRICH
GROUP DIRECTOR OF OPERATIONS: CHRISTINA CAVANO
GROUP DIRECTOR OF MARKETING: JANE COOPER
PENTON MEDIA INC.
CHIEF EXECUTIVE OFFICER: DAVID KIESELSTEIN david.kieselstein@penton.com
CHIEF FINANCIAL OFFICER: NICOLA ALLAIS nicola.allais@penton.com
SENIOR VP, DESIGN ENGINEERING GROUP: BOB MACARTHUR bob.macarthur@penton.com
1166 AVENUE OF THE AMERICAS, 10TH FLOOR
NEW YORK, NY 10036 T | 212.204.4200
Electronic Design | Machine Design | Microwaves & RF | Medical Design | Source ESB | Hydraulics & Pneumatics | Global Purchasing | Distribution Resource
Power Electronics | Defense Electronics | Electronic Design Europe | Engineering TV
MACHINE DESIGN
2014 LEADERS PROFIL

2
PROFILE
LE
BALLUFF, INC.
WEB |
EMAIL |
TEL |
FAX |
www.balluff.us
Balluff@balluff.com
800-543-8390
859-727-4823
8125 Holton Drive

Florence, KY 41042
SENSING, NETWORKING, AND IDENTIFICATION

FOR INDUSTRIAL AUTOMATION
alluff, Inc. is one of the worlds leading sensor

manufacturers, providing innovative and practical
sensing solutions for a wide range of applications
and industries. Balluff specializes in delivering dependable,
rugged products for industrial sensing, networking, and ID to
help prevent downtime and eliminate errors.
Balluff adds value to automated systems by offering a wide
range of enabling technologies that unlock hidden productivity potential. As a global leader in sensors, linear transducers,
and RFID, we have been in the forefront of seamless networking all the way down to the sensor level.
RUGGED INDUSTRIAL PRODUCTS

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RELIABLE PRODUCTS AND SUPPORT

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2014 LEADERS PROFIL

2
PROFILE
LE
WEB |
AUTOMATIONDIRECT
EMAIL |
TEL |
FAX |
www.automationdirect.com
sales@automationdirect.com
800.633.0405
770.889.7876
3505 Hutchinson Road

Cumming, GA 30040
utomationDirect is a distributor of thousands of industrial automation products including

Programmable Logic Controllers (PLCs), Programmable Automation Controllers (PACs),
AC drives/motors, operator interface panels/HMI, power supplies, DC motors, sensors, push
buttons, NEMA enclosures, pneumatic supplies, and much more. In business since 1994, the company
headquarters is located just north of Atlanta.
OUR PRICES ARE LOW.
Our prices are well below the list price of more

traditional automation companies because with
our business model and focus on efficiency,
AutomationDirect has the lowest overhead in the
industry.
WE MAKE ORDERING EASY AND
OUR SERVICE IS EXCEPTIONAL.
Shop online with our exhaustive product listings or

browse our online catalog; fax or phone usyoull get
friendly, efficient service from the most helpful sales
team in the business. Independent surveys completed
by readers of Control Design magazine placed us

at the top of the list for service 14 years in a row
in their Readers Choice awards. Other surveys by
magazines such as Control Engineering and Control
have echoed the results.
WE SHIP SUPER FAST (AND
FREE ON ORDERS OVER $49).
The majority of our products are stocked for

same-day shipping, when you place your order by
6p.m. E.T. (with approved company credit or credit
card). Plus, you get free two-day (transit) shipping
on orders over $49 U.S. within the U.S., Canada,
and Puerto Rico; shipped via ground
service or LTL (certain heavy items are
excluded).
WE GUARANTEE IT.
We want you to be pleased with every

order. Thats why we offer a 30-day
money-back guarantee on almost every
stock product we sell, including our
software (see Terms and Conditions for
certain exclusions).
For more information,
contact us at 800-633-0405
or visit www.automationdirect.com.
MACHINE DESIGN
C-more Touch Panels
Higher Performance, Lower Price

6 Color TFT
$
499.00 u.s.
10 Color TFT
EA9-T6CL-R
Serial only
EA9-T10CL
Serial and Ethernet
6 Color TFT
$
1290.00 u.s.
699.00 u.s.
EA9-T6CL
Serial and Ethernet
12 Color TFT
$
8 Color TFT
$
1790.00 u.s.
EA9-T12CL
Serial and Ethernet
999.00 u.s.
EA9-T8CL
Serial and Ethernet
15 Color TFT
$
1999.00 u.s.
EA9-T15CL
Serial and Ethernet
The popular C-more HMIs have

ALWAYS been a great value, but now
they are better than ever. We have
included some of the latest
technology into the latest EA9 series C-more panels,
and all at a lower cost to you. But dont let the lower
price fool you - with a redesigned, more robust housing,
thinner bezel, LED backlights and more communications
and data storage options, the EA9 series offers even
more value and performance.
ALL EA9 SERIES C-MORE PANELS INCLUDE:

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Order Today, Ships Today!

* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
The C-more EA9 series

12- and 15-inch panels now
have an HDMI video output
port. This allows you to
connect HDMI devices like
larger screen TVs to the
C-more panels for
longer-distance viewing
of operator screens.
Research, price, buy at:

www.automationdirect.com/c-more
1-800-633-0405
the #1 value in automation
2014 LEADERS PROFIL

2
PROFILE
LE
SMALLEY STEEL
RING COMPANY
WEB |
EMAIL |
TEL |
FAX |
www.smalley.com
info@smalley.com
847.719.5900
847.719.5999
555 Oakwood Road

Lake Zurich, IL 60047
or over 50 years, Smalley Steel Ring Company has been the leading
manufacturer of Spirolox Retaining Rings, Constant Section Rings,
and Wave Springs.
Spirolox Retaining Rings, available exclusively from Smalley, have No Ears
To Interfere with the mating components in the assembly. Spirolox Rings
offer a 360 retaining surface and are interchangeable with standard stamped
ring grooves. No special tooling is required for assembly or removal.
Smalley Wave Springs reduce spring heights by up to 50% while offering the
same force and deflection as standard coil springs. Wave springs fit in tight
radial and axial spaces. With a smaller assembly size and less material used
in the manufacturing process, a cost savings is realized.
Smalley offers over 10,000 standard parts available in carbon
and stainless steel off the shelf. There is No-Tooling-Charge
on specials; available from .200 to 120 diameters. Exotic
alloys are readily available. Smalley is ISO 9001, ISO/TS
16949, AS9100, and ISO 14001 certified.
SMALLEY OFFERS AN exclusive Circular-Grain Manufacturing
Process. This process is not a stamping, but rather a continuous

coil that is made from edge-wound, pre-hardened, springtempered flat wire. The flat wire has a grain structure that is
linear, providing exceptional strength and dimensional stability.
Smalleys unique manufacturing process reduces scrap,
allowing for the economical production of special alloy products
including a large selection of stainless-steel retaining rings and
wave springs. Smalleys Circular- Grain Process offers unusual
flexibility in production. There is no special tooling needed,
even for prototype or custom configurations. This results in low
prototype cost and quick deliveries.
10
In addition to Spirolox Retaining Rings and Wave Springs,

Smalley also offers a variety of engineered solutions to design
engineers:
Constant Section Rings: often specified for heavy-duty or
impact-loading applications.
Laminar Sealing Rings: a metallic labyrinth seal consisting
of multiple rings in a groove. A series or rings, seals assembly
components of contamination. Laminar Rings are able to
withstand high temperatures and corrosive environments.
Hoopster Rings: fit into much shallower grooves than regular
retaining rings. Hoopsters have a minimal radial projection and a
shallow groove depth. Hoopster Retaining Rings are suitable for
light to heavy loads and are ideal for thin wall tubes.
Linear Springs: are a continuous wave-formed wire length
that act as a load-bearing device, having approximately the same
load/deflection characteristics as a wave spring. Axial pressure is
obtained by laying the linear spring flat in a straight line.
Smalley will send samples of catalog items for evaluation, free
of charge.
MACHINE DESIGN
2014 LEADERS PROFIL

2
PROFILE
LE
IGUS INC.
WEB |
TEL |
www.igus.com
800.521.2747
PO Box 14349
East Providence, RI 02914
gus has been manufacturing engineered plastics

for 50 years, and develops each of the materials
and all technology behind its products. Committed
to using its innovative plastic materials to develop
products that provide creative solutions and exceed
customer expectations while delivering fast, accurate
service, igus plastic blends are used throughout its
range of product lines of cable carriers, plastic bushings,
spherical bearings, and linear bearings, guides, and slide
tables. With constant advancement and technological
breakthroughs, igus is continually expanding its range of
materials, and performs rigorous testing to ensure every
product meets and exceeds industry standards.
igus sales engineers are available throughout North
America for on-site technical support. Friendly customer
service is available 8 a.m. 8 p.m., and igus offers over
100,000 parts in stock, ready to ship as early as that day.
igus also offers 3D CAD files, samples, and online tools,
all completely free of charge.
MOTION PLASTICS SOLUTIONS FOR ANY
APPLICATION
IGUS OFFERS A wide range of motion plastic solutions
from lubricant-free cable carrier systems, to self-lubricating

bearings and linear systems, and continuous-flexing motion
cables. These unique products offer reliable, tested quality,
and dependable lifetimes, all backed up with years of tested
research.
igus engineers develop more than 100 new polymer
compounds each year for use in its iglide bearings. Each
of these materials is tested extensively in the igus lab in
Cologne, Germany. More than 7,000 tests are conducted
on each material to analyze tribological properties, wear
resistance, and more, and all results are placed into an
12
extensive material database. Using this data, igus engineers can

offer a precise prediction of the lifetime for an iglide bearing in
nearly any given application.
igus Energy Chain Systems cable carriers are available with
the optimal selection of all components, including cables, interior
separators, crossbars, and guide troughs. igus also offers its
own line of Chainflex continuous-flexing cables, as well as
ReadyChain: a completely pre-harnessed cable carrier system.
Applications where igus cable-carrier systems are proven
include steel plants, mining and crane industries, machine tools,
and offshore applications. Even cleanroom, FDA approved,
and high-temperature-resistant materials are available for
exceptionally demanding applications.
To learn more about igus products and technologies, visit
www.igus.com.
MACHINE DESIGN
Ready-to-install
cable carrier systems:
Energy Chains + Chainex Cables
= ReadyChains
ReadyChain is a pre-harnessed system that is ready to

plug-and-play upon delivery. Shipped in 24 hours!
Request a free sample:

Tel: 800.521.2747
sales@igus.com
www.igus.com/the-chain
2014 LEADERS PROFIL

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PROFILE
LE
WEB |
HOTWATT INC.
EMAIL |
TEL |
FAX |
www.hotwatt.com
sales@hotwatt.com
978.777.0070
978.774.2409
128 Maple Street

Danvers, MA 01923-2096
ELECTRIC HEATING ELEMENTS MADE IN USA
otwatt, established in 1952, has maintained leadership in manufacturing resistance heating elements for over
60years. We supply customized and stock electric heaters. We are dedicated to the design and manufacturing of
resistance heating elements for a variety of OEM, industrial, medical, commercial, packaging, instrumentation,
aviation, transportation, and military applications. In addition, we can supply compatible accessory items, which enable us
to offer a complete heater system.
We began with the manufacturing of one product, the open-coil heating element. Since then Hotwatt has expanded
our product line to include cartridge, air process, immersion, strip and finned strip, tubular and finned tubular, band, foil,
flexible glasrope, crankcase, and ceramic heaters.
OUR MOST POPULAR product
stainless-steel fins. Mica Insulated Strip

Heaters are also available in various sizes.
is the Cartridge Heater. We

make low/medium and high
watt density Cartridge Heaters.
Cartridge Heaters provide
localized heat to restricted
work areas requiring close
thermal control. Dies, platens,
and a variety of other types
of processing equipment are
efficiently heated. Closely
controlled work temperatures
up to 1400 deg. F (760 C) are
obtained by a combination of heater
location and proper wattage output.
FOIL HEATERS ARE a self-contained

one-piece assembly. A resistance
element is laminated between two
layers of aluminum foil. This heater
is ideally suited for area and surface
heating applications. Operating
temperatures up to 300 F (150 C).
Sizes range from 1.25 to 60 wide
with lengths of 4 and up. Glasrope
Heaters are flexible heaters available
in various lengths, sheath materials,
and terminations. Operating
temperatures up to 900 F (485 C).
IMMERSION HEATERS ARE
STAINLESS-STEEL STRIP HEATERS
provide clean, dependable heat with

sheath temperatures up to 1200 F
(650 C) and watt densities up to 40
watts per square inch. Finned Strip
Heaters are available with aluminum or
ideally suited for heating various

liquids. They are available in various
sheath materials and watt densities
tailored for your specific applications.
Units may be supplied for single-,
three-phase, or three-heat operation.
The lead end of the unit may be
sealed for extreme environmental
conditions.
AIR PROCESS HEATERS will provide hot

air and gas up to 1400 F (760 C) with
infinite control by varying the voltage
and air flow. Air heaters are available
with various male and female fittings,
hose adapters (entry only), and flanges.
We can also provide temperature
sensing control.
14
MACHINE DESIGN
Electric Heating Elements

Made in U.S.A.
for Over 60 Years
Hotwatt has been a
leader in manufacturing
resistance heating
elements since 1952,
producing cartridge, air
process, immersion, strip
and finned strip, tubular
and finned tubular, band,
foil, flexible glasrope,
crankcase and ceramic
heaters.
We make low to medium
and high watt density
cartridge heaters.
Cartridge heaters
provide localized heat
to restricted work areas
requiring close thermal
control. Dies, platens and
a variety of other types
Tel: 978777-0070
Fox: 9787742409
of processing equipment
are efficiently heated.
Closely controlled work
temperatures up to 1400
F (760 C) are possible.
Basic designs are readily
adaptable to a variety
of applications, special
requirements, sizes and
ratings.
We are a quality
supplier to OEMs in the
packaging, industrial,
instrumentation, medical,
aviation, transportation,
commercial, and military
fields. The size, sheath,
terminations and ratings
can be adapted to your
heating requirements.
email: sales@hotwatt.com
www.hotwatt.com
2014 LEA
2
LEADERS
ADERS PROFIL
PROFILE
LE
E
MICROMO
WEB |
TEL |
www.micromo.com
800.807.9166
14881 Evergreen Ave.

Clearwater, FL 33762
WHO WE ARE- THE MOTION SOLUTIONS EXPERTS
ICROMO, a member of the global

FAULHABER Group, has been a
full service, value added partner
to the medical, robotics and defense industry
in North America for custom micro motion
solutions for over 50 years. MICROMO
offers excellence in micro motor and encoder
technology as well as design customization.
MICROMO brings together value-added services
and cutting-edge technologies from around the world
through high efficiency, high performance rotary and
linear offerings, such as brushed, brushless, stepper,
thin-profile DC, piezoelectric and linear motors for
diverse applications (www.micromo.com). MICROMO
provides full service design, sourcing and manufacturing
BENCHMARK SOLUTIONS
MICROMO IS A QBSUPGNBOZOFXUFDIOPMPHJFTBDSPTT
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MICROMOS VALUE-ADDED CAPABILITIES JODMVEFUIF
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16
capability on a global basis to deliver benchmark motion

solutions.
Decades ago in Germany, it all started with the
FAULHABER coil, the landmark invention by Dr. Fritz
Faulhaber. The self-supporting, ironless rotor coil design
paved way for a new industry that produces millions of
motors today.
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MACHINE DESIGN
The Worcester Polytechnic Institute

AIM Lab's Neurosurgery Robot for MRI
guided brain cancer therapy utilizes
Piezo LEGS Rotary LR50 and Linear
LL10 non-magnetic motors, the ideal
solution for the requirements of MRI.
MICROMO Piezo Motor

Technology Powers
Groundbreaking MRI Robot
MICROMO partners with the robotics
market to deliver the next generation of
technologies. Not only does MICROMO
offer the widest selection of the best
motion system products on the market
today, MICROMO provides a full range of
engineering, design, testing, manufacturing
and micro motion technical support
servicesright here in North America.
Lets get started and deliver your
next great idea to market first.
Piezo LEGS Rotary LR50
Piezo LEGS Linear LL10
EXPLORE,
BUILD AND BUY
ONLINE TODAY
Check out MICROMOs new
MOTION SYSTEM SELECTOR.

Delivery in three days or less is available for many products.
Other companies sell rotary motors or

modules. What we needed was to design
an entire custom device. In terms of compact
and self-contained performance, MICROMO
has no competition.
Greg Fischer, Worcester Polytechnic Institute Professor
http://aimlab.wpi.edu/
Clearwater, Florida (800) 807-9166 www.micromo.com
2014 LEADERS PROFIL

2
PROFILE
LE
GALIL MOTION
CONTROL INC.
WEB |
EMAIL |
TEL |
FAX |
www.galil.com
support@galilmc.com
800-377-6329 (US Only)
916-626-0102
270 Technology Way

Rocklin, CA 95765
WE MOVE YOUR SOLUTIONS
n 1983, we introduced our first microprocessorbased servo motion controller. Since then,
we have been developing high-performance,
intelligent motion controllers and drives for customers
in diverse industries. Galil continues to lead the
industry in motion and I/O control by anticipating our
customers urgent demands and shifting needs.
Today we have more than 750,000 motion and I/O
controllers working worldwide. Galil has the depth and
breadth of motion control experience to help you move
your systems with positive, successful results. We do so
by partnering closely with you to solve a myriad of
control challengesno matter how big, small or
INNOVATING INTO THE FUTURE

AS THE ECONOMIC landscape shifts, the need to
keep equipment costs down continues to increase.

From concept to production, you can rely on Galil to
strengthen your ability to compete by providing technically
advanced controllers that are easily programmable, lowcost, and flexible.
Technically Advanced. We use the latest
microcomputers to solve the most challenging motion
and I/O control problems. Our broad array of controllers
can accommodate the most demanding applications with
absolute precision.
Easy-to-Use. Galils controllers are easy to program
18
demanding the application. By partnering with us, you

can rest assured that we will do everything in our power to
make you successful.
with simple, two-letter, intuitive commands. Our software tools

provide fast, easy, and accurate automatic tuning and analysis.
Cost-Effective. Galils price guarantee means the lowest
price for high-performance controllers. Compare our prices to
the competition. We believe that you will be pleasantly surprised.
Flexible. Galils controllers are available in a variety of
formats: single- and multi-axis, card-level and box-level, busbased and stand-alone. Mix-and-match step and servo motors
are available on any combination of one through eight axes.
Custom Solutions. If our standard controllers dont meet
your specifications, Galil will design one specifically for you,
cost-effectively and efficiently.
Superior Support. Galils highly trained application
engineers offer free technical support through the entire design
and production cycle.
MACHINE DESIGN
2014 LEADERS PROFIL

2
PROFILE
LE
EAGLE
STAINLESS TUBE &
FABRICATION INC.
WEB |
EMAIL |
TEL |
FAX |
www.eagletube.com
generalsales@eagletube.com
800.528.8650
508.520.1954
10 Discovery Way
Franklin, MA 02038
ranklin, Mass.-based Eagle Stainless Tube &

Fabrication Inc. is serving customers in medical,
aerospace, and high-tech manufacturing since 1982.
Eagle Stainless manufacturing facilities are ISO 9001, ISO
13485, and AS 9100 aerospace industry certified. With a
record of on-time delivery, fair pricing, product quality,
and highly skilled employees dedicated to continuous
improvement and training, Eagle has earned its reputation as
a supplier of choice for off-the-shelf stainless-steel products
and fabricated stainless-steel components for Fortune 500
companies.
CUSTOM FABRICATED STAINLESS-STEEL
COMPONENTS:
CUT TUBING:
Eagle is a leading supplier of ultra-high-precision, cut-tolength, stainless-steel tubing and bar for medical, electronic,
semi-conductor, industrial, and aerospace applications. Eagle
cuts and deburrs any diameter tubing in quantities from 1
piece to 100,000 pieces or more, from lengths of 0.040 and
longer with tolerances +/-.005.
Eagle Stainless has been delivering some of the most intricately formed stainless-steel parts imaginable. Working on
diameters ranging from .008 to 24, were ready to meet the
needs of your most demanding applications.
Bending, coiling, swaging, spinning, welding, machining.
Eagle does it all.while meeting or exceeding required
ASTM or MIL specifications.
PRIMARY SOURCE FOR STAINLESS-STEEL PRODUCTS

A DESIGN AND manufacturing guidebook offers up-to-date
technical information to help you select the proper size and

material composition. Machining, welding, cutting, assemblies,
bendingwe do it all while meeting or exceeding specifications.
Serving medical, aerospace, and high-tech industries.
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fractional, metric and pipe
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20
MACHINE DESIGN
ISO 9001
ISO 13485
AS 9100
perfection in
stainless steel
Laser machining
CNC machining
Eagle has the skills

and the technology
required to produce
all of your custom
exotic metal parts.
Let us help !
Eagle Stainless is the

supplier of choice for
close-tolerance, exotic
metal parts in bores
from 0.032" to 2" .
Come to us !
Cut-to-length
Eagle has what it takes
to meet your needs for
precision cut-to-length
parts and fabricated
exotic metal parts.
Call us. You won't get
voicemail!
Tube bending
Eagle has the expertise
and the specialized
machinery for bending
tubing exactly to spec.
Call us for a quote !
Come to us. Let us help!

Eagle Stainless $ISCOVERY7AYs&RANKLIN-!
0HONE WWWEAGLETUBECOM
2014 LEADERS PROFIL

2
PROFILE
LE
MAXON PRECISION
MOTORS
WEB |
EMAIL |
TEL |
www.maxonmotorusa.com
info@maxonmotorusa.com
508 677 0520
101 Waldron Road

Fall River, MA 02720
MAXON DRIVES SET THE

WORLD IN MOTION
axon motor combines electric motors, gears,

and DC motor controls into high-precision,
intelligent drive systems that can be custommade to fit the specific needs of customer applications.
maxon motor helps provide innovative solutions at
competitive prices for numerous applications in various
markets, such as industrial automation and medical
technology,
OFFERING SOLUTIONS THAT

FIT YOUR CUSTOMIZED NEEDS
MAXON PRECISION MOTORS focuses on
comprehensive solutions optimized through a

diversified product range and client consultation.
maxon motor manufactures small, high-quality
brush and brushless DC motors ranging in size
from 6 mm to 90 mm and up to 500 watts. maxons
rhombic wound ironless rotor motors provide
exceptionally high efficiency, low EMI emissions,
fast acceleration, no preferred rotor position,
torque constants, and long service life. The drive
components are assembled and designed within our
modular system according to your individual needs.
You can combine, according to your requirements,
motors with 10 different product classes with
planetary, standard, or special gearheads, feedback
devices, brakes, and control electronics.
With over 50 years of experience, high-tech
innovations, and superior product quality, maxon is
the reliable partner in drive technology. Individual,
customized drive solutions are our greatest strength.
22
MORE VERSIONS, MORE POWER

NEW DCX MOTORS AND GPX GEARBOXES
NOW EVEN STRONGER, more efficient, and with yet more combination options:
There are new additions to the maxon family of X drive products. Several long
versions of brushed DC motors, with higher torques and more power, have
been added to the product range along with matching planetary gearheads.
Each of the 3-stage versions can now be combined with the next smaller
motor. This saves space, weight, and costs.
maxon motors X drives are extremely powerful, easy to configure online,
and ready for shipment within 11 business days. maxon has taken its best
brushed drives and made them even better. These innovative motors with
ironless rotor have matching gearheads and sensors. The gearheads consist
of individually configurable gear stages and are now even quieter and more
robust than equivalent-sized gearheads. Matching maxon ENX encoders
feature a strong industrialized design and high signal quality. These encoders
are ideal for high-precision position and speed-control applications. When
combined, the maxon DCX, GPX, and ENX form a high-precision, robust
drive system ideal for any application from aerospace to medical to robotics
anywhere that requires a compact, powerful, quiet, and strong drive system.
With just a few clicks of the mouse, it is possible to configure a powerful DCX
drive with reliable and fast delivery. In addition, detailed product data may be
viewed immediately online and 3D CAD data for the configuration is available
for downloading. Visit dcx.maxonmotor.com for more information.
MACHINE DESIGN
Motion made easy.

System Solutions from one single source
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LEADERS
IN OEM
Engineering Careers
STEPHEN MRAZ | Senior Editor
Where do companies find
ENGINEERING
TALENT?
Our panel of industry leaders discusses where and
how they find technical employees.
s technologies change, companies that rely on those technologies to bring new and innovative
products to market need to stay ahead of their competitors by recruiting and retaining the best
engineering talent they can find. But where do they find those people and how do they make
them part of the company?
To get the answers to these and other questions regarding engineering talent, Machine Design assembled a
group of engineering leaders for some of the top OEMs and suppliers.
Lets see what they have to day.
Where does your company find

technically educated and trained people
to hire as engineers and technicians?
STEVE DIMARCO: We find experienced technical peo-
ple to hire through online job postings and recruiters.

We also do college recruiting for entry-level people.
MARK WALLACE: Hiring highly capable, skilled, innovative, and motivated people is fundamental to our
companys success. The ultimate responsibility for
acquiring talent rests with each hiring manager, and
they use an infrastructure and support model managed by our global staffing team. We find talent from
a variety of sources including recent college grads, job
postings in a variety of sources, and social media. And
one of our best sources of talent is referrals from our
own employees.
neer. But we have been successful with recruitment

ads in newspapers, using both digital and print platforms. We have also used agencies in the past and we
have relied upon referrals.
Are you looking to change how you

recruit new technical talent? If so,
what changes would you make?
MARK WALLACE: As market needs shift, such as were
seeing in software, the skill sets our new hires need

will also shift. The market for engineers with skills in
software development, computer programming, and
RF microwave is highly competitive. The skill sets we
seek and the total rewards package we offer are regularly reviewed to ensure we are competitive and able to
attract the top talent.
PAUL HAZLIT: We do not see any need to change our
PAUL HAZLIT: Our company produces a niche product
that requires looking for a very specific type of engi-
24
recruitment methodology at this time. New Jersey has

some great engineering schools, and the surround-
MACHINE DESIGN
We have started
using social media
sites to prospect for
qualified people and we
expect to do more of that
in the future.
Our panel
STEVE DIMARCO is
president of Tolomatic
Inc. (www.tolomatic.
com), Hamel, Minn.,
a leading supplier
of electrical linear
actuators and electric
linear motion control
and pneumatic
actuators and
cylinders.
ing states have always been an engineering-rich

environment. We are lucky to have employees who
stay with the company for a long time. But when
its necessary to recruit again, we will use our tried
and true methods. If they dont yield the best candidates, we will adjust our methods accordingly.
STEVE DIMARCO: We have started using social
media sites to prospect for qualified people and we

expect to do more of that in the future.
Do you find that recent bachelordegree graduates from engineering

colleges are up to the task of
contributing to your companys
efforts? If not, what do they
seem to lack?
MARK WALLACE: We establish relationships with
many universities, providing them with technology and knowledge through our University
Relations Programs. We also
maintain strong intern and
campus hiring programs.
These programs help us prepare graduates for employment at our company. Overall, Im very impressed with
the talent level and capability
we have been recruiting from
our universities.
PAUL HAZLIT: Yes, the newly
graduated engineers are up to
the tasks we put before them.
But for us it depends on many
PAUL HAZLIT is director

of engineering at
Servometer (www.
servometer.com)
Cedar Grove, N.J., a
company that designs
and manufactures
metal bellows, bellows
assemblies, flexible
shaft couplings,
spring contacts, and
electroforms.
MARK WALLACE is vice president and
general manager of American Field
Operation for Keysight Technologies
Inc. (www.keysight.com), Santa Rosa,
Calif., a global technology and market
leader whose electronic measurement
instruments, systems, software, and
services are used in designing,
developing, manufacturing, installing,
deploying, and operating electronic
equipment.
25
Engineering Careers
A bachelor-degree
graduate needs to know
and understand engineering
principles, and think critically.
They also need to be able to
solve real world problems.
real world of
factors. Most engineerengineering.

ing students are never
Can you give an
exposed to the devices we
example?
make in their entire college career metal belS T E V E D I M A R C O : We
have excellent engineering
lows and electroforms.
schools and technical colWe dont expect them to
be familiar with bellows
leges in Minnesota. All of
technology, but a bachelor-degree graduate needs to these schools give students a solid foundation of skills.
know and understand engineering principles, and We just need more young people to choose engineering.
think critically. They also need to be able to solve realworld problems.
MARK WALLACE: We work with talented students at a
Some schools focus more on problem-solving disci- number of colleges around the world. In the past year
plines than others, so this is a factor, too. Also, many we hired graduates from over 200 institutions globschools offer students a co-op, which lets them gain ally. We are familiar with programs at schools with
valuable exposure to the industry and acclimate to the which we have developed relationships. In the U.S.,
corporate culture. This is helpful. I have also read a this includes Cal Poly SLO, University of California
number of articles discussing how industry is working Davis, Colorado State, and Georgia Tech. Globally, we
with some colleges to train engineering students to hire from Beijing University; University of Technolmeet the needs of industry. If a school is not collabo- ogy, Malaysia; University of Science, Malaysia; Shefrating with industry, they should.
field Hallam University in the UK; and the University
Generally speaking, I have noticed a shift during the of Malaga in Spain, among others.
course of my career in how students approach problem
solving. In the past, technical advertisements would PAUL HAZLIT: From our perspective, some colleges do a
focus on the capabilities of a product. Engineers at the better job than others at preparing engineers for the real
time would read these and envision potential uses in world. For example, we have seen graduate engineers
their applications. Now, more ads focus on applica- draw a blank when asked about free body diagrams.
When dealing with forces
tions, so engineers can see
applied to mechanical
a use similar to what they
We just need more
systems, even an intuitive
might need and adapt it.
young people to
understanding of such a
The engineers we look
diagram is critical.
for need to create soluchoose engineering.
Our products are custions out of real-word
mechanical problems.
tom designed in collaboThey need a strong ability to solve problems. Its great ration with our customers. The products could be
to be able to build off similar solutions, but they also considered as analog solutions in a digital world. So
need to be able to create original solutions. A lot of for us, strong problem-solving skills and real-world
products we design for dont exist yet, except as a con- mechanical aptitude are a must.
Are recent grads from masters and PhD engineercept in an engineers or designers imagination.
ing programs noticeably more educated or capable
than those with just bachelor degrees?
STEVE DIMARCO: Regardless of degrees, our new
hires need time to learn our products and how we do
business. Recent graduates we have hired have strong PAUL HAZLIT: You would hope that they were more
basic engineering skills, but they still need time on the educated thats the point of an advanced degree.
job before they can contribute to their full potential.
They should bring a broader scope of knowledge and
education to the table. And masters and PhD students
should have a greater ability to bring this knowledge
Are undergrads from most colleges
to bear. However, they should still be able to move
the same or do some colleges do a
from abstract and theoretical concepts to practical
better job preparing students for the
26
MACHINE DESIGN
Advanced degrees
can give an engineer
a quicker start out of the gate.
But in engineering, handson experience with design
projects is critical to the
learning process.
application concepts.
A lot depends on the
masters or PhD students focus, aptitude, and
background. This is why
co-ops, internships, and
real-life experience helps
determine what graduates
can offer an organization,
and thus their perceived value to the organization.
MARK WALLACE: For our R&D and development

engineering roles, advanced degrees are often mandatory to secure the right depth of experience and capability. However, Ive seen the gap between undergrad
and graduate engineering students begin to narrow
as more advanced concepts are taught earlier in the
curriculum and then refined in invaluable intern and
co-op opportunities.
STEVE DIMARCO: We hire people with a wide range of
educational backgrounds and experience. For much
of the work we do, we need people who are highly
mechanically inclined. This skill set doesnt necessarily correlate with more education. I believe advanced
degrees can give an engineer a quicker start out of the
gate. But in engineering, hands-on experience with
design projects is critical to the learning process.
them involved with actual

design solutions, working with our experienced
design engineers. The
capabilities of our primary
product can be broken
down into simple key concepts. Our design teams
skill is taking these simple concepts and combining them to answer complex
design applications. This skill cant be taught; it needs to
be developed through experience. This is why we look
for a specific type of individual when we are hiring.
STEVE DIMARCO: We dont have a formal training pro-
gram for new hires. We get people involved in projects

as soon as possible and coach them through an onthe-job experiential learning process. We believe this
is the fastest way to bring people up to speed and get
them contributing as soon as possible.
Are there any technical areas or

engineering disciplines in which it is
difficult to find talented people? What
are those areas and disciplines? Any
theory on why it is hard to find
people in these areas?
MARK WALLACE: Theres no question that software
Do you have a formal training program

for newly hired engineers? Can you
briefly describe it? If you do not have
such a program, can you explain
why it is unneeded?
engineers, computer engineers, computer programmers, and specialty focus positions such as RF microwave engineers are in high demand. In this day of
extensive networking tools and social media, finding
top talent is not as difficult as creating a compelling
value proposition that attracts that talent.
MARK WALLACE: Our onboarding program helps

new hires assimilate quickly into our environment. It
includes several courses, development opportunities,
and partnerships. Each of our businesses develops
customized training programs that include elements
such as job shadowing, mentoring, and job rotation,
depending on the business needs and the new hires
background.
PAUL HAZLIT: We are a fairly small company. Our

design focus is electromechanical components, so all
our engineers are mechanical engineers with good
problem-solving and mechanical aptitude. We have
been fortunate to find such individuals. I think this
is more of a problem for larger companies with more
diverse design and manufacturing platforms.
PAUL HAZLIT: We have a quasi-formal program for
training newly hired engineers. As we are fortunate to

have little turnover among design engineers, it is still
evolving. Once we find the individual with the right
skills and aptitude, they get an intensive indoctrination in our products and design software. Then we get
STEVE DIMARCO: We find that most technical roles

at our company take time to fill as these people are
in high demand. The industrial automation field has
been growing quickly since the recession and there
arent enough qualified people in the U.S. right now to
fill all of the available positions.
27
2014 LEADERS PROFIL

2
PROFILE
LE
WEB |
COGNEX
EMAIL |
TEL |
FAX |
www.cognex.com
contactus@cognex.com
844.222.1114
508.650.3333
One Vision Drive

Natick, MA 01760
COGNEX BARCODE READERS

ANY CODE, EVERY TIME
ognex is the worlds most trusted vision company, with over

1 million systems installed in facilities around the world, and
over 30 years of experience focused solely on machine vision
and image-based industrial ID technology. Products include barcode
readers, machine vision sensors, and machine vision systems that are
used in factories, warehouses, and distribution centers around the
world to guide, gauge, inspect, identify, and assure the quality of items
during the manufacturing and distribution process.
Cognex offers the most advanced technology available for 1-D
barcode and for 2-D Data Matrix code reading, regardless of the
barcode symbology, size, quality, printing method, or surface the
codes are marked on. The DataMan Barcode Readers offer the most
advanced technology available for 1-D barcode and for 2-D Data
Matrix code reading. These barcode readers are optimized with
patented algorithms for the highest read rates (99.9%) in the most
challenging DPM (Direct Part Mark) and label-based identification
applications.
VERSATILE, HIGH-PERFORMANCE BARCODE READER

FOR ALL APPLICATIONS
COGNEX DELIVERS THE

HIGHEST READ RATES
COGNEX DATAMAN FIXED-MOUNT barcode readers represent a
DATAMAN 8600 HANDHELD direct part
breakthrough in combining unmatched code performance, ease of use,

and an extremely small size. The DataMan 300 series is the most versatile
Cognex fixed-mount barcode reader, offering multiple integrated lighting
and lens options, an intelligent autotune feature, and multiple models
and resolutions to select from.
mark (DPM) barcode readers combine

industry-tested 2DMax+ algorithms and
Cognex UltraLight technology to read
the most challenging DPM codes. These
readers provide Ethernet communication
with industrial protocols enabling seamless
integration with factory automation
equipment. The DataMan 8600 series also
offers field interchangeable communication
modules, allowing readers to be configured
to meet customer-specific communication
requirements.
28
MACHINE DESIGN
DataMan barcode readers are powered by industry-leading algorithms and provide the
worlds most advanced barcode reading technology for decoding the most challenging
Direct Part Mark (DPM), 2-D and 1-D codes. Patented imaging systems and exclusive
modular industrial communications enable these flexible barcode readers to handle codes
of varying sizes, quality or marking methods in the harshest environments.
Call 844-BARCODE (844-227-2633)

www.cognex.com/readers
2014 LEADERS PROFIL

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PROFILE
LE
R+W COUPLING
TECHNOLOGY
www.rw-america.com
info@rw-america.com
TEL | 630.521.9911
FAX | 630.521.0366
1120 Tower Lane
Bensenville, IL 60106
WEB |
EMAIL |
COUPLING TECHNOLOGY FOR MOTION

CONTROL AND POWER TRANSMISSION
ith a philosophy of meeting customer requirements from conception

to production, R+W has supplied many thousands of custom
coupling designs, creating a wealth of knowledge about the technical
requirements associated with a wide variety of industries and applications.
Constant new product development takes place in-house, in addition to intensive
collaboration with universities and technical schools, keeping R+W at the
forefront of technical development and product innovation in its field. Over the
past 24 years, this has resulted in a position of market leadership for metal bellows
couplings, with an excellent price to performance ratio, and global availability.
Many elastomer coupling models ship from stock, and include the benefit of a
proprietary calibration process to ensure smooth running. All couplings and torque
limiters are designed to operate free of wear and backlash, and help to ensure
efficient and safe operation of rotating equipment. R+W employs a qualified and
motivated staff, requiring quick reaction times to customer inquiries, and the
shortest possible channels of communication. The result is a flexible and efficient
organization.
AS THE GLOBAL market leader in bellows couplings, R+W
understands precision motion control applications. Knowing

that performance dynamics and installation space restrictions
can be critical, many hundreds of designs of bellows couplings,
elastomer couplings, and line shafts have been developed into
catalog standards over the years. Our applications engineers
are a phone call away, and ready to discuss your unique
requirements with standard or custom designs.
30
OVER THE PAST five years R+W has undergone a major capacity
expansion, with a minimum tenfold increase in the torque ratings
of all its torque limiters, metallic flexible couplings, and elastomer
couplings. Its been a highly successful undertaking, providing
the opportunity to draw upon the numerous coupling technology
advancements of the recent decades. Contact R+W today to
see whats new.
MACHINE DESIGN
THE PERFECTIONIST
FOR DYNAMIC PRECISION APPLICATIONS:
OUR METAL BELLOWS COUPLING.
RW-AMERICA.COM
THE COUPLING.
2014 LEADERS PROFIL

2
PROFILE
LE
FREUDENBERG-NOK
WEB |
EMAIL |
TEL |
www.fnst.com
information.us@fnst.com
734.451.0020
47690 East Anchor Court,

Plymouth, MI 48170
LEADING BY EXAMPLE
echnology is a world of extremes extreme temperatures, pressures,

altitudes, depths, sizes, and chemicals. In striving to do more, to go further
and move faster, technological industries continue to push the limits of
system integrity under more challenging conditions. The difference between
improbably and possible at this level of innovation often comes down to the choice
of critical sealing technology. Freudenberg-NOK Sealing Technologies offers you
solutions for every application.
GLOBAL EXPERTISE WITH LOCAL REPRESENTATIVES
Freudenberg Sealing Technologies (FST) in the Americas is represented

by FreudenbergNOK Sealing Technologies, a joint venture partnership
between Freudenberg & Co. in Germany and NOK Corp. in Japan.
Established in 1989 to address the sealing needs of customers in the Americas,
Freudenberg-NOK has grown to become a leading supplier of oil seals, fluid power
products, O-rings, special sealing products, gaskets, boots, integrated molded
components, and engineered plastics, with approximately 20 locations in the United
States, Canada, Mexico, and Brazil.
Today, as part of the FST global network, Freudenberg-NOK maintains a leadingedge focus on the core competencies of sealing and elastomeric technologies. The
company relentlessly pursues product and process perfection through proprietary
lean manufacturing and Six Sigma programs. We are a valued development partner
for OEMs, distributors, and system suppliers seeking reduced warranty and total
costs and an innovative industry leader.
OUR SERVICE KNOWS NO BOUNDARIES

FREUDENBERG-NOK BRINGS a unique combination of services
for you, globally. Always delivering superior customer service,

our network offers the worlds largest product range from a
single source.
32
MACHINE DESIGN
OFTEN INVISIBLE
ALWAYS ESSENTIAL
Extreme temperatures leave us cold

For FreudenbergNOK Sealing Technologies,
the power to innovate is key. Our compound
portfolio spans hundreds of individual mixtures,
GCEJVCKNQTGFVQCURGEKECRRNKECVKQPGCEJ
ECRCDNGQHUVC[KPIGZKDNGCPFQRGTCVKQPCNKP
the most adverse conditions. And our engineers
CTGCNYC[UUVTKXKPIVQPFPGYUQNWVKQPUHQTVJG
next big challenge. So, when the temperature
drops below 40C, were cool with that.
www.fnst.com
2014 LEADERS PROFIL

2
PROFILE
LE
BIMBA
MANUFACTURING
WEB |
TEL |
FAX |
www.bimba.com
800.442.4622
708.235.2014
25150 S. Governors Hwy,

University Park, IL 60484
LEADERS IN
ACTUATION
imba Manufacturing provides

industry-leading pneumatic,
hydraulic, and electric solutions,
including a variety of stainless-steel body
air cylinders that are easy-to-use, reliable,
and ready for your engineering challenges.
BIMBA ANNOUNCES NEW
BLUE AND IMPROVED ORIGINAL
LINE CYLINDERS
BIMBA MAN UFACTURING Company, a
provider of pneumatic, hydraulic, and electric

solutions, announced a series of product
enhancements to its industry-leading round
line, non-repairable Original Line product
series.
These changes include design
modifications to further extend the catalog
life rating of the cylinders from 1,400 miles to
3,000+ miles, as well as new product labeling
and packaging.
These design enhancements are the
culmination of more than three years of
product testing and communications with
our customers. It will more than double the
life of our Original Line, enhancing the value

to our customers of the industrys hardestworking, longest-lasting cylinder, said Jerry
Scherzinger, Bimbas OL Product Marketing
Manager. Additionally, we are updating the
look of the cylinder by replacing our preexisting red logo with an updated blue logo,
as well as introducing new packaging that will
be easier for customers to remove prior to
installing our cylinders.
Scott Meldeau, Bimbas Vice President of
Sales and Marketing, said, These changes
reflect the aggressive corporate approach
Bimba is taking to strengthen our existing
products, in addition to developing new
products to position us for future growth.
To learn more, visit www.bimba.com.
34
MACHINE DESIGN
Predictive Failure
diagnose cylinder issues
before they happen
Machine Efciency
measure optimal
stroke time
Remote Monitoring
collect data on cylinders
from multiple locations
Production Improvement
move from emergency repair
to proactive upgrades
WELCOME TO THE PNEU AGE OF CONDITION-BASED MONITORING

Introducing IntelliSense, a one-of-a-kind technology platform that delivers real-time
performance data on standard Bimba pneumatic devices for maximum uptime.
See the future at bimba.com/smarter
Copyright 2014 Bimba Manufacturing Company. All Rights Reserved.
2014 LEADERS PROFIL

2
PROFILE
LE
PROTO LABS
TECHNOLOGY-DRIVEN MANUFACTURING
FOR RAPID PROTOTYPING AND LOWVOLUME PRODUCTION
WEB |
EMAIL |
TEL |
www.protolabs.com
customerservice@protolabs.com
877-479-3680
5540 Pioneer Creek Drive

Maple Plain, MN 55359
roto Labs is a technology-driven company

committed to being a solution for getting
things done quickly and a catalyst for
great ideas. We have three distinct manufacturing
services that produce custom parts for designers
and engineers around the world. Our proprietary
software and automated manufacturing processes
allow for rapid prototyping and low-volume
production of plastic, metal, and liquid silicone
rubber parts through quick-turn injection molding,
CNC machining, and additive manufacturing.
Product developers can upload their 3D CAD
model online and receive an interactive quote with
free design analysis and real-time pricing information
within hours. The manufacturability analysis helps
customers eliminate problems, like sink or internal
undercuts, during prototyping so modifications can be made early and often.
Its an iterative process that lets designers
FINELINE ADDITIVE MANUFACTURING
and engineers avoid product developOUR ADDITIVE MANUFACTURING service offers three rapid prototyping processes:
ment speed bumps so they can get their
stereolithography (SL), selective laser sintering (SLS), and direct metal laser sintering
product to market as fast as possible.
(DMLS). Whether small parts with precise geometries or large, highly detailed
patterns are needed, Fineline provides another option during early prototyping. Get
low quantities of SL, SLS, and DMLS prototypes built in as fast as one day.
FIRSTCUT CNC MACHINING
THROUGH A SUBTRACTIVE manufacturing process, Firstcut uses three-axis milling
from up to six sides to machine low volumes of parts from plastic and metal
materials including ABS, Nylon, PC, Delrin, PEEK, Ultem, aluminum, magnesium,
steel, stainless steel, and more. The result is functional prototypes within days that
can be used for jigs, fixtures, or one-off projects.
PROTOMOLD INJECTION MOLDING

FOR CUSTOMERS THAT need low-volume production or bridge tooling, Protomold
can injection-mold 25 to 10,000+ parts from hundreds of thermoplastic, liquid

silicone rubber, and stainless-steel materials, in three weeks or less. The injectionmolding service machines its molds in a fraction of the time and cost in comparison
to traditional mold manufacturers to produce custom parts across all industries.
36
MACHINE DESIGN
Some say theyre FAST...
But do they have the

SCALE to deliver?
At Proto Labs, were optimized to deliver quick-turn additive, machined and molded parts in as fast as one
business day. Our three distinct services allow us to manufacture prototype and production parts for thousands
of customers each day, many with dozens of designs that need to be simultaneously tested. Since 1999, weve
shipped millions of parts to product designers and engineers around the world.
Our proprietary software and automated technology let us make parts for you faster than anyone else, but we
back it up with large-scale manufacturing facilities on three continents that house hundreds of 3D printers, CNC
machines and injection-molding presses.
Whether your project requires a single prototype or thousands of parts from 50 different designs, we have the
capacity to meet your manufacturing needs every time.
2015 Cool Parts Calendar

Request your free calendar at
go.protolabs.com/DA4D
Visa/Mastercard Accepted | ISO 9001:2008 Certied | ITAR Registered

2014 Proto Labs, Inc. | protolabs.com | 877.479.3680
201
2
014 LEADERS PROFIL
PROFILE
LE
DESIGNATRONICS INC.
WEB |
EMAIL |
TEL |
FAX |
www.designatronics.com
info@designatronics.com
516-328-3300
516-326-8827
2101 Jericho Turnpike

New Hyde Park, NY 11040
ENGINEERED SOLUTIONS FOR A WORLD IN MOTION
esignatronics provides complete mechatronic

engineered solutions and services. Through our
brands, we develop comprehensive mechanical
solutions that optimize value in the global markets
we serve, such as aerospace and defense, automation,
robotics, oil and gas, packaging, and
medical. Applications include hightech surveillance camera systems,
satellites, UAVs, 3D printers, and
diagnostic and medical devices. If
youre looking for a solution, in small
to large production runs, look to
Designatronics.
At Designatronics, integrated design,
engineering, and manufacturing are
under one roof. Whether its developing a complete design or choosing
the right standard or custom part
for the job, our engineers are here to
help. Designatronics manufacturing facility houses the most

advanced CNC machines and technology available. Our
commitment to lean manufacturing standards and AS9100
Quality System ensures the component or assembly you
receive will meet the most exacting specifications.
Engineered Solutions for a World in Motion

PROVIDING SOLUTIONS TO MEET YOUR NEEDS

STOCK DRIVE PRODUCTS Setting
convenient place. Find gears, timing
Ideas into Motion is the One-stop

Shop for Mechatronic Components.
SDP offers both inch and metric small
off-the-shelf mechanical components.
Thousands of stock components can
easily be located and purchased in one
belts and pulleys, couplings, bearings,

shafts, gearheads and speed reducers,
clutches and brakes, and other
mechanical drive components.
STERLING INSTRUMENT Your Partner
in Innovation. SI is unsurpassed as a
custom precision gear manufacturer.
Fine- to medium-pitch gears are
manufactured to AGMA 14, +/-.0001
tolerance, in aluminum, brass, bronze,
steel alloys, stainless steel, and
titanium. Our expertise is not limited
to gear making; it also includes the
design and production of precision gear
assemblies, gearboxes, differentials,
speed reducers, and other motion

control products. Boeing Certified.
QTC METRIC GEARS Supplying
North America with Metric Gears.
If your application requires a metric
dimensioned gear, coarse to fine pitch,
find it here.
QBC The Bearing Marketplace. Look
to QBC for all your bearing needs.
AAC Global Source for Shock and
Vibration Solutions.
Contact us for customized design
and technical support. Learn more at
our websites; shop 24/7 and download
free 3D models and all the latest
product information.

38
MACHINE DESIGN
Fairloc is the Better Way

to Fasten Rotating Components
Easy Adjustment
Will Not Mar Shaft
Outstanding Reliability
Compact, Self-Contained Design
Maintains Shaft Alignment When Others Fail
Superior to Other Fasteners in High-Torque Applications
Fairloc can be tightened and released

repeatedly without affecting its torque transmitting abilities.
After clamping the Fairloc hub in place the unique design prevents
the central axis of the shaft from shifting its position and keeps the
shaft perfectly aligned. Few other clamping methods can make this claim.
Fairloc is an Exclusive Design - Not Available Anywhere Else

,ZDVVRKDSS\WRQGWKH)DLUORFLWZRUNVPXFKEHWWHUWKDQDVWDQGDUGVHWVFUHZ0LFKDHO71&
Customers specify Fairloc on all their components:

gears, pulleys, couplings, shaft collars, shaft reducers and extenders, and precision hubs.
$SSOLFDWLRQVLQFOXGHDHURVSDFHFRPSRQHQWVDLUFUDIWLQVWUXPHQWDWLRQPDFKLQHWRROVPLOLWDU\UHFRQWURO
systems, medical devices, optical equipment, and power drives.
Customized Design and Engineering Assistance Available

Call today about your application: +1 516.328.3300
Visit us on the web at: www.designatronics.com
AS9100C REGISTERED
ITAR Compliant DDTC Registered
2014 LEADERS PROFIL

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PROFILE
LE
BALDOR ELECTRIC
COMPANY
WEB |
EMAIL |
TEL |
FAX |
www.baldor.com
baldorleads@baldorleads.com
479.646.4711
479.648.5792
5711 R.S. Boreham, Jr. St.

Fort Smith, AR 72901
PROVIDING A WEALTH OF
SOLUTIONS AND SUPPORT
aldor Electric Company, headquartered

in Fort Smith, Ark., is a leading marketer,
designer, and manufacturer of energy-saving
industrial electric motors, drives, and mechanical power
transmission products. The company was founded in
1920 on the premise that a better motor is one that uses
less electricity, and that belief holds true today. Baldor
products have exceptionally strong brand recognition for
quality and value with our customers. In January 2011,
Baldor was acquired by ABB and is now a proud member
of the ABB Group.
Baldor is the largest motor and mechanical power transNJTTJPODPNQBOZJO/PSUI"NFSJDB#BMEPSr3FMJBODF
motors range from 1/50th through 15,000 horsepower
and have leading customer preference and market share.
Baldor sells and supports the entire line of ABB IEC
WE ARE A leading producer of mechanical power

USBOTNJTTJPOQSPEVDUT JODMVEJOH#BMEPSt%PEHF
engineered mounted bearings, enclosed gear products
and power transmission components, as well as
#BMEPSt.BTLBQVMMFZTBOEDPVQMJOHT
Baldor offers strong support and product solutions
for the mining, food & beverage, oil & gas, paper & forest,
aggregate & cement, unit & air handling, water and power
HFOFSBUJPOJOEVTUSJFT5IFDPNQBOZQSPWJEFTSFMJBCMF
40
motors and medium voltage motors, along with the full range
of ABB industrial drives. Customers can now create packaged
solutions of Baldor & ABB industrial motors and drives for
most industrial applications.
BQQMJDBUJPOTQFDJGJDQSPEVDUTBOEFYQFSULOPXMFEHFGPSFBDIPG
UIFTFNBSLFUT*OTUBMMFE#BTF&WBMVBUJPOTBSFBMTPBWBJMBCMFUP
BJEFOEVTFSTJOSFEVDJOHFOFSHZDPOTVNQUJPOXJUIUIFSJHIUNJY
of industrial motors, drives and gearing in a single application or
UISPVHIPVUBOFOUJSFGBDJMJUZ
DEFINING A SOLID VALUE FORMULA
MORE THAN 30 ZFBSTBHP #BMEPSDBSFGVMMZEFGJOFEi7BMVFw
BTJUJTQFSDFJWFECZPVSDVTUPNFST7BMVFJTEFGJOFEJOUFSNT
PG2VBMJUZBOE4FSWJDF CPUIBTQFSDFJWFECZUIFDVTUPNFS
JO
SFMBUJPOUP$PTUBOE5JNF XIJDIBSFCPUINFBTVSBCMF
5IF
SFTVMUJTPVSi7BMVF'PSNVMB wXIJDIIBTCFDPNFBQBSUPGPVS
DVMUVSF*UHVJEFTPVSUIJOLJOHBOEEJSFDUTPVSXPSLFWFSZEBZ
MACHINE DESIGN
A New Line of Motors
Fit to Wear Our Name

Whether you pump it, compress it, blow it or convey
it, the new line of Baldor GPM motors are the perfect
choice for safe area, general purpose applications. With
ratings of 250 1500 Hp, Baldor GPM motors are easy
to order and are suitable for use with adjustable speed
drives. Plus, many of the motors you need are available
from stock or with the shortest lead time in the industry.
Fastest Delivery in the Industry

Unmatched Quality
Superior Reliability
Since 1920, our goal has been to design and build the
highest quality, most reliable industrial motors in the
world. And, 94 years later our commitment remains the
same so that you can rest assured Baldor GPM motors
not only fit your needs but are fit to wear our name.
Designed for Safe Operation
baldor.com
American Made Since 1920
479-646-4711
i%DOGRU(OHFWULF&RPSDQ\
LEADERS
Advanced Manufacturing
IN OEM
3D Printing
Goes Big-Time for

Short Production Runs
Increasingly sophisticated 3D printers and materials are changing
industries by letting OEMs make end-use plastic parts on demand,
before traditional tooling gets set up.
D printing is starting to evolve from a prototyping technology into a production technology. Its whats called a bridge-manufacturing technique, a means of making moderate
quantities of parts to go into real working products. Bridge
manufacturing lets OEMs bring designs to market faster and
modify features to customer demands before finalizing tool-
42
ing to make the best part iterations in bulk. Also called pilot
or rapid manufacturing, the technique potentially lets OEMs
get new versions of products into production without tool
changes for every design modification.
The 3D printing of final-run parts has grown exponentially
over the last decade, according to Wohlers Associates Inc.,
Fort Collins, Colo. Last year, 28.3% of the $2.2 billion spent on
RedEye uses a bank of 3D-printing machines
surpass 3D printing of prototypes, even though
for bridge manufacturing parts in bulk. Wohlers
its still an uncommon production method. Thats
consultant Tim Caffrey predicts 3D printing of
partly because production parts often outnum-
end-use parts, many of them plastic, will soon
ber forerunning prototypes 1,000 or more to one.
MACHINE DESIGN
GE prints fuel nozzles (above) for

its production LEAP jet engines.
3D printing went to making end-use parts, up from 4% only a

decade ago. Analysts expect that trend to continue unabated.
METALS BEEN THERE, DONE THAT
Some OEMs, particularly those that make sophisticated

metal parts for medical designs, have already evolved 3D
printing beyond prototyping and bridge manufacturing into
The Artiphon musical instrument docks an iPhone that lets the

player make myriad sounds. But the instruments manufacturer
didnt want to get locked into one design, because smartphones
a full-scale production practice. Consider Arcam AB in Sweden, which builds electron-beam-melting (EBM) printers
and supplies cobalt chrome and titanium for the machines to
process. Its largest customers are orthopedic-device companies that 3D print dental, shoulder, and hip replacements in
batches of thousands or more.
Likewise, tooling OEMs increasingly make mold inserts
for injection-molding plastic parts with direct-metal lasersintering (DMLS) machines from EOS GmbH in Germany.
(See July 2014 Machine Design, How To Design 3D-Printed Metal Tooling.) Space Exploration Technologies Corp.
(SpaceX), Hawthorne, Calif., also uses DMLS and regenerative
cooling to 3D print engine chambers in Inconel, a superalloy
with high strength and toughness. The chambers go in thruster engines that fit into the sidewalls of the Dragon manned
spacecraft. A set of eight engines produces up to 120,000 lb of
axial thrust and lets astronauts land the craft (via propulsion
control) if theres an emergency during launch.
In the same way, GE Aviation, Lafayette, Ind., now prints
fuel nozzles for LEAP jet engines at its Cincinnati facility, with
direct-metal laser-melting (DMLM) directly from CAD files.
The parts maintain the same material properties and density
as traditionally manufactured pieces, but with far more complex geometries. So, theyre 25% lighter and five times stronger
than previous nozzles.
constantly evolve. So instead of creating a tool for injection molding,

which would have taken months and significant upfront investment,
PLASTICS CATCH UP
Artiphon 3D printed the instruments phone cradle with RedEye using
Advances in additive-manufacturing machines and materials to print plastic-composite parts are spurring new uses of
bridge manufacturing. Its a boon to consumer-product and
FDM. That let the company change the design to fit the iPhone 5
before the first commercial release.
43
The engine chambers on

the SpaceX SuperDraco
thruster are 3D printed
out of Inconel.
synthetic-component makers, because the forming of plastic

parts by traditional injection molding is notoriously expensive
and slow.
The early adopter was the electronics industry, says Jeff
Hanson, director of business development at the contract
printer RedEye by Stratasys Inc., Eden Prairie, Minn. Even
now, these companies use additive manufacturing as a bridge
to traditional manufacturing processes because many of their
end-use parts are made of the same thermoplastics used in
fused-deposition modeling (FDM). Second only to selectivelaser sintering (SLS), FDM, under the generic category of
fused-filament fabrication or thermoplastic extrusion, lets
OEMs launch parts in low volumes.
Also leveraging bridge manufacturing is the medical-device
industry, mostly to make device skins for clinical trials and
limited market releases. According to Hanson, such manufacturers favor FDM and PolyJet prints of biocompatible materials because they can bring low product volumes to the highly
regulated medical market.
Consumer products could be next. Olloclip LLC, Huntington Beach, Calif., which makes souped-up camera lenses for
cell phones, has 3D printing in its plans. When we finalize
a new design, it takes six to eight weeks to produce the tooling for the injection molds, says founder Patrick ONeill. It
would be nice to use 3D printing to deliver products in that
in-between time, so we can get to market faster. The company
44
is considering an Objet 500 Connex3 printer from Stratasys,

because that machine could print clear lenses and colored
bodies all in one shot.
THE BIG PLASTICS CHALLENGE
Bridge manufacturing for plastic-parts production also

eliminates the abrupt transition from design to production. In
traditional product development, ideas germinate into sketches and models, which spur prototypes. Then market input and
testing prompts design changes.
But once a product gets the green light, everything comes
to a screeching halt, and drawings and models are locked
down for production tooling, only to reemerge weeks or
months later as a mountain of deliverable product, rushing off
to market, says Gus Breiland, customer service engineering
manager at Proto Labs Inc., Maple Plain, Minn.
Nowhere is this transition more pronounced than in plastic
molding, where molds can cost tens or hundreds of thousands of dollars and take weeks or months to make. Its risky
for manufacturers to requisition molds before they finalize a
products details, because even small changes make old molds
useless. In the past, manufacturers either took that risk or
delayed moldmaking until the product was perfect. But now
use of rapid or quick-turn injection molding is commonplace.
Rapid injection molding is still far more common for bridge
and low-volume manufacturing of plastic parts than 3D print-
MACHINE DESIGN
ing. But even Proto Labs, a leader in

quick-turn injection-mold making, is
putting money down on the future of 3D
printing. Its recent acquisition of Fineline, an additive-manufacturing service
company based in North Carolina, helps
OEMs blur the lines between prototype
and production.
Fineline makes parts by stereolithography, SLS, and DMLS to (in its words)
offer production without tooling services for OEMs in medical, aerospace,
electronics, consumer products, and
industrial machinery. In fact, Proto Labs
says many of its customers already use
additive manufacturing during product
development.
Where production needs outweigh
the restrictions of traditional manufacturing, additive manufacturing lets
engineers design for manufacturability
and satisfy the we need it now demands
of changing markets, says Breiland.
So instead of investing in injectionmolding tools, companies can quickly
get low part volumes made through
additive manufacturing and start selling products while assessing fit and
function before going to full-scale
production.
The matte-black 3D-printed Windform parts for e-bikes are functional and can even be metallized or painted.
SMALL PRODUCT VOLUMES
A medical-device manufacturer
recently had RedEye print a small lot
of catheter parts with redesigned thermoplastic sockets and consoles. Why?
The likelihood of design modifications
was high, and the company only needed
small volumes for foreign clinical trials
and (after tweaks) functional tests and a
limited-market release.
In the same way, materials and racecar-parts maker Cevolini Rapid Prototyping (CRP) Group, Italy, recently
designed an electric motorcycle called
the Energica Egos (for sale starting
in 2015). The e-bike sports myriad
3D-printed parts including the fairings, cooling ducts, seat, and intake
manifold made by SLS granules of
CRPs carbon-fiber-and-polyamide
The Ego e-bike has a 100-kW PMAC synchronous motor (for torque to 160 Nm) and can reach
speeds to 240 km/hr, with a range of 150 km at 70 km/hr. Controls include ride-by-wire with
selectable power maps and regenerative brakes (based on an F1 design) to recapture energy.
But the manufacturer, CRP, credits its expertise in short-run 3D-printed parts production,
mostly for race-car applications, with the successful launch of the e-bike.
45
Windform SP. But once Ego sales ramp up, CRP plans to make
the plastic parts by traditional mass production molding.
CRP also plans to swap the current engine frame, forks, and
battery pack for ones out of cast aluminum. The benefit of
delaying is that they can revise the design and resume production in a few days if market reaction to certain features is
lukewarm.
BETTER MATERIALS AND MACHINES
Wherever 3D-printed parts go into end-use products, they

must be made of lab-tested materials so they dont fail under
regular use. Its no wonder, then, that CRP uses bridge manu- The olloclip
facturing. The company owns five proprietary 3D-printing smartphone
material formulations, permutations on the polyamide-based accessory includes
(nylon) Windform product that include aluminum, glass, or fisheye, wide-angle,
carbon fiber to make strong, functional parts. For example, and macro lenses to let
Windform SP has a tensile strength of 76 Mpa and flexural users take better pictures
modulus of 4,647 Mpa to replace reinforced composites in with their iPhones. Its
maker aims to use 3D printing
some applications.
In fact, most of the parts that industrial-grade SLS machines for bridge manufacturing.
print are made out of nylon, partly because new polyamide
formulations can now make parts
with stiffness that rivals that of molded parts. SLS machines can also print
parts out of PEEK, polyetherketoneketone, and copolyesters released
over the last few years to meet stringent design requirements for toughness, strength, and incombustibility.
But RedEye usually recommends
FDM for bridge manufacturing jobs,
because the technique can build parts
of more engineering-grade thermoplastics. These withstand extreme
temperatures and exposure to some
chemicals and replicate the functions
of parts made through traditional
injection molding. Manufacturers can sand and tumble FDM parts
to get good surface finishes. Using
FDM also lets engineers pick from
polyphenylsulfone, ABS, polycarbonate, amorphous thermoplastic polyetherimides (PEIs), polyester, and
other options.
Weve even started to work with Printed parts on the KySat-2 satellite (inset) include a lens cover, annulus, and mounting hardware
automotive and aerospace compa- for a camera that acts as an attitude-determination system; solar-panel parts; extensions for sepanies on bridge-to-tooling appli- ration switches; clips for stowing antennas; and a battery mounting bracket. CRPs stateside divications as weve added stronger sion, CRP USA, Mooresville, S.C., makes the parts out of carbon-filled polyamide, Windform XT 2.0,
materials such as flame-resistant so theyre tough enough for space. Students at the University of Kentucky and Morehead State
University launched the satellite so they could get direct access to hard data.
ULTEM PEI, Hanson says.
46
MACHINE DESIGN
Digital micromirror device

Light
source
Lens
Z stage
Resin
surface
Tank
X
Liquid
resin
Built physical
model
Platform
MIP-SL takes a digital 3D model and virtually slices it into horizontal

planes. A projector shines the mask image into a pool of photocurable liquid resin and cures it in the current layers shape. Then the
cycle repeats. MIP-SL could one day speed up bridge manufacturing.
Consider how igus inc., East Providence, R.I., known for its
power-transmission components made of high-performance
plastic, recently began offering spools of iglide I170-PF and
I180-PF thermoplastic polymers in filament form. The company is keen to stress that parts 3D printed from the filament
dont have the high strength of molded iglide parts. Even so,
theyre 50 times more resistant to abrasion than conventional
printed parts. Oscillating and linear-wear tests against steel
show both filaments have the wear rate of about 3 to 6 m/
km, depending on pressure and velocity for parts that are
up to 40 times more durable than ABS parts and 100 times
more durable than polycarbonate parts. The spools are on
backorder.
Its not just material makeup that affects printed-parts
strength and durability, though. A parts properties also
depend on which directions the material is fused. For example, when laid correctly, carbon-fiber materials eliminate the
directional weaknesses of SLS parts and FDM parts.
To this end, a machine from Markforged Inc., Somerville, Mass., prints and strengthens parts by thermoplastic
extrusion. In one arrangement, the printer accepts a spool of
thermoplastic filament and a spool of carbon-fiber filament.
Then when the machine prints a part, it alternates between
the two materials and myriad path patterns according to

software that precalculates the best way to lay down the
carbon-fiber material to maximize strength. Such technology already drives small-scale bridge manufacturing.
Soon, stereolithography machines could find use in bridge
manufacturing as well. Right now, parts made by the other
means have higher strengths and moisture resistance. But
photopolymers are evolving and providing options to make
parts with all kinds of textures, even to rubber-like consistencies, with an array of conductivity values.
Whats more, stereolithography is becoming faster and
could soon address one of 3D printings drawbacks slow
printing speed. Researchers at the University of Southern
California, Viterbi School of Engineering, Los Angeles, are
perfecting ways to speed up 3D printing of heterogeneous
objects made of multiple materials. USC Viterbi professor
Yong Chen and colleagues have reduced fabrication time from
(in some cases) hours to minutes with an improved version of
multijet modeling.
The technique, called mask-image projection-based stereolithography (MIP-SL), takes a digital 3D model and virtually slices it into horizontal planes. Then a computer converts
each slice into a 2D mask image. A projector shines the mask
image into a pool of photocurable liquid resin and cures it in
the current layers shape. Then the process repeats. In fact, the
speed of MIP-SL plus next-generation photopolymer formulations could soon spur new types of bridge manufacturing.
PRINTERS FOR HIRE
No matter the additive-manufacturing subtype, bridge

manufacturing often gets outsourced. Thats because shared
facilities often make the most of general-purpose machinery
and dedicated staff for additive manufacturing. That happens
at RedEye, Fineline, the National Additive Manufacturing
Innovation Institute (NAMII), Youngstown, rapid-prototype and manufacturing company, rp+m LLC of Thogus
Inc., Avon Lake, Ohio, and a dozen more commissioned
facilities in the U.S. In fact, Hanson says his organization has
helped lots of companies use 3D printing for bridge manufacturing. Some plan to go to traditional manufacturing but
then decide its viable and more cost effective to continue
3D-printing parts in production.
If theres any doubt that 3D printing is viable for plastic-parts
manufacture, consider how OEMs already use it. CRP 3D
prints functional intake manifolds for Formula 1 engines with
race-car parts maker Magneti Marelli S.p.A. in Brazil. Made of
CRPs polyamide-fiberglass Windform GF2.0, the fully functional manifolds are airtight, withstand temperatures to 350F,
and boost power and fuel economy. Likewise, the Boeing Co.
now 3D prints hundreds of plastic ducts, hinges, and panels for
aircraft.
47
2014 LEADERS PROFIL

2
PROFILE
LE
MOOG COMPONENTS
GROUP
WEB |
EMAIL |
TEL |
FAX |
www.moog.com/components
mcg@moog.com
540.552.3011
540.557.6400
1213 North Main Street

Blacksburg, VA 24060
MOOG LEADS THE WAY WITH PRODUCT SOLUTIONS
oog Components Group provides innovative design and manufacturing capabilities in motion,
electronics, and fiber optics. Both standard and custom product solutions are available for industrial,
medical, marine, energy, aerospace, and defense applications.
As the worlds leading slip ring manufacturer, Moog offers more than 10,000 slip ring designs that are used in
medical equipment, ranging from large CT scanners to smaller models on packaging systems, as well as rugged
space and aircraft vehicles. Slip rings are used in systems that require continuous rotation while transmitting
power and data from a stationary unit to a rotating device.
Moog is also a U.S. market leader in supplying
fractional horsepower brushless DC motors. These
high-performance motors are used in a wide range of
applications, including medical pumps and blowers,
packaging equipment, and robotics. The motors are
recognized for their quiet and highly efficient
operation.
Moogs portfolio offers a wide array of products and

solutions, including actuators, air-moving products,
alternators, multiplexers, position sensors, and
solenoids.
Moog has a legacy for providing high-quality
products used in mission-critical defense and space
applications. Over the years, this experience has
expanded to a broad spectrum of other markets.
The company is ISO9001 and AS9100 certified
and utilizes world-class manufacturing concepts,
including Six-Sigma and Lean Manufacturing to
allow the company to produce the highest-quality
products at competitive prices.
Moog has learned over the years that many projects
require a product that has unique specifications
either designed from scratch or modified from
another design. One of Moogs strong points is providing exactly the right solutionexactly when it is
needed. Many of our components are also integrated
into higher-level assemblies.
Moog understands that a companys best chance of
surviving and prospering in todays business climate
depends on its well-trained, expert employees who
are dedicated to meeting each customers requirements. With recent acquisitions, Moog has expanded
into new applications and markets and now customers have one company for all their motion solutions.
48
MACHINE DESIGN
Brushless DC Motors
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www.moog.com/components
2014 LEADERS PROFIL

2
PROFILE
LE
HELICAL PRODUCTS
COMPANY INC.
WEB |
TEL |
ounded in 1958 as the originator of the HELI-CAL Flexure and located

in Santa Maria, Calif., the companys facility manufactures the HELI-CAL
Machined Spring Flexible Couplings and U-Joints to stringent AS9100/
ISO9001 Standards. With more than 120 employees providing outstanding technical
support and customer service, Helical Products Co. has become the standard for
innovation by todays machine designer.
FAX |
www.Heli-Cal.com
www.MachinedSprings.com
877 435 4225
805 928 2369
P.O. Box 1069

Santa Maria, CA 93456
WHETHER USED AS a Machined Spring, Flexible Coupling,
or U-Joint, the HELI-CAL Flexure utilizes its curved-beam

and one-piece construction to meet design and performance
requirements in a wide variety of applications such as: industrial
equipment, food processing, surgical tools, aviation, and
spacecraft.
The HELI-CAL Machined Spring employs the same
HELI-CAL Flexure technology to provide the desired spring
performance in compression, extension, torsion, and lateral
bending modes. The ability to produce multiple-start flexures
solves many of the limitations associated with conventional
springs. By design,
the HELI-CAL
Machined Spring
can be configured
to resolve moments
during compression/
extension, or provide
pure moments
when used as a
torsion spring. The
most demanding
compression,
torsion, and lateral
spring applications can benefit from the HELI-CAL Flexure
concept, and our ability to machine most modern high-strength
materials. OEM system designs can be enhanced because
the HELI-CAL Machined Spring provides increased precision,
reliability, and overall value.
When used as a Flexible Coupling,
the HELI-CAL Flexure is designed to
transmit torque while compensating for
angular misalignment, parallel offset,
and axial motion between two shafts.
50
HELI-CAL Flexures are available in a wide range of

standard flexible couplings to custom-designed couplings,
each engineered to meet the specific requirements of a unique
application.
The HELI-CAL Flexure is an advanced U-Joint solution that
generally exceeds the capabilities of traditional u-joint designs. A
Helical u-joint is really a HELI-CAL Flexure capable of over 5 of
angular misalignment. It may accommodate up to 90 of angular
misalignment in certain circumstances. This type of u-joint will
also compensate for axial and parallel misalignment.
Another significant advantage of Helicals Machined Spring,
Flexible Coupling, or U-Joint is the one-piece construction,
which enables integrating customer-specified end attachments
(tangs, flanges, gears, removable caps, etc.) as well as unique
bore configurations (D bore, hex, spline, shaft, etc.), all into a
single machined piece.
MACHINE DESIGN
FLEXIBLE SOLUTIONS
MACHINED SPRINGS
FLEXIBLE COUPLINGS
FLEXURED U-JOINTS
0RUHWKDQ\HDUVRISURYLGLQJWKHSHUIHFWVROXWLRQZKHQH[LELOLW\LVQHHGHGIRUFULWLFDODSSOLFDWLRQV)URPWKHLQnovative HELI-CAL Machined Spring to a large range of standard couplings to value adding custom couplings and
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For more information call (877) 435-4225

ZZZ+HOL&DOFRPZZZ0DFKLQHG6SULQJVFRP
When Stratasys merged the three leading advanced manufacturing

service bureaus, we created a powerful set of tools to challenge
traditional manufacturing. We partner with companies like Mission
Motors to provide the solutions they need to push the boundaries of
design and engineering. When they set out to build a high-performance
electric motorcycle, they turned to us to manufacture the complex
integrated dashboard that would have been impossible without our 3D
printing and advanced manufacturing technologies. The freedom to
create. The power of additive manufacturing. The power of together.
MERGING THE BES T SERV ICE BURE AUS TO CRE ATE THE NE W FACE OF A DVA NCED M A NUFAC T URING.
PROJECT
CLIENT
MISSION R
MISSION MOTORS
PA R T S
D AY S
Download our recent white paper to learn how Stratasys is redefining manufacturing. S T R A T A S Y S T O G E T H E R . C O M
19
4
2014 LEADERS PROFILE
STRATASYS
WEB |
EMAIL |
STRATASYSTOGETHER.com
info@StratasysTogether.com
THE NEW FACE OF ADVANCED

MANUFACTURING SERVICES
tratasys merged the three leading service bureaus to challenge

conventional approaches to manufacturing. The newly
combined 3D printing and advanced manufacturing group
now offers the full spectrum of custom manufacturing solutions to take
ideas from 3D printed prototypes to end-use parts.
In combining Solid Concepts, Harvest Technologies, and RedEye,

Stratasys is now the countrys largest, most experienced custom
manufacturing service bureau, offering every major 3D printing
technology and various traditional manufacturing processes. The
technology, materials, and expertise offered by Stratasys helps
customers manufacture products better, faster, and more affordably.
3D printing encourages new approaches to design and manufacturing.
Stratasys enables engineers to minimize assembly by consolidating
dozens of pieces into one integrated part. And with a wide range of
materials and technologies to choose from, engineers and designers
can manufacture complex designs that wouldnt have been possible
using traditional methods.
Visit www.STRATASYSTOGETHER.com to learn how Stratasys is
transforming manufacturing.
STRATASYS + SIE TEAM UP TO BUILD THE ORBIS FLYING EYE HOSPITAL
STRUCTURAL INTEGRITY ENGINEERING (SIE), an aircraft retrofitting
company, was tasked with building the next-generation Flying Eye
Hospital for Orbis Internationalan organization that uses a converted
MD-10 aircraft to improve access to quality eye health around the world.
SIE chose a Stratasys Service Bureau to manufacture a critical part for

its redesigned aircraft: a geometrically complex air duct responsible for
filtering air between the cockpit and operating rooms. Given the parts
complicated geometry and strict FAA airflow certifications, the team at
SIE quickly realized traditional manufacturing processes were

not an option.
With the guidance of Stratasys, the engineers at SIE opted to
use a 3D printing process called Fused Depositon Modeling
(FDM) to manufacture the duct using ULTEM, a thermoplastic
material engineered to meet harsh environmental factors.
Using FDM, SIE was able to receive its end-use part in a matter
of days, and should they need it, a replacement duct could
be manufactured in under one week. Additionally, 3D printing
provided an economic advantage, allowing SIE to save on
weight and part countboth important components in aircraft
manufacturing.
To learn more about how Stratasys is redefining manufacturing,
visit www.STRATASYSTOGETHER.com for case studies and
to download their latest white paper.
53
MACHINE DESIGN
2014 LEADERS PROFIL

2
PROFILE
LE
ALLIED ELECTRONICS
llied Electronics, a subsidiary of Electrocomponents plc (LES:ECM), is a

high-service-level distributor of industrial automation products, electronic
components, and electromechanical products with more than 45 sales
offices serving the United States, Mexico, and Canada.
INTRODUCING DESIGNSPARK MECHANICAL
DesignSpark Mechanical is a groundbreaking new software

package brought to you by Allied Electronics and RS
Components. With its intuitive interface, DSM allows
electrical and mechanical engineers to quickly and easily
build models and prototypes in three dimensions without the
use of expensive and complicated Computer-Aided Design
(CAD) programs.
BEST OF ALL, ITS ABSOLUTELY FREE
Available in multiple languages, DesignSpark Mechanical

levels the playing field, allowing you to compete in a much
larger arena by
enabling the fast
creation of highly
professional concept
designs for product
proposals. Developed
in collaboration with
SpaceClaimthe
leading provider of
flexible and affordable
3D modeling software
for engineersand TracePartsthe worlds foremost 3D
content companyDesignSpark Mechanical allows you to
thinkallied.com
Elisa.Weber@alliedelec.com
TEL | 800.433.5700
FAX | 817.595.6444
7151 Jack Newell Blvd. S.
Fort Worth, Texas, 76118
WEB
EMAIL |
be up and running within minutes. It even generates its own

Bill of Materials (BOM), saving you the time and effort of
sourcing and ordering parts individually.
DesignSpark Mechanical offers a host of important features,
including:
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anyone to create solid models almost instantly. Pull, Fill,
Move, and Combine tools enable hands-on 3D design.
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designs for product proposals.
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geometry without ever leaving a 2D cross-section.
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element.
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into an assembly and vice versa.
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CAD specialist engineers. No more waiting for the CAD
department to make changes and alterations in design.
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prototype builds via 3D printers.
Visit DesignSpark.com/Mechanical to access an informative
video, detailed product information, and a link to download
the software, all absolutely free.
Once you start working with DesignSpark Mechanical, you
wont know how you lived without it.
54
MACHINE DESIGN
YOUR GIFT HAS ARRIVED
The gift of invention is yours with

DesignSpark Mechanical from Allied Electronics.
At Allied Electronics, we want engineers to have the freedom to make their ideas a reality.
DesignSpark Mechanical is a powerful 3D software solution created to enable
every engineer to rapidly design great products. As a gift to all engineers and designers,
weve made this incredible tool available FREE.
LEARN HOW DESIGNSPARK MECHANICAL

CAN HELP YOU CREATE THE FUTURE
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Allied Electronics, Inc 2013. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
An Electrocomponents Company.
2014 LEADERS PROFIL

2
PROFILE
LE
WEB |
TEL |
HARMONIC DRIVE, LLC
FAX |
harmonicdrive.net
800.921.3332
978.532.9406
247 Lynnfield Street

Peabody, MA 01960
armonic Drive LLC designs and manufactures

precision Harmonic Drive servo actuators,
gearheads, and gear component sets. We
work with industry-leading companies of all sizes to
provide both standard products and custom-engineered
products. We deliver high-precision, high-performance
solutions to meet customers mission-critical application
requirements.
APPLICATIONS
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Automation
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production teams continually develop enabling technologies
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EXPERT, EXPERIENCED ENGINEERING
KNOWLEDGEABLE SALES TEAM
OUR FULL-SERVICE ENGINEERING department truly
ALL OF OUR sales engineers are degreed engineers. We speak

your language and understand your challenges. With an average
of 17 years in the industry and experience in Robotic, Defense,
Aerospace, and Machine tool applications, the Harmonic Drive
LLC sales team has the skills, knowledge, and products to
provide a solution for your design project.
partners with our customers. We solve problems, and work

to provide realistic, timely solutions. Application engineers
with expertise in motion control are available to assist you
with your concept and detailed designs, free of charge. We
love what we do and are eager to share our knowledge and
passion with our customers.
Harmonic Drive is a registered trademark

of Harmonic Drive LLC.
Robonaut and Phoenix images courtesy of NASA/JPL-Calt

56
MACHINE DESIGN
Building a high-precision
actuator is easy!
:PTWS`JV\WSLHU`ZLY]VTV[VY[VVULVM
V\YWYLJPZPVU8\PJR*VUULJ[NLHYOLHKZ
*VTWSL[LSPULVMNLHYOLHKZUV^H]HPSHISL
/HYTVUPJ+YP]LVY/HYTVUPJ7SHUL[HY`NLHYOLHKZ
ALYVIHJRSHZOHUKSV^IHJRSHZO]LYZPVUZ
9H[PVZ!!!
7LHR;VYX\L! 5T 5T
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6\[W\[*VUN\YH[PVUZ!/VSSV^:OHM[-SHUNL2L`LK:OHM[
/HYTVUPJ+YP]L33* ^^^/HYTVUPJ+YP]LUL[
/HYTVUPJ+YP]LHUK/HYTVUPJ7SHUL[HY`HYLYLNPZ[LYLK[YHKLTHYRZVM/HYTVUPJ+YP]L33*
LEADERS
Cables, Connectors, and Enclosures
IN OEM
When
FLEXIBLE CABLE
Doesnt Flex for Long
Its easy to get confused by terms thrown
around for cables meant to last a long time
on moving, automated machinery.
hen science-fiction writer Isaac

Asimov first penned stories about positronic robots in the 1940s, its doubtful
he could have foreseen that one of the
weak points real robots would have is relatively mundane: the
cabling used to connect their moving parts. This wiring can flex
millions of times in normal use. The problem is that most cable
is not designed for this sort of repeated bending, twisting, and
movement. Repeated flexing can eventually cold harden conductors to the point of failure. Similarly, the friction arising between
various components of a moving cable can generate enough heat
to eventually make the insulation and jacketing fail.

None of these factors would be problematic if there were standards for the amount of flexing that cables used in repetitivemotion applications should be expected to handle. Unfortunately,
there are no such standards. Cable manufacturers typically devise
their own tests to give some confidence that cables can stand up
to flex cycles numbered in the tens of millions.
Moreover, there is no standard way of referring to cable meant
to last for millions of flex cycles. Some manufacturers call cables
for motion applications high-flex-life cable, but that moniker is
not universal. Many cable makers just use their own trade name
to denote cable with a long flex life.
There is another point of confusion with regard to cable naming. Users sometimes confuse cables labeled high-flex-life with
another type called flexible or high-flex cable. The two categories
of cable behave completely differently when flexed numerous
One test motion cables undergo at cable maker igus inc. is repeated twisting. Here, cables sit inside Twisterband cable carriers, which rotate
thousands of degrees per cycle.
58
MACHINE DESIGN
times. The latter is designed to be supple and highly flexible

or limp. The limp quality arises because the cable uses finely
stranded conductors. Trouble is, finely stranded conductors do
not necessarily withstand the kind of repeated flexing seen in
automated settings.
Further confusing the matter is that both flexible cable and
high-flex-life cable may use fine-stranded inner conductors.
However, the outer jacket of limp cable often consists of soft PVC
or other elastomer. But cables built for a high-flex-life tend to use
outer jackets of TPE because it resists abrasion and is more rugged. TPE polyurethanes also tend to have more shape memory
than softer jacketing materials. Makers of high flex-life cables say
plastics with shape memory typically work better where highflex-life is important.
All in all, cable makers say the stiffness or limpness of the
cable has nothing to do with its flex life. Some high-flex-life
designs are relatively stiff, more so than others that dont last as
long. And there is no industry standard for quantifying cable
limpness or stiffness.
INSIDE THE CABLE
Cables wear because of two factors, heat from friction and

cold hardening of the conductors. There are multiple layers
CounterBalance...
The strongest lift you can buy
Stop for clamp
UL TEST SETUP
Specimen
Clamp at end
of specimen
Clamp at
end of
specimen
Wire
(not specimen)
Weight
Pulleys (circular
groove) on mount
that shuttles back
and forth horizontally
Stop for
clamp
Wire
(not specimen)
Weight
UL 1582 specifies a test for cable flexing that runs lengths of cable
back and forth over two pulleys. But it stops after 15,000 cycles. Makers of motion cable may run similar tests but typically extend the duration to millions of cycles.
in a cable. These layers typically include an outer jacket, the

individual conductors, fillers, and wraps (serves). To keep
down the heat from friction, cable makers insulate conductors
with a low-friction material, often a polyester elastomer. (Some
manufacturers may use a different material but treat it with a
lubricant.) Materials used in the other layers are specd with
an eye toward minimizing friction as well. For example, some
So why use outdated and expensive technologies

like gas springs? For hinged lifting,
use CounterBalance!
CounterBalance provides:
%"
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CounterBalance lifts and supports:
%

%!
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CounterBalance systems are used in:
%$!
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CounterBalance Corporation

#"

1025 Louis Drive

www.cbal.com
59
Cables, Connectors, and Enclosures
manufacturers keep down friction between the outer jacket

and the wire bundle by wrapping the conductor bundle with
PTFE tape.
Wire cold hardens when stretched beyond its yield point. In
cable, cold hardening often arises if a conductor is bent around
a too-small radius that forces it to stretch. Repeated stretching
beyond the yield point changes the wires internal structure,
hardening it and eventually causing it to become brittle and
break. The acceptable bend radius is proportional to the wire
diameter. Thus, the finer the wire gauge, the less prone it will be
to cold hardening because it can bend around a smaller radius.
Most cable manufacturers recommend a minimum bend radius
over which their cables should flex.
Thus, the failure mechanisms associated with numerous flex
cycles are well known. But industry standards for cables tend to
ignore these mechanical qualities. The primary focus of standards promulgated by bodies such as UL and CSA is fire safety.
These cable tests typically dont consider lengthy repetitive use.
For example, consider UL 1581, a cold-bend test. Here, cable
soaked at a cold temperature is bent around a mandrel, only
once. The cable then is returned to room temperature and
straightened. It passes the test if there are no cracks in any of its
insulation layers. Similarly, the UL 1582 test covers the flexing
of shielded cords. It runs 15-ft lengths of cable over two pulleys,
but it stops after only 15,000 cycles. The 2007 version of the
NFPA 79 electrical standard for industrial machinery is the first
version of that code to call out motion cables as a special class
and provides guidelines for the construction of a motion cable.
But it falls short on outlining mechanical performance criteria
and which tests to perform.
In the absence of industry standards, cable makers have
devised their own tests designed to ensure lifetimes in the millions of cycles. One of the common starting points is to modify
Moving
arm
Arm motion
Cable clamp
Continuity
check
Blocks
Weight
Cable
under
test
Some cable makers adapt a tick-tock mil-standard test for judging

flex life in motion cables. The original test ran for thousands of cycles;
makers of motion cable extend that number into the millions. The test
consists of repeatedly bending a length of cable back and forth over
blocks while hanging a weight on the opposite end. A continuity test
checks for cold hardening by measuring cable resistance.
cable tests spelled out either by UL or in mil standards. The

difficulty is that these standards can only be a starting point
because they arent specifically concerned with flex life. Thus,
the typical approach is to begin with a procedure spelled out in
mil specs, in standards by UL, or in those by another regulating
body, and then conduct it over millions of cycles.
Examples include a rolling flex test. Typical rolling and torsional flex (twist and flex) testing entails pulling the cable over a
wheel and twisting it 360. The portion of cable between the grip
and the wheel is the part that undergoes twist. A weight hangs
on the cable as it twists. One cycle comprises a 90 twist in each
Cable makers often
TWIST-AND-FLEX TEST
simulate the twisting
Continuity
Cable grip
TICK-TOCK CABLE TEST
check
and bending action that

motion cables typically
see through a twist and
Tension
Cable
under
test
bend test. The typical

approach is to put a
Cable length
cable sample under
under tension
tension while twisting

it 360 in clockwise
Twist
and counterclockwise
directions while simultaneously monitoring
Tensioning pulley
cable resistance for evi-
Cable maker igus inc. tests cable jackets for resistance to
dence of shorts or cold
abrasion by scraping samples millions of times against cable-
hardening.
carrier crossbars. Motion cables frequently see deployment

inside cable carriers .
60
MACHINE DESIGN
first flex 90 over a nylon block, then back to neutral, and

finally flex backward 90 over another nylon block. A weight
hangs on the cable as it flexes. One cycle completes every few
seconds.
Finally, cable makers have also adapted standards aimed
at ensuring that wiring resists abrasion. The type of abrasion
of most interest for motion cable is that which happens when
cables move around in cable carriers where they may experience rubbing abrasion, pinching, and twisting. UL typically
tests cables for abrasion (as in UL 719) using emery cloth
dragged across a sample cable at a specified force for only
5,000 cycles. Cable makers devise similar tests, which, of
course, run into the millions of cycles.
RESOURCES:
Cable makers frequently do life tests of their motion cables while flex-
AutomationDirect, www.automationdirect.com/adc/Overview/
ing in different chemicals and oils as depicted in this test run by igus inc.
Catalog/Cables/Motion_Control
igus inc., www.igus.com/energychains
direction. Tests typically run at a rate of about 30 cycles/min.

Similarly, the bending flex (tick-tock) test is based on a milstandard procedure. It keeps one end of the cable stationary
while another point in the cable bends around a fixed object.
One complete cycle of this test consists of having the cable
Lapp Group USA, lappusa.lappgroup.com/olflex.html

Northwire Inc., www.northwire.com/
W.L. Gore & Associates Inc., www.gore.com/en_xx//products/cables/
index.html
Together, we can reduce

engineering and service
complexity.
You know Parker as the global leader in providing unprecedented performance and value for
hydraulic systems with high-pressure applications. GlobalCore provides a simple solution of
robust hydraulic hoses designed to endure the tough conditions where work gets done. It is the
future that OEMs and end users around the world have been asking for.
GLOBALCORE
Five Hoses. Two Fittings. One Solution.
www.parkerglobalcore.com 1 800 C-Parker
2014 LEADERS PROFIL

2
PROFILE
LE
AMETEK PRECISION
MOTION CONTROL
Haydon Kerk Motion Solutions and PITTMAN Motor brands
are part of AMETEK Precision Motion Control
headquartered in Kent, OH (www.ametekpmc.com).
WEB |
EMAIL |
TEL |
www.ametektip.com
amie.sedlock@ametek.com
330.677.3327
100 E. Erie St., Suite 200

Kent, OH 44240
ABOUT HAYDON KERK

MOTION SOLUTIONS
aydon Kerk Motion Solutions is the

joining of 2 world class brands in
the field of linear motion; Haydon
and Kerk. Together, the brand offers a broad
range of precision linear motion products.
Recognized as a leading manufacturer of
precision acme lead screw and anti-backlash
nut assemblies, stepper motor based linear
actuators, and linear rail and guide systems,
Haydon Kerk Motion Solutions offers high
performance in demanding applications
such as laboratory automation, medical
instrumentation, semiconductor fabrication,
electronic testing and assembly, and any other
application where precision motion is critical.
ABOUT PITTMAN MOTORS
The PITTMAN motor line spans a wide variety

of dc motor sizes and technologies ranging
from miniature brushless slotless dc motors
used in high speed medical applications to
large NEMA frame dc servo motors used
in sophisticated automation equipment. If
theres a need for precision motion, more than
likely theres a Pittman solution to meet your
requirements.Pittman Motors can be customized
to meet just about any engineering need. Options
include unique shaft configurations, various
bearing systems, output devices such as pinions
and gears, special leadwire assemblies, EMI/
RFI suppression networks, optimized motor
windings, permanent magnet options, and
various brush materials.
62
MACHINE DESIGN
Haydon Kerk Motion

Solutions: Experts in
Linear Motion
PITTMAN: The Gold

Standard in DC
Motor Technology
Automation Grade
AB23000
brushless
57 mm (2.25-in)
NEMA mount,
rated IP65 with
integrated sensor
and motor
connectors
6210 Series
22 mm (0.866-in)
diam. DC brush
servo with
encoder
Haydon
Hybrid Linear
Actuators:
Size 17 (43 mm
/1.7-in sq.)
captive,
non-captive,
external
lead-screws
BGS06 linear
rail with Haydon
size 17 stepper
motor, Kerk
lead-screw, and
precision
ball slide
8540 Series
30 mm (1.18-in)
diameter DC
brush motor
Can-Stacks:
G4 Series 19000
(20 mm / 0.8-in. diameter)
external, captive and
non-captive lead-screws
Haydon Kerk Motion SolutionsTM provides a broad

range of sophisticated, application-specific
precision motion control products including
lead-screws/anti-backlash nut systems, linear rails
and guides, linear actuator stepper motors and
electronic drives. Hybrid motors range from 21 mm
to 87 mm square (0.8-in to 3.4-in); Can-Stack
diameters from 15 mm to 46 mm (0.59-in to 1.8-in).
1 800 243 2715

www.HaydonKerk.com
Haydon Products Division Kerk Products Division
Ph: 203 756 7441
Ph: 603 465 7227
Waterbury, CT 06705 U.S.A.
Hollis, NH 03049 U.S.A.
Europe: +33 2 40 92 87 51
Asia:
+86 519 85113316
High performance
slotless
brushless
9.5 mm
(0.375-in)
diameter
PITTMAN offers a broad range of DC brush and

brushless motors with various power ratings and
sizes. Standard brushless motors include instrument grade, automation grade, and slotless motor
configurations, and a series with integrated
controllers. Options include encoders, brakes and
gearboxes. Motors can be customized to accommodate any application-specific requirement.
1 267 933 2105

www.Pittman-Motors.com
343 Godshall Drive
Harleysville, PA 19438 U.S.A.
Europe: +33 2 40 92 87 51
Asia:
+86 21 5763 1258
2014 LEADERS PROFIL

2
PROFILE
LE
SPECIALTY MOTIONS INC. (SMI)

WEB |
EMAIL |
TEL |
FAX |
smi4motion.com
sales@smi4motion.com
951 735 8722
951 735 8915
1801 Railroad Street

Corona, CA 92880
AUTOMATION TECHNOLOGY MADE

SIMPLE WITH SMI4MOTION.COM
MI, under the smi4motion.com brand, is a manufacturer of a variety of linear

actuators and an integrator of customized integrated automation equipment for
industrial or laboratory automation. Our expertise and forte is in creating actuators
for Automation Systems with travel lengths from .001 to 120, with load-carrying capacities
from ounces to 15,000 lbs. Accuracy levels achieved including straight line travel and resolution are .0001.
Smi4motion.com is the brand name used by Specialty Motions Inc., located in Corona, Calif. SMI formed in
1990 as a complete solutions house for linear motion applications and offers design assistance and standard as
well as custom actuator solutions. The company can design, build, assemble, wire, program, test, and deliver
complete electromechanical motion solutions with a variety of Human/Machine interfacing from handheld
controls to foot pedal, touchscreen, computer,
PLC, or remote control.
Its customer list includes 3M, Apple, NASA,
MIT, Purdue, Bose, Oakley, Lockheed, Honeywell, and many others.
Visit smi4motion.com or call 800-283-3411 to
see what smi4motion.com can do for you.
LINEAR ACTUATORS FROM SMI4MOTION.COM
From our smallest hand-driven micrometer stage to our largest Servo-powered gantry-style actuator, smi4motion.com
creates actuators based upon real-world needs for real-world
solutions. Smi4motion.coms actuators are born from 25 years
of satisfying customer demands with low cost, high-capacity,
quick-delivery
and quality-driven
solutions.
Smi4motion.com
is a U.S. manufacturer with the
drive and desire
to compete in this
competitive world
of Linear Actuators
and Automation.
64
LET SMI4MOTION.COM BUILD

YOUR NEXT CUSTOM ACTUATOR
SMIs engineering staff, machine facility, assembly department, and experience lend themselves well to supplying
volume, intricate electromechanical assemblies for OEM
applications. Design your custom actuator device and let SMI
manage the complex BOMs, suppliers, and vendors; stage
and control work flow; and build, test, and certify to your
standards while you save your valuable resources for what
you do best.
MACHINE DESIGN
2014 LEADERS PROFIL

2
PROFILE
LE
WEB |
THE LEE COMPANY

THE LEADERS IN MINIATURE FLUIDICS
EMAIL |
TEL |
www.theleeco.com/
Inquiry@leeimh.com
860.399.6281
2 Pettipaug Rd, PO Box 424

Westbrook, CT 06498-0424
or over 60 years, The Lee Company has pioneered the

development of miniature fluid-control components
for aerospace hydraulic and fuel systems, medical
and scientific instrumentation, down-hole oil tools, machine
tools, automotive, inkjet printing, and other industries
worldwide. The Lee Company continues to redefine
miniature fluidics by integrating new and more advanced
technology into smaller packages.
Lees unique capabilities in miniaturization and engineering expertise keep the company at the forefront of fluid flow
technology, and enable it to work effectively with customers
to solve difficult fluid-control problems.
The Lee Company employs over 800 people at its Technical
Centers in Westbrook and Essex, Conn., where all engi-
neering and manufacturing is performed. Lee Company

sales offices, staffed by degreed sales engineers, are located
throughout the United States and Europe, and the Companys
distribution network spans the entire globe.
PRODUCT GROUPS
Lees Electro-Fluidic Systems (EFS) group produces highquality miniature solenoid valves (general purpose and
chemically inert models), high-speed micro-dispense valves,
atomizing and dispense nozzles, fixed and variable volume
pumps, integrated fluidic manifolds, inert tubing, and fluid
control components and custom engineered designs. These
products are used in medical and scientific instrumentation,
analytical/clinical chemistry, in vitro diagnostics, drug discovery, and ink jet printing applications.
The Precision Microhydraulics group supplies Lee Plugs,
high-pressure solenoid valves, single- and multi-orifice
restrictors, nozzles, safety screens, check valves, relief valves,
flow controls, and shuttle valves to a wide range of industries. These include hydraulic and pneumatic applications on
commercial and military aircraft, spacecraft, missiles, naval
vessels, machine tools, downhole oil tools, power generation
equipment, motor sports, etc.
The Industrial Microhydraulics (IMH) group supplies expansion plugs, check valves, calibrated orifices, and other miniature fluid-control components to the automotive, medical,
commercial, and industrial markets. IMH products meet the
requirements for quality, economy, and ease of automated
installation, which are of paramount importance to these
industries.
Approximately half of all Lee products are special or custom
items designed to meet the requirements of specific applications. The Lee Company sales and engineering staffs are
eager to help you in solving your fluid-control problems
with special products that meet your needs. Contact The Lee
Company today. www.theleeco.com.
66
MACHINE DESIGN
ww w . th elee c o. c om
Go ahead, push us to your limits.
We love a good challenge.

If you need a uid handling component for whatever reason, no matter
how extreme, talk to The Lee Company. Weve been solving complex
uid control problems in all kinds of industries for more than 60 years.
Our extensive family of precision uid control products offers unsurpassed
reliability in just about every conguration you could imagine, including:
Miniature Solenoid Valves
Were not just talking about off-the-shelf solutions, either. A Lee

engineer will be happy to discuss your application, and develop a
custom design if needed. From managing nanoliter droplets to
creating fully integrated uidic systems, were unsurpassed in breadth
and experience to deliver the precise, reliable performance you require.
Whatever problem you face, make the solution easy.
Contact The Lee Company today.
Fixed and Variable Volume Pumps

Atomizing and Dispense Nozzles
Innovation in Miniature
Micro Dispensing Valves

Integrated Fluidic Manifolds
SCAN THIS CODE
Custom Engineered Designs
The Lee Company 2 Pettipaug Road | Westbrook, CT 06498-0424

Tel: 860-399-6281 | 800-533-7584 | www.theleeco.com
Westbrook
London
Paris
Frankfurt
Milan
Stockholm
LEADERS
Fluid Power
IN OEM
MATTHIEU GUILBERT | Business Development Manager

Hydraulic Pump Div., Parker Hannin Corp., Marysville, Ohio
Electronic controls
boost hydraulic efficiency

A new generation of hydraulic-pump controls is rapidly gaining
acceptance for mobile and industrial applications.
obile and industrial equipment manufacturers, and their customers, are rapidly embracing a new class of electronic
controls for open-circuit, medium-pressure piston pumps like the Parker P1/PD Series. Such circuits
are often used where the hydraulics must perform more than
one task on the same machine. A backhoe with a loader on one
side and excavator on the other is an excellent example. Instead

of relying on a bank of valves to manage hydraulic power, all
the control can now be handled by software.
This potentially reduces size and weight while permitting
smoother motion with higher precision and repeatability.
Electronic controls also lead to higher operating efficiencies
and usually offer better value than standard load-sense con-
Electronically controlled, open-circuit pumps are often

used where hydraulics must power more than one operation on the same machine, such as a backhoe with a loader
on one side and excavator on the other.
68
MACHINE DESIGN
Parkers P1 variable-displacement,
axial-piston pumps are designed
for open-circuit applications. Maximum outlet pressure is 4,000 psi
(280 bar) with flow ranging from 15
to 71 gpm (57 to 269 lpm), depending on the model.
trols. For all these reasons, electronic pump controls are

gaining rapid acceptance among OEMs and users.
Heres a look at how the controls work, and how equipment manufacturers are taking advantage of the benefits
in new and retrofit designs.
TRADITIONAL LOAD SENSING
Pressure compensation, often called load sensing, lets

a pump provide full flow at pressures below the compensator setting. When pump flow is restricted, say by a
downstream load, pressure builds up to the setting of the
compensator; then the pump destrokes (reduces flow) to
the level needed to maintain pressure at that setting.
With load-sensing compensation, output flow will
increase or decrease to maintain a constant pressure
drop (P) across the metering orifice regardless of
A Greenerd 300-ton compression-molding press produces carbon-fiber panels. An electronically controlled pump that simultaneously manages pressure and flow gives precision control of
300-TON PRESS
ENGINEERS AT Greenerd Press and Machine, Nashua, N. H., streamlined a press that compression molds carbon-fiber composite panels.
Hydraulics controls the closing speed of the press, as well as the tonnage
(applied force), and the process demands precision and repeatability in
both tooling motion and force levels.
In the original design, the main platen on the 300-ton finishing press
would close and hot-form a part at a specific tonnage, dwell time, and
decompression rate. The previous hydraulic circuit incorporated a proportional directional-control valve, as well as a proportional-relief valve. The
relief valve usually controlled the variable-volume pumps compensator
setting, unless pump response was deemed too slow for the application.
In such instances, a large full-flow proportional system was used to chop
off pressure spikes and prevent overpressurization at differing tonnages,
to protect tooling from damage.
To simplify the press, the redesign incorporated a Parker PD axial-piston
pump with an ECU. The ECUs P/Q capabilities (the ability to simultaneously manage pressure and flow) made the press more intuitive to program
in terms of recipe management for different panel shapes and profiles. And
the units graphical-user-interface software made tuning straightforward,
according to Greenerd officials.
The press cylinder incorporated a linear-feedback transducer, and
lookup tables stored in the machines PLC controlled closing speed in
an open-loop fashion. Because pump output is extremely repeatable,
the correlation between the indexing table and actual speed was also
repeatable. This eliminated the need for more-cumbersome closed-loop
feedback within the PLC, while still yielding results that mimic closed-loop
speed control.
The end result was a smooth-acting, highly repeatable press. P/Q
electronic control more than paid for itself by simplifying the design and
eliminating components, while increasing throughput. It also cut operating
costs by reducing the number of components that had to be maintained
platen force and speed.
69
Fluid Power
DRY-ICE PELLETIZERS
Dry ice is extruded at low speeds to control

quality and save energy.
load conditions. With this arrangement,

the pump always waits for system feedback to react and adjust the flow.
This is the basis of todays traditional
open-circuit pumps. The hydraulic circuit
reacts to an external load and the pump
adjusts flow based on system requirements. Load sensing is generally considered a reliable, proven technology. But
they usually cant match the performance
possibilities offered by electronic pump
controls.
DRY-ICE PELLETIZERS made by Tomco2 Systems, Loganville, Ga., rely on variablespeed hydraulics to turn CO2 snow into hard, uniform pellets. First, loose, dry-ice
powder is injected into a chamber inside the pelletizer. Next, a hydraulic cylinder
strokes at high speed to compress the snow to a suitable density for extrusion. The
pump then destrokes to minimum flow, reducing cylinder speed for extrusion.
Dry ice is extruded through the die at low speeds to tightly control quality and
reduce the horsepower required to produce pellets. When the extrusion stroke completes, hydraulic valves shift to retract the cylinder at high-speed (full pump flow) back
to the home position.
The operating environment is extremely harsh. Dry ice is processed at
109.3F, and moisture builds up during machine operation, forming ice on steel
components. In a previous version of the machine, the hydraulic pump had a
minimum volume stop and a compensator control block that mechanically shifted
from high to low speed as extrusion began.
The new pump had to at least match the performance of the previous unit,
operating at both partial and full flow, at pressures to 3,000 psi, and 24/7. Tomco2 engineers opted for Parkers PD pumps with electronic control for this opencircuit application. The new pump boosts efficiency through horsepower control
by tightly managing both pump flow and pressure.
During the extrusion process, the working pressure starts high and, as the
extrusion of dry ice begins, pressure tapers off. The electronic control monitors
and adjusts extrusion speed based on load resistance. In turn, this let the company decrease overall cycle time and produce a more-consistent extrusion.
In addition to a slightly faster production cycle, the company also improved process
efficiency and product consistency. Electronic controls also made it possible to eliminate two pressure-reducing valves along with a valve that controlled pump decompression. Now, software handles decompression.
ELECTRONIC CONTROLS
Electronic control of hydraulic piston pumps is not new. But

the approach, as well as the underlying hardware and software,
have significantly changed in recent years, giving OEMs more
versatility, superior control, and even options like wireless
monitoring.
Early versions mounted the electronic controller on the
pump. This required purchasing the pump and controller
with all of the supporting electronic cards. The next development moved the electronic cards from the pump to a more
appropriate and protected location on the machine, providing
mounting flexibility and added durability.
Todays open-circuit pumps with a programmable electronic-control unit (ECU) often include graphical-user-interface
software that lets users quickly set up pump-specific parameters; adjust for machine behavior if needed; set up a data log
and monitor pump and wiring status; and calibrate sensors.
With these controls, the pump includes the displacement sensor and electronic valves, as well as a pressure sensor, if pres-
70
sure control is needed.

The pumps are built with either a maximum-displacement
default position-control valve for electrical power-loss critical
applications, such as fan drives, or with a zero displacement
default position control valve which limits flow or pressure for
added safety in mobile applications.
Electronically controlled pumps are also available without
ECUs. Control logic is then integrated into the machines ECU.
Both versions include the directional-proportional valve
with optional, but recommended, displacement feedback
sensor and hydromechanical pressure limiter.
Thus, electronically controlled pumps are intelligent
hydraulic components that let OEMs upgrade performance
and improve machine operations. For instance, they can
reduce fuel consumption and emissions in mobile equipment
by supplying the exact amount of hydraulic power when
needed, and no more, based on commands from the ECU or
inputs from remote sensors. Specific benefits of electronic
control include:
Performance. Compared to load-sensing systems, elec-
MACHINE DESIGN
applications, theyve proven to save large amounts of electricity (or fuel) when extracting oil with hydraulic rod pumps.
COST VERSUS VALUE
Hydraulic cylinders on the Tomco2 pelletizer compress and extrude

dry ice.
tronic controls are significantly faster in closing the loop

on the output flow at the pump. That can equate to better
response and higher precision.
Efficiency. Electronic controls improve pump efficiency
by reducing control leakage in the pump, compared to a
load-sense system. Leaks generate heat. To prevent problems
caused by excessive temperatures such as shortened fluid
and seal life hydraulic fluid must be cooled, requiring a
higher-capacity cooling system and a larger fluid reservoir.
Simplified installation. In addition to inlet and outlet lines,
typical load-sensing pumps require installing hydraulic loadsense lines to the pump. Electronic control, on the other hand,
is a complete package, including the computer. Installing the
latter requires less hose, fewer fittings, and less manpower.
Tamperproof. Because there is no adjustment screw, as with
load-sense units, electronically controlled pumps are essentially tamperproof. Once set up, the software defines the system.
In a straight cost comparison between electronic-controlled pumps and traditional load-sense pumps, the latter
will win outright. But more important than looking at purchase price, however, is evaluating the total system cost.
For example, electronically controlled pumps come as a
complete unit. With load-sense pumps, on the other hand,
additional components like proportional valves cost extra.
And, as mentioned earlier, load-sense pumps require extra
hoses and fittings that add to assembly and setup time, as well
as costs.
For any system, the real question centers on productivity
and overall economics. With electronically controlled units, for
instance, how many hours are saved by running faster? What
is gained thanks to better precision? And what are the savings
due to higher efficiency, lower operating temperature, simplified installation, and wireless monitoring and reporting? Two
applications that document the value electronic control brings,
a press and a dry-ice extruder, are detailed in the accompanying
sidebars.
PRECISE. ACCURATE.
EFFICIENT.
LINEAR SHAFT MOTOR
SUB-MICRON MOTION
7KH/LQHDU6KDIW0RWRULVWKHUVWOLQHDU
motor designed for the ultra high-precision
market. No cogging, less generated heat,
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for ultra high-precision motion.
HIGH EFFICIENCY
Because of its design features, the
Linear Shaft Motor is 50% more energy
HIFLHQW* than competing linear motors.
TYPICAL APPLICATIONS
Open-circuit pumps with programmable ECUs are used

for such basic functions as proportional flow control, flow
and pressure control, and overcenter operation (where flow
direction is reversible) for energy-recovery applications.
In simplified terms, anything that can be electronically controlled can take advantage of these systems. A few examples
include hydraulic fan drives, booms and lift arms, and industrial presses. Machines that require two separate hydraulic
functions that are completely different in terms of performance and horsepower management, such as the previously
mentioned backhoe loader, are good candidates for these
systems. And the pumps overcenter capability paired with
electronic control can be used for energy recovery. In oilfield
SYSTEM APPLICATIONS
(QHUJ\HIFLHQF\GHWHUPLQHGLQDQ
independent study conducted by the
University of Virginia in October 2010.
You can design the Linear Shaft Motor

into a wide range of systems, including
high-precision robots, Gantry/Cartesian
robots, and high-force actuators.
NPM
Nippon Pulse
Your Partner in Motion Control
www.nipponpulse.com | info@nipponpulse.com | 1-540-633-1677
71
2014 LEADERS PROFIL

2
PROFILE
LE
AMETEK PRECISION
MOTION CONTROL
WEB |
EMAIL |
TEL |
www.ametektip.com
amie.sedlock@ametek.com
330.677.3327
100 E. Erie St., Suite 200

Kent, OH 44240
METEK Dynamic Fluid Solutions DFS business unit offers Brushless DC

Motor, Pump, Brushless and Regenerative Blower, and Controller-based
solutions for numerous applications. You may recognize our products as
Rotron, Windjammer, and Nautilair. AMETEK DFS is an ideal choice for such
varied applications as transportation, fuel cells, medical instruments, packaging
equipment, pumps, compressors, business machines, printing equipment, chemical
processing, aquaculture, electric-powered vehicles, hydraulic pumps, electroplating,
fume / smoke removal systems, or any other precise fluid motion applications.
At AMETEK DFS, we work closely with our customers to assure that we match each
products capabilities to the specific requirements of each application. Our Field
Sales and Factory Application Engineers are available to provide you with expert assistance and evaluation
whether designing an individual unit or an entire air moving systemand to assure that all AMETEK DFS
products perform properly and efficiently.
With the widest range of products available, AMETEK DFS has the expertise to tackle every application
requiring a motor, pump, or air-moving device.
COME SEE US AT UMA MOTORCOACH

OR AHR EXPO IN 2015
HERE AT AMETEK we strive to help our customers in any way that
we can. We promote our products through magazines, our website,

social media, and trade shows. In January we will be attending the
UMA Motorcoach Expo in New Orleans and also the AHR Expo in
Chicago. If you plan on attending either trade show, make sure you
stop by to learn more about our products and the value that we
can provide to you and your company! If you have questions for us
about our capabilities, please bring those questions with you or feel
free to contact us at the email listed (amie.sedlock@ametek.com).
We will be at booth 826 at the UMA Motorcoach show and we will
be in the North Hall booth 2912 at the AHR Expo.
72
MACHINE DESIGN
SOLUTION CITY
2013 by AMETEK Inc. All rights reserved.
FANS
PUMPS
BLOWERS
All roads lead to

SOLUTION CITY
Welcome back to Solution City, where you
always nd the biggest brand names and
largest selection of dynamic solutions for air
and uid movement.
Our line of variable-speed brushless (electrically
commutated) blowers, fans, and pumps as well as our regenerative/side-channel blowers offer custom-engineered solutions
unmatched in the industry. Whether your need is our latest electronic/microprocessor technology, our eld-proven uid motion
solutions, or a customized design option, we work closely with you to evaluate your unique application/specication requirements,
ensuring a fully compliant product, tailor-made for your application.
To put your ideas for dynamic air or uid movement in motion, contact your local AMETEK technical sales and application expert,
or visit us at: ametektip.com.
2014 LEADERS PROFIL

2
PROFILE
LE
ROTOR CLIP
www.rotorclip.com
sales@rotorclip.com
TEL | 732.469.7333
FAX | 732.469.7898
187 Davidson Avenue
Somerset, NJ 08873
WEB |
EMAIL |
GO FOR IT
ouve gone the traditional route with fasteners on many of your designs to date. But why settle on the
same ones for your current design? Take an innovative approach to your fastener requirements and
consider retaining rings.
Rotor Clip manufactures three types to choose from: tapered, constant-section, and spiral. But its not about
picking one of these from a catalog. Its understanding
how to use retaining rings in the most efficient way possible for your application. And our engineers are available to help you do just that.
If space is tight, maybe an inverted retaining ring is better than a standard one.
If noise or vibration is a consideration, perhaps a bowed
or beveled ring to take up endplay will suit your design
perfectly.
Or, maybe the three-point contact of a lower-cost
constant-section ring is all the holding power you need
for your application.
So go for it. Work with Rotor Clip engineers and set
new standards for cost reduction on fasteners using
retaining rings.
GO FOR MORE SAVINGS WITH

TRUWAVE WAVE SPRINGS
IF YOURE USING coil springs in your next design, consider
replacing them with wave springs. Traditional coil springs need

work heights up to twice as large as wave springs, adding to the
costs of the assembly. You can
realize considerable
savings by designing your assembly
around the many
advantages wave
springs offer, such
as axial space savings, consistent
spring force and increased travel over
disc springs.
74
A ONE-TWO COMBINATION FOR SAVINGS

THERE ARE MANY applications that can use both retaining rings
and wave springs to save costs. For example, a retaining ring
can be used to provide a shoulder for a wave spring, which then
exerts a preload on a bearing. In the photo above, a two-turn,
spiral retaining ring and a single turn wave spring retain the filter
element in this centrifugal pump.
MACHINE DESIGN
2014 LEADERS PROFIL

2
PROFILE
LE
SYMMETRY
ELECTRONICS CORP.
WEB |
TEL |
FAX |
symmetryelectronics.com/
877.466.9722
310.536.6188
5400 West Rosecrans Avenue

Hawthorne, CA 90250
with product expertise in wireless, video, and embedded

products. Expertise in these key areas helps get customers to
market quickly, saving them time, money, and resources.
NOT JUST ANOTHER DISTRIBUTOR
customer visit. Each member of the team can provide guidance

and support in all phases of the design cycle.
ymmetry Electronics, founded in 1998, is a global,

factory-authorized distributor focused on supporting
OEM and CEM customers through the design cycle
SYMMETRY ELECTRONICS DIFFERENTIATED approach to
electronics distribution starts with expertise in products and

product management. Every item on their line card is the result
of much time and consideration to ensure that it best meets the
needs of the customers the company serves. All of the products
are in the companys expertise wheelhouse, Symmetry President
Ken Davison explained. Symmetry works closely with each of
its suppliers to form a partnership that supports customers
collaboratively and effectively.
TECHNICAL SALES ENGINEERS
A skilled sales team is invaluable in aiding customers and is a
key component of Symmetrys model. Symmetry deploys a very

technical field sales team that are primarily engineers themselves
so they are able to provide a great deal of support on every
TECHNICAL SUPPORT
TECHNICAL MARKETING ENGINEERS
Symmetry knows that technical support and application
expertise is critical to supporting customers design

requirements and has developed a quick-response model for
specific technologies with a centralized Technical Marketing
team. Also engineers, this team has hands-on experience with
development kits, and focus on specific technologies to quickly
provide detailed design support as well as design reviews.
SEMICONDUCTORSTORE.COM
In addition to its technical distribution model, Symmetry makes
research and online purchasing simple with its informative and

award-winning ecommerce site, SemiconductorStore.com. It
is a valuable resource featuring the most current datasheets,
custom selector guides, application notes, reference designs,
whitepapers, and a vast library of supporting documents for all
sorts of design projects.
MARKETS SERVED
A custom Telit LTE IN-A-BOX development kit designed by

Symmetrys in-house technical support division that includes
hardware, software, and technical documentation. Available
online at SemiconductorStore.com.
S Y M M E T RY
76
Symmetrys philosophy is simple: focus on innovative products

and the markets that need them. Their strong industry
experience shines through in many market segments, including;
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ELECTRONICS
MACHINE DESIGN
2014 LEADERS PROFIL

2
PROFILE
LE
HAWE HYDRAULICS
NORTH AMERICA
www.haweusa.com
info@hawehydraulics.com
TEL | 704.509.1599
FAX | 704.509.6302
9009-K Perimeter Woods Dr.
Charlotte, NC 28216
WEB |
EMAIL |
SOLUTIONS FOR A WORLD UNDER PRESSURE
AWE Hydraulics is a leading global manufacturer and supplier of sophisticated hydraulic

components and systems for the mobile, industrial, and renewable energy markets. Since
1997, HAWE has provided superior components to North American by way of its parent
company HAWE Hydraulik SE. Today, Americas most rugged industries rely on over 60 years of
HAWEs dependable German engineering expertise. The companys strategic positioning allows it to
produce sustainable hydraulic solutions while tackling global ever-changing technological challenges.
HAWE Hydraulics North America has offices in Charlotte, N.C., Portland, Ore., and Houston. The
company offers a comprehensive package that includes design, manufacture, setup, a large distribution network, local inventory, and after-sales
support. HAWEs product offering is second to
none and includes a variety of pumps, valves,
power units, and electronics. The company is
known for its steel-manufactured, highpressure, modular components. In addition
to its product line, HAWE adds value to its
customers through experienced sales and technical engineers who assist customers at their
offices and out in the field.
HAWE SERVICE SOLUTIONSSM

THE HAWE SERVICE SOLUTIONSSM team is available for direct
on-site assistance. HSSSM capabilities include maintenance,

reconditioning and repair of individual components as well
as entire hydraulic
systems. In time-critical
situations, professional
hydraulic technicians
promptly assist with
your hydraulic needs.
Our team provides
extensive know-how
and expertise for all
hydraulic brands. The
HSSSM comprehensive
package also
offers after-sales
support including
product training,
troubleshooting, and
field services.
78
SYSTEC: SYSTEM TECHNOLOGY SOLUTIONS

GIVE US YOUR specifications and well give you a perfectly
customized hydraulic solution. Our proficiencies in system
integration allow us to improve applications regardless of other
the OEM components placed on the machine. We provide a
complete range of integrated servicesfrom consultation, design,
component procurement, to plug-and-play installation. Meeting
extraordinary requirements is nothing out of the ordinary for us.
MACHINE DESIGN
Slim Dimensions
Solid Performance
The V60N high-pressure pump with 130 ccm
Adding value through skillful design

The V60N-130, axial piston pump excels with slim dimensions and reliable
performance. Operating pressures of 420 bar make this a one of a kind, genuine
high-pressure pump. The benchmark figures for this product permit a wide
range of application options. Find out more at www.haweusa.com
LEADERS
Advertisers Index
IN OEM
COMPANY ......................................................... PAGE

ALLIED ELECTRONICS ...................................... 54-55
ALTECH CORP. ...................................................IFC-1
AMETEK PRECISION MOTION CONTROL ......... 72-73
AMETEK/HAYDON KERK MOTION
SOLUTIONS/PITTMAN .................................. 62-63
AUTOMATIONDIRECT.COM ............................... 3, 8-9
BALDOR ELECTRIC CO ..................................... 40-41
BALLUFF INC. ........................................................ 6-7
BIMBA MFG CO. ................................................ 34-35
COGNEX CORPORATION .................................. 28-29
COUNTERBALANCE CORP..................................... 59
DESIGNATRONICS INC ...................................... 38-39
EAGLE STAINLESS TUBE CORP. ....................... 20-21
FREUDENBERG-NOK SEALING TECH. ............. 32-33
GALIL MOTION CONTROL INC. ......................... 18-19
HARMONIC DRIVE LLC ...................................... 56-57
HAWE HYDRAULICS.......................................... 78-79
HELICAL PRODUCTS CO INC............................ 50-51
HOTWATT INC. .................................................. 14-15

IGUS INC............................................................ 12-13
MAXON MOTOR USA ........................................ 22-23
MICROMO ELECTRONICS ................................. 16-17
MOOG COMPONENTS GROUP ......................... 48-49
NIPPON PULSE AMERICA INC. .............................. 71
PARKER HANNIFIN ............................................. 5, 61
PROTO LABS, INC. ............................................ 36-37
R & W AMERICA................................................. 30-31
ROTOR CLIP CO. ............................................... 74-75
SMALLEY STEEL RING CO ................................ 10-11
SPECIALTY MOTIONS ........................................ 64-65
STRATASYS ....................................................... 52-53
SYMMETRY ELECTRONICS CORP. ................... 76-77
THE LEE COMPANY .......................................... 66-67
YASKAWA AMERICA, INC. .............................. IBC-BC
At EngineeringTV.com
users can browse
video libraries using technology-based navigation to focus

on specific technology topics. They can also browse by
company brand, trade show, or by publication-specific
video playlists.
From tutorials to trade-show coverage, Engineering TV is
the video site for design-engineering professionals.
76
MACHINE DESIGN
2014 LEADERS PROFIL

2
PROFILE
LE
YASKAWA
AMERICA INC.
WEB |
EMAIL |
TEL |
www.yaskawa.com
marcom@yaskawa.com
800.YASKAWA (800.927.5292)
2121 Norman Dr. South

Waukegan, IL 60085
s a machine builder or equipment user you have limited time, limited resources,
and tight deadlines. You need a supplier that can not only deliver the right
products, services, and solutions, but can also deliver consistently and reliably.
For nearly 100 years, Yaskawa has been providing cutting-edge automation technology,
operational excellence, and a breadth of engineering expertise to help customers solve their specific motion
challenges
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real impact on your equipment effectiveness. You have the confidence that your machines will work as
expected every time, and give you a competitive advantage in the market.
t0QFSBUJPOBM&YDFMMFODF:BTLBXBFNQPXFSTZPVUPDPOTJTUFOUMZEFMJWFSSFMJBCMFFRVJQNFOUUPZPVSDVTUPNFST
and have that equipment continue to operate without unscheduled downtime.
t&OHJOFFSJOH&YQFSUJTF:BTLBXBXPSLTBTBOFYUFOTJPOPGZPVSFOHJOFFSJOHTUBGGUPQSPWJEFZPVXJUIUIFUJNF
resources, and confidence to create elegant, reliable automation.
DRIVES AND MOTION PRODUCTS

OUR BROAD PRODUCT range of rotary, linear, and direct-drive
motors matched with digital SERVOPACKS (3W 55kW) can

be matched with our single- or multi-axis machine controllers for
a system with the best quality and reliability in the industry. Our
Industrial AC drives cover every application need in the industrial
plant, offering the greatest selection of size and performance
available, with power ranges from fractional HP to 2250 HP.
YASKAWA MOTOMAN ROBOTICS
WITH NEARLY 300,000 robot arms installed worldwide, Yaskawa
Motoman Robotics is committed to a comprehensive,

customer-centered approach. Our line of industrial robots
increases efficiency, provides consistent quality, and boosts
productivity to deliver outstanding ROI. The Yaskawa Robotic
product portfolio ranges from 4-15 axis industrial robots with
load capacities of 2 to 800 kg to special machines, devices, and
turnkey systems.
20 MILLION INVERTERS
10 MILLION SERVOS
300,000 ROBOTS
Yaskawa. Proven. Worldwide.

Nobody enjoys a larger installed base of inverters,
servos and robots around the world than Yaskawa.
Our experienced engineers, proven technology and
unsurpassed quality can
all be combined to give proven solutions in which
you can have total condence.
In a recent internal study of 100,000 servo motors
shipped, Yaskawa found that only 7 were returned
for warranty repair. To put that in perspective, a
typical out-of-box failure rate goal for manufacturers
of brushless servo motors is 0.5% (or 500 failures
per 100,000 motors shipped).
No matter how you add it up, nobody equals Yaskawa.

Call us today.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M
2014 Yaskawa America Inc.
For more info:

http://Ez.com/yai704

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FIVE HOSES. TWO

ou know Parker as the global leader in

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SMALLEY OFFERS AN exclusive Circular-Grain Manufacturing

Process. This process is not a stamping, but rather a continuous

In addition to Spirolox Retaining Rings and Wave Springs,

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gus has been manufacturing engineered plastics

from lubricant-free cable carrier systems, to self-lubricating

extensive material database. Using this data, igus engineers can

ReadyChain is a pre-harnessed system that is ready to

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stainless-steel fins. Mica Insulated Strip

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