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4NEWS WIRE

Ahead of Its Time: HP Developed a Smartwatch in 1977

PRODUCT WATCH

ARISO Platform from TE Connectivity TE's zQSFP+ Interconnects Innovative Assembly Services from Ohmite

INDUSTRY INTERVIEW

Fully Automated Assembly for Ultra-fast PrototypingInterview with Robert Bodor VP & GM of the Americas, Proto Labs

EEWEB FEATURE

A New Way to Power the WorldSimpliPhi Revolutionizes Mobile Off-grid and On-grid Energy Storage

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Ahead of its TIME...

Hewlett-Packard Introduced the First Smart Watch in 1977

By Max Teodorescu www.electronicproducts.com

WHEN HISTORY BUFFS recant that history repeats itself, most listeners nod in an absent-minded agreement, unable

to provide a single concrete example but conscious that

some correlation between past and present exists. If you

want to make these folks feel utterly flabbergasted, simply

tell them that the first smart watch was actually constructed

38 years ago, decades before the Apple Watch, Android Wear,

or Pebble.

Newswire

The watch in question is not some archaic version of the 90s Casio calculator watch, but some beastly device called the HP-01 that achieved an unprecedented level of complication in 1977 with its seven character bright-red LCD display, 28-button keyboard, built-in ability to store and recall data, alarm clock, stop watch, calculator, and a 200-year calendar. All this was powered by three batteries stuffed along with six circuit boards into a 40 mm x 45 mm x 15 mm frame that weighs 6 ounces (170 grams)massive by watch standards.

The HP-01 wasnt the first calculator watch, that honor goes to the 1975 Calcron and Pulsar device, but it was the first to tie in so many smart features within a single package. Its advertising motto put it: With the HP-01,you can compute and then count down the time it takes for a command to reach a spacecraft several hundred million miles away. Which is not far from the truth; by permitting users to manipulate metrics like time and speed, the watch can technically calculate the required travel

time to a specific point, or determine the date when a specific task would end.

Whats more, HP-01s ability to recall data meant that the watch could double as digital agenda; although, typing on the miniature keyboard wasnt an easy task, particularly for those with sausage fingers. The crafty HP designers foresaw this problem and designed a discrete stylus that could be tucked away in the bracelet buckle.

The watch could maintain an accuracy of up to 30 seconds per year, a feat considered relatively impressive by the standard in which we evaluated quartz movement with digital displays at that time. Even today, average quartz watches are precise up to 15 seconds per year.

So, how much would this baby set you back? In 1977 it costs $695, which, after adjusting for inflation, is equal to $2,729 by todays value. Clearly, way, way more than contemporary smart watches.

Source: Hodinkee.com

finallinkhere

5Visit: eeweb.com

NEWSWIRE

Ahead of its TIME...

Hewlett-Packard Introduced the First Smart Watch in 1977

By Max Teodorescu www.electronicproducts.com

WHEN HISTORY BUFFS recant that history repeats itself, most listeners nod in an absent-minded agreement, unable

to provide a single concrete example but conscious that

some correlation between past and present exists. If you

want to make these folks feel utterly flabbergasted, simply

tell them that the first smart watch was actually constructed

38 years ago, decades before the Apple Watch, Android Wear,

or Pebble.

Newswire

The watch in question is not some archaic version of the 90s Casio calculator watch, but some beastly device called the HP-01 that achieved an unprecedented level of complication in 1977 with its seven character bright-red LCD display, 28-button keyboard, built-in ability to store and recall data, alarm clock, stop watch, calculator, and a 200-year calendar. All this was powered by three batteries stuffed along with six circuit boards into a 40 mm x 45 mm x 15 mm frame that weighs 6 ounces (170 grams)massive by watch standards.

The HP-01 wasnt the first calculator watch, that honor goes to the 1975 Calcron and Pulsar device, but it was the first to tie in so many smart features within a single package. Its advertising motto put it: With the HP-01,you can compute and then count down the time it takes for a command to reach a spacecraft several hundred million miles away. Which is not far from the truth; by permitting users to manipulate metrics like time and speed, the watch can technically calculate the required travel

time to a specific point, or determine the date when a specific task would end.

Whats more, HP-01s ability to recall data meant that the watch could double as digital agenda; although, typing on the miniature keyboard wasnt an easy task, particularly for those with sausage fingers. The crafty HP designers foresaw this problem and designed a discrete stylus that could be tucked away in the bracelet buckle.

The watch could maintain an accuracy of up to 30 seconds per year, a feat considered relatively impressive by the standard in which we evaluated quartz movement with digital displays at that time. Even today, average quartz watches are precise up to 15 seconds per year.

So, how much would this baby set you back? In 1977 it costs $695, which, after adjusting for inflation, is equal to $2,729 by todays value. Clearly, way, way more than contemporary smart watches.

Source: Hodinkee.com

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ARISO

Inside the Lab is a webseries sponsored by Arrow Electronics dedicated to exploring the latest in technology and electronics. In this episode well introduce you to TE Conncetivitys ARISO Contactless Connectivity Platform, a system delivering contactless power and data that simplifies complex connections and enables completely new applications.

The ARISO Platform is capable of transmitting up to 12 watts and eight channels of data over a 7mm air gap. TE provides a demonstration kit that includes a transmitter, which transmits power to the receive side, which will turn on the light. As the user closes the gap in the 7mm window, the light will turn off. ARISO can tolerate up to 30 degrees of tilt and up to 5mm of misalignment before the connection breaks.

The contactless nature of ARISO brings certain benefits to the table. Because it is contactless, it has unlimited mating cycles, whereas a traditional connector will eventually wear out and need to be replaced, causing downtime and maintenance costs. The platform also allows for on-the-fly connections. In a manufacturing environment, for example, if a device is passed down a manufacturing line, the user can power them and exchange data with them, whether that is a program or calibration data.

Another one of the benefits of ARISO is rotation. The transmitter can be rotated and it will remain working, even at high RPMs. If you have a

Sponsored by Arrow Electronics

CNC or a lathe, ARISO will continue to provide power and data to them as they rotate. This is a great replacement for slip rings, which also have problems in harsh environments, and is something that ARISO is designed to work in.

TEs ARISO Contactless Connectivity platform is a truly innovative system for transferring data and power. ARISO provides tremendous benefits in the form of unlimited mating cycles, reliable operation in harsh environments, and the ability to replace complex connection systems. For more information, visit Arrow.com.

Click the image below to watch a video demonstration of the ARISO Platform.

Contactless Connectivity Platform

ARISO PROVIDES TREMENDOUS BENEFITS IN THE FORM OF UNLIMITED MATING CYCLES, RELIABLE OPERATION IN HARSH ENVIRONMENTS, AND THE ABILITY TO REPLACE COMPLEX CONNECTION SYSTEMS.

CLICK

ARROW.COM

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PRODUCT WATCH

ARISO

Inside the Lab is a webseries sponsored by Arrow Electronics dedicated to exploring the latest in technology and electronics. In this episode well introduce you to TE Conncetivitys ARISO Contactless Connectivity Platform, a system delivering contactless power and data that simplifies complex connections and enables completely new applications.

The ARISO Platform is capable of transmitting up to 12 watts and eight channels of data over a 7mm air gap. TE provides a demonstration kit that includes a transmitter, which transmits power to the receive side, which will turn on the light. As the user closes the gap in the 7mm window, the light will turn off. ARISO can tolerate up to 30 degrees of tilt and up to 5mm of misalignment before the connection breaks.

The contactless nature of ARISO brings certain benefits to the table. Because it is contactless, it has unlimited mating cycles, whereas a traditional connector will eventually wear out and need to be replaced, causing downtime and maintenance costs. The platform also allows for on-the-fly connections. In a manufacturing environment, for example, if a device is passed down a manufacturing line, the user can power them and exchange data with them, whether that is a program or calibration data.

Another one of the benefits of ARISO is rotation. The transmitter can be rotated and it will remain working, even at high RPMs. If you have a

Sponsored by Arrow Electronics

CNC or a lathe, ARISO will continue to provide power and data to them as they rotate. This is a great replacement for slip rings, which also have problems in harsh environments, and is something that ARISO is designed to work in.

TEs ARISO Contactless Connectivity platform is a truly innovative system for transferring data and power. ARISO provides tremendous benefits in the form of unlimited mating cycles, reliable operation in harsh environments, and the ability to replace complex connection systems. For more information, visit Arrow.com.

Click the image below to watch a video demonstration of the ARISO Platform.

Contactless Connectivity Platform

ARISO PROVIDES TREMENDOUS BENEFITS IN THE FORM OF UNLIMITED MATING CYCLES, RELIABLE OPERATION IN HARSH ENVIRONMENTS, AND THE ABILITY TO REPLACE COMPLEX CONNECTION SYSTEMS.

MYLINK

MYLINK

LINK HERE

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zQSFP+ Interconnects

As data usage continues to rise, designers need interconnect solutions that can provide increased data rates while maintaining a consistent level of reliable performance. TE Connectivitys comprehensive zQSFP+ interconnect portfolio helps to meet this need by offering 2.5 times more throughput than existing interconnect solutions while offering backwards compatibility with QSFP products. These features provide a flexible upgrade path to increase data rates from 10 Gbps to 25 Gbps, providing four channels with data rates of 25 GB/s, the zQSFP+ interconnect supports 100 Gbps Ethernet and 100 Gbps InfiniBand enhanced data rate requirements for high-speed designs.from TE Connectivity

11Visit: eeweb.com

PRODUCT WATCH

zQSFP+ Interconnects

As data usage continues to rise, designers need interconnect solutions that can provide increased data rates while maintaining a consistent level of reliable performance. TE Connectivitys comprehensive zQSFP+ interconnect portfolio helps to meet this need by offering 2.5 times more throughput than existing interconnect solutions while offering backwards compatibility with QSFP products. These features provide a flexible upgrade path to increase data rates from 10 Gbps to 25 Gbps, providing four channels with data rates of 25 GB/s, the zQSFP+ interconnect supports 100 Gbps Ethernet and 100 Gbps InfiniBand enhanced data rate requirements for high-speed designs.from TE Connectivity

12 Visit: eeweb.com

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TEs zQSFP+ interconnects help optical, module, and cable assemblies reach new levels, increasing data transfer rates by 2.5-times more than existing solutions. Since increased data rates can make EMI protection more challenging, the ZQSFP+ interconnect product portfolio is designed to enable improved EMI protection through 25 Gbps. Design flexibility for thermal management is crucial for customers. As such, TEs single-row cages have

been designed to be belly-to-belly compatible so that in higher-load thermal applications, customers can separate ports for improved thermal transfer.

With a comprehensive portfolio, including behind and thru bezel cages with various light pipe and heatsink options, designers achieve ultimate flexibility in function and performance. In response to the significant market demand for technology and data center

applications, TE offers a comprehensive zQSFP+ interconnect product portfolio, providing customers with one of the widest product selections in the market.

Enable faster speeds in todays designs with TEs comprehensive zQSFP+ interconnect portfolio, providing a scalable interface to easily move from 10 gigabits-per-second to 25 gigabits-per-second data rates. To learn more, contact your TE representative or distributor today.

13Visit: eeweb.com

PRODUCT WATCH

TEs zQSFP+ interconnects help optical, module, and cable assemblies reach new levels, increasing data transfer rates by 2.5-times more than existing solutions. Since increased data rates can make EMI protection more challenging, the ZQSFP+ interconnect product portfolio is designed to enable improved EMI protection through 25 Gbps. Design flexibility for thermal management is crucial for customers. As such, TEs single-row cages have

been designed to be belly-to-belly compatible so that in higher-load thermal applications, customers can separate ports for improved thermal transfer.

With a comprehensive portfolio, including behind and thru bezel cages with various light pipe and heatsink options, designers achieve ultimate flexibility in function and performance. In response to the significant market demand for technology and data center

applications, TE offers a comprehensive zQSFP+ interconnect product portfolio, providing customers with one of the widest product selections in the market.

Enable faster speeds in todays designs with TEs comprehensive zQSFP+ interconnect portfolio, providing a scalable interface to easily move from 10 gigabits-per-second to 25 gigabits-per-second data rates. To learn more, contact your TE representative or distributor today.

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Innovative ASSEMBLY Services from Ohmite

Ohmites decades of experience in building electro-mechanical assemblies has led to a broad set of capabilities and extensive expertise. Ohmites own power resistor and rheostat applications involve assembling multiple components in series or parallel, combined with fans and heat sinks to achieve power ratings exceeding 5000 watts. The companys recent acquisition of ARCOL adds to the product base available in these assemblies, particularly ARCOLs robust aluminum housed resistors. ARCOL is located in the UK and improves Ohmites worldwide reach.

Ohmites 75,000 square- foot facility includes product assembly and manufacture

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PRODUCT WATCH

Innovative ASSEMBLY Services from Ohmite

Ohmites decades of experience in building electro-mechanical assemblies has led to a broad set of capabilities and extensive expertise. Ohmites own power resistor and rheostat applications involve assembling multiple components in series or parallel, combined with fans and heat sinks to achieve power ratings exceeding 5000 watts. The companys recent acquisition of ARCOL adds to the product base available in these assemblies, particularly ARCOLs robust aluminum housed resistors. ARCOL is located in the UK and improves Ohmites worldwide reach.

Ohmites 75,000 square- foot facility includes product assembly and manufacture

ohmite.com

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Ohmites 75,000-square-foot facility includes metal fabrication, epoxy-molding, connector fabrication, wire winding, and welding capabilities to manufacture and assemble nearly any product.

Ohmite also provides custom thick-film solutions, including double-sided, multilayer, and via capabilities in a QS9000-approved facility. Substrates include ceramic, FR4, insulated metal alloys, aluminum nitride, and plastic, with sizes up to 6-inches x 5-inches. A variety of conductors and dielectric materials are available with line width and spacing from 4- to 8-mils and sheet resistance from 0.10 to 1000 M/square and tolerance as low as 0.25%. Ohmite offers automated laser trimming for tight tolerance thick film parts. For high-energy thick film applications, Ohmite provides scan cut laser trimming to provide better pulse handling capabilities.

Ohmites PCB assembly service supports high-mix, low- to mid-volume assembly of PCBs with SMD, through-hole, or mixed components in an ISO 9001-2008 approved facility. Ohmite can offer inventory management services for all subcomponents. Beyond assembly, Ohmite provides design engineering support to help the customer transition from prototype to production volumes as well as cost reduction through component sourcing and designing for manufacturability.

For more information on Ohmites extensive assembly service portfolio, visit Ohmite.com.

Substrates include ceramic, FR4, insulated metal alloys, aluminum nitride, and plastic,

with sizes up to 6-inches x 5-inches.

Schematics.com

Your Circuit Starts Here.Sign up to design, share, and collaborate

on your next projectbig or small.

Click Here to Sign Up

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Proto Labs is a rapid manufacturing provider, boasting a fully automated system that yields ultra-fast turnaround speeds. Founded in 1999 by Larry Lukis, the company initially operated as The ProtoMold Company for its specialty in injection molding prototyping services. As the company grew and its capabilities expanded, The ProtoMold Company became Proto Labs to reflect a broader market for its services. With a customer-based approach, the company placed major emphasis on automating the manufacturing and prototyping processfrom

Interview with Robert Bodor VP & GM of the

Americas, Proto Labs

Proto Labs Provides Fully Automated Process for

Ultra-fast Prototyping

front-end to back-endto aid the time to market that so many customers demand. The result is custom prototypes and low-volume production parts in 15 days or lesseasily the fastest turnaround in the industry. In fact, a customer could theoretically place an order for a part at 2PM and Proto Labs could have the part out on a 7PM shipment that same day. How does the company do it? EEWeb spoke with Robert Bodor, Vice President and General Manager of Proto Labs, to gain some insight on the process.

19Visit: eeweb.com

INDUSTRY INTERVIEW

Proto Labs is a rapid manufacturing provider, boasting a fully automated system that yields ultra-fast turnaround speeds. Founded in 1999 by Larry Lukis, the company initially operated as The ProtoMold Company for its specialty in injection molding prototyping services. As the company grew and its capabilities expanded, The ProtoMold Company became Proto Labs to reflect a broader market for its services. With a customer-based approach, the company placed major emphasis on automating the manufacturing and prototyping processfrom

Interview with Robert Bodor VP & GM of the

Americas, Proto Labs

Proto Labs Provides Fully Automated Process for

Ultra-fast Prototyping

front-end to back-endto aid the time to market that so many customers demand. The result is custom prototypes and low-volume production parts in 15 days or lesseasily the fastest turnaround in the industry. In fact, a customer could theoretically place an order for a part at 2PM and Proto Labs could have the part out on a 7PM shipment that same day. How does the company do it? EEWeb spoke with Robert Bodor, Vice President and General Manager of Proto Labs, to gain some insight on the process.

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How has Proto Labs positioned itself in the manufacturing industry?

Proto Labs is a contract manufacturer that specializes in speed. We have done that by bringing in a lot of modern technology and automation to both traditional and newer manufacturing processes. Proto Labs has fully automated the front end of the automation process, which means we have developed a digital thread basically going from a 3D CAD file all the way to the manufacturer of that part, and we built all of our systems and manufacturing processes to deliver

on that. This means that our customer can upload a 3D CAD file through our website, where we then analyze it using proprietary software that we developed, which uses algorithms to analyze the part geometry and calculate how we are going to manufacture the parts. If it is an injection-molded part, it will calculate what we need to do in order to generate that part and will also configure the tool selection for how we are going to cut the blocks and determine the tool path to make the mold. If it is a machined part, the software will similarly create the fixturing for that geometry, and establish what tools we will use. We then virtually

manufacture the part in our software on large parallel computing clusters that are our own architecture.

We actually send back a quote to our customer that includes the final price because we know how much it will cost us since we have calculated everything we are going to need to manufacture it. Furthermore, the quote includes a 3D rendering of the finished part that is compared to the source CAD file and highlights any differences. We apply the design for manufacturability rules for that particular manufacturing process as

well. When you get a quote back from us, which usually comes back in a few hours, you have an interactive 3D rendering of the part that you can rotate and zoom in on. All of the specifications are highlighted for the customer in the custom quote onlinewe quote thousands of parts every day. By automating the front end of the process, weve transformed the entire quoting experience, from a traditionally slow and iterative process, to a very fast, interactive and highly customized one.

When you get a quote back from us, which usually comes back in a few hours, you have an interactive 3D rendering of the part that you can rotate and zoom in on.

21Visit: eeweb.com

INDUSTRY INTERVIEW

How has Proto Labs positioned itself in the manufacturing industry?

Proto Labs is a contract manufacturer that specializes in speed. We have done that by bringing in a lot of modern technology and automation to both traditional and newer manufacturing processes. Proto Labs has fully automated the front end of the automation process, which means we have developed a digital thread basically going from a 3D CAD file all the way to the manufacturer of that part, and we built all of our systems and manufacturing processes to deliver

on that. This means that our customer can upload a 3D CAD file through our website, where we then analyze it using proprietary software that we developed, which uses algorithms to analyze the part geometry and calculate how we are going to manufacture the parts. If it is an injection-molded part, it will calculate what we need to do in order to generate that part and will also configure the tool selection for how we are going to cut the blocks and determine the tool path to make the mold. If it is a machined part, the software will similarly create the fixturing for that geometry, and establish what tools we will use. We then virtually

manufacture the part in our software on large parallel computing clusters that are our own architecture.

We actually send back a quote to our customer that includes the final price because we know how much it will cost us since we have calculated everything we are going to need to manufacture it. Furthermore, the quote includes a 3D rendering of the finished part that is compared to the source CAD file and highlights any differences. We apply the design for manufacturability rules for that particular manufacturing process as

well. When you get a quote back from us, which usually comes back in a few hours, you have an interactive 3D rendering of the part that you can rotate and zoom in on. All of the specifications are highlighted for the customer in the custom quote onlinewe quote thousands of parts every day. By automating the front end of the process, weve transformed the entire quoting experience, from a traditionally slow and iterative process, to a very fast, interactive and highly customized one.

When you get a quote back from us, which usually comes back in a few hours, you have an interactive 3D rendering of the part that you can rotate and zoom in on.

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PULSE

When you say that Proto Labs specializes in speed, how fast can a customer receive a part after submitting a design?

This process has allowed us to offer qualifying machined parts the same day the customer orders. You could technically order a part at 2 PM and, depending on the parts geometry, we can ship it by 7 PM that nightI dont believe there is anybody else in the world that can do that. Similarly, we can cut metal molds and shoot parts only one business day later. We also bring this kind of speed to 3D printing and additive processes. In total, we have nine processes: three that are in the 3D printing space, and the rest in more traditional manufacturing processes.

In what ways has Proto Labs overcome the bottlenecks of the prototyping and manufacturing industry?

By automating the quoting process, it has allowed us to better serve product developers who were otherwise a relatively underserved part of the industry. The founder of Proto Labs began working at a company that made large format laser printers, which were not a high-volume item. The company was struggling to get plastic parts made and prototyped in a timely fashion because they werent making many printers each year, so it was difficult to find molders that were interested in taking on their projects.

Proto Labs automates everything about the manufacturing process. Traditionally,

manufacturing has only automated the things in the back end of the process where every part is the same. If you have an injection-molding machine, every time the mold opens, parts may fall out but every part is the same as the others, so it is pretty straightforward to automate the steps. Automating this step has allowed Proto Labs to create opportunities for OEMs, inventors and companies looking to bring products to market, where they had a difficulty prototyping but now, they can do it in the final process that they are going to use.

Similarly, if customers need a few thousand parts, we can be a very inexpensive solution for them because we are an on-demand manufacturer and we can fulfill orders in a few days. This takes some of the risk out of the equation for our customers that no longer have to maintain inventories and place large orders in order to get the product to the market or if it is a product that has a lot of volatility in its demand. We can make the parts at very short notice for the customer and handle that volatility we bear the risk in that volatility.

Does Proto Labs do anything with original designs, or do you primarily focus on refining design for manufacturing?

We start with a CAD file, so the customer has to come to us with a design. We will sometimes refer people to design firms if they do not have in-house designers. We accept nearly every CAD format, and we will sometimes give consultation around the material selection. In fact,

even in their quotes, users can see how one material would perform in a mold versus another and pricing automatically adjusts based on the material chosen.

Is there a lot of manual processing in the workflow where people are actually handling the product, like in 3D printing processes?

The popular view of 3D printing is that it is very simple and you push a button and the machine delivers the finished part. Unfortunately, that isnt the case in reality, especially if you want to get good parts. Of course, the level of finishing that is required varies on the 3D printing process that you are talking about. For stereolithography (SL), it is a photopolymer-based manufacturing process where the parts come out of a liquid vat and some resin will cling to the parts. Resin cures with light, so if you dont properly clean the parts, the shape will change and the resin that remains will become part of the part. That is a step that has to happen in post-processing. Often times, the parts are supported on the build platform by thin support structures that need to also be removed from the finished part. Some of that can be automated, but some of it can be done manually, so you need to have that manual finishing in that process.

Another additive manufacturing process we use is direct metal laser sintering (DMLS), which is makes metal parts in titanium, stainless steel and other metals. This is a powder-based process where the laser hits the powder bed and fuses the particles together to make the

solid shape in the metal. That needs supports as well. If you are making a part in stainless steel, for example, then the supports also must be stainless steel. When the part comes out of the build chamber, it is then put into a heat treatment, and then you are able to remove the supports. The removal of the supports can be cut away in a variety of methods, but it does require the use of a machine shop and it is often a manual process. We have automated the process more than anyone else in the industry, but there are still some steps that are manual and require skilled people to do it.

Where are all of Proto Labs locations around the world?

We have five facilities in the United States and additional facilities in Europe and Japan. Our manufacturing facility in England, along with locations in Germany and Finland, serve our European customers.

There are customers who want some advice. I mentioned that we have nine manufacturing processes, which means many times we can produce the same part in the same material in three different ways. For example, with stainless steel, we can 3D print it, machine it and even mold it. A customer may need 57 stainless steel parts with a certain geometry and need advice on how to do it. We can consult with them on the part geometry and end-use application as well as their economic needs. This is where our global sales teams come into play.

ABOUT ROB BODOR

Robert is currently Vice President and General Manager, Americas at Proto Labs, a leading online and technology-enabled quick-turn manufacturer of custom parts for prototyping and low-volume production. At Proto Labs, Robert has also held roles as Chief Technology Officer and Director of Business Development. Prior to joining Proto Labs, Robert held leadership roles at Honeywell and McKinsey & Company, and has been on the executive team of two early-stage software companies in the Twin Cities. Robert holds B.S., M.S. and Ph.D. degrees in Engineering and

Computer Science.

You could technically order a part at 2 PM and, depending on the parts geometry, we can ship it by 7 PM that nightI dont believe there is anybody else in the world that can do that.

23Visit: eeweb.com

INDUSTRY INTERVIEW

When you say that Proto Labs specializes in speed, how fast can a customer receive a part after submitting a design?

This process has allowed us to offer qualifying machined parts the same day the customer orders. You could technically order a part at 2 PM and, depending on the parts geometry, we can ship it by 7 PM that nightI dont believe there is anybody else in the world that can do that. Similarly, we can cut metal molds and shoot parts only one business day later. We also bring this kind of speed to 3D printing and additive processes. In total, we have nine processes: three that are in the 3D printing space, and the rest in more traditional manufacturing processes.

In what ways has Proto Labs overcome the bottlenecks of the prototyping and manufacturing industry?

By automating the quoting process, it has allowed us to better serve product developers who were otherwise a relatively underserved part of the industry. The founder of Proto Labs began working at a company that made large format laser printers, which were not a high-volume item. The company was struggling to get plastic parts made and prototyped in a timely fashion because they werent making many printers each year, so it was difficult to find molders that were interested in taking on their projects.

Proto Labs automates everything about the manufacturing process. Traditionally,

manufacturing has only automated the things in the back end of the process where every part is the same. If you have an injection-molding machine, every time the mold opens, parts may fall out but every part is the same as the others, so it is pretty straightforward to automate the steps. Automating this step has allowed Proto Labs to create opportunities for OEMs, inventors and companies looking to bring products to market, where they had a difficulty prototyping but now, they can do it in the final process that they are going to use.

Similarly, if customers need a few thousand parts, we can be a very inexpensive solution for them because we are an on-demand manufacturer and we can fulfill orders in a few days. This takes some of the risk out of the equation for our customers that no longer have to maintain inventories and place large orders in order to get the product to the market or if it is a product that has a lot of volatility in its demand. We can make the parts at very short notice for the customer and handle that volatility we bear the risk in that volatility.

Does Proto Labs do anything with original designs, or do you primarily focus on refining design for manufacturing?

We start with a CAD file, so the customer has to come to us with a design. We will sometimes refer people to design firms if they do not have in-house designers. We accept nearly every CAD format, and we will sometimes give consultation around the material selection. In fact,

even in their quotes, users can see how one material would perform in a mold versus another and pricing automatically adjusts based on the material chosen.

Is there a lot of manual processing in the workflow where people are actually handling the product, like in 3D printing processes?

The popular view of 3D printing is that it is very simple and you push a button and the machine delivers the finished part. Unfortunately, that isnt the case in reality, especially if you want to get good parts. Of course, the level of finishing that is required varies on the 3D printing process that you are talking about. For stereolithography (SL), it is a photopolymer-based manufacturing process where the parts come out of a liquid vat and some resin will cling to the parts. Resin cures with light, so if you dont properly clean the parts, the shape will change and the resin that remains will become part of the part. That is a step that has to happen in post-processing. Often times, the parts are supported on the build platform by thin support structures that need to also be removed from the finished part. Some of that can be automated, but some of it can be done manually, so you need to have that manual finishing in that process.

Another additive manufacturing process we use is direct metal laser sintering (DMLS), which is makes metal parts in titanium, stainless steel and other metals. This is a powder-based process where the laser hits the powder bed and fuses the particles together to make the

solid shape in the metal. That needs supports as well. If you are making a part in stainless steel, for example, then the supports also must be stainless steel. When the part comes out of the build chamber, it is then put into a heat treatment, and then you are able to remove the supports. The removal of the supports can be cut away in a variety of methods, but it does require the use of a machine shop and it is often a manual process. We have automated the process more than anyone else in the industry, but there are still some steps that are manual and require skilled people to do it.

Where are all of Proto Labs locations around the world?

We have five facilities in the United States and additional facilities in Europe and Japan. Our manufacturing facility in England, along with locations in Germany and Finland, serve our European customers.

There are customers who want some advice. I mentioned that we have nine manufacturing processes, which means many times we can produce the same part in the same material in three different ways. For example, with stainless steel, we can 3D print it, machine it and even mold it. A customer may need 57 stainless steel parts with a certain geometry and need advice on how to do it. We can consult with them on the part geometry and end-use application as well as their economic needs. This is where our global sales teams come into play.

ABOUT ROB BODOR

Robert is currently Vice President and General Manager, Americas at Proto Labs, a leading online and technology-enabled quick-turn manufacturer of custom parts for prototyping and low-volume production. At Proto Labs, Robert has also held roles as Chief Technology Officer and Director of Business Development. Prior to joining Proto Labs, Robert held leadership roles at Honeywell and McKinsey & Company, and has been on the executive team of two early-stage software companies in the Twin Cities. Robert holds B.S., M.S. and Ph.D. degrees in Engineering and

Computer Science.

You could technically order a part at 2 PM and, depending on the parts geometry, we can ship it by 7 PM that nightI dont believe there is anybody else in the world that can do that.

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SimpliPhi founder Stuart Lennox had been helping people make the most of energy technology when his company first came to life in a humble garage in 2002. Working in the film and photography industries early in his career, Lennox played a crucial role in providing reliable access to power in any number of challenging remote environments for cameras and lighting equipment, innovating with available technology to leverage just about any power source beyond the limits of transmission lines. With so much experience in off-grid solutions, combining knowledge of traditional fuel-based generation as well as renewables, along with a healthy knowledge of standard grid technology, Lennox ultimately found himself in an ideal position to innovate for the sake of more than just small-scale productions.

Revolutionizes Mobile OFF-GRID and ON-GRID

Energy Storage

SimpliPhi

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SimpliPhi founder Stuart Lennox had been helping people make the most of energy technology when his company first came to life in a humble garage in 2002. Working in the film and photography industries early in his career, Lennox played a crucial role in providing reliable access to power in any number of challenging remote environments for cameras and lighting equipment, innovating with available technology to leverage just about any power source beyond the limits of transmission lines. With so much experience in off-grid solutions, combining knowledge of traditional fuel-based generation as well as renewables, along with a healthy knowledge of standard grid technology, Lennox ultimately found himself in an ideal position to innovate for the sake of more than just small-scale productions.

Revolutionizes Mobile OFF-GRID and ON-GRID

Energy Storage

SimpliPhi

26 Visit: eeweb.com

PULSE

During those early days as a rugged field innovator, Lennox was also one of the first to work with the now-common lithium-cobalt oxide chemistry in rechargeable lithium-ion batteries. At this nascent stage in the energy storage game, however, three particular issues remained to push the innovative drive that would ultimately take form with SimpliPhis current work. First, persistent thermal runaway stood as a barrier to efficiency and generated a stubborn heat profile. Then, the relatively short cycle life of lithium cobalt provided a barrier to longevity and, therefore, cost. Finally, the heat profile generated by this particular chemistry also demanded additional costs in terms of necessary ventilation and cooling. Clearly, there was much room for improvement.

In the mid-1990s, a newer, safer chemistry emerged in the form of what is now commonly known as lithium iron phosphate. In short, this chemistry eliminated thermal runaway and provided a major extension of cycle life,

lowering costs significantly. With these advantages in hand, and plenty of room left to maximize their effectiveness, SimpliPhi began the work it continues today, looking to provide safe, simple, reliable energy storage for both residential and commercial customers, all with a focus on renewables.

Much of what defines SimpliPhis impressive work involves the companys proprietary battery architecture, in which the flow of charged electrons is optimized to eliminate the common problems of impedance. In SimpliPhis architecture, the lack of impedance translates to an over 98% input to output efficiency and eliminates thermal loss. The lack of a heat profile also provides a host of cost savings for the user as well, making considerations of cooling and ventilation virtually unnecessary. To meet the many possible needs of size, weight, cycle life, and adaptive discharge, SimpliPhi designs are not only cell agnostic, but chemistry agnostic as well. This allows the company to present an

unusually diverse array of power storage solutions, and thereby, a broad portfolio of products that is only continuing to grow to meet the world of energy and its consumerson mutual terms.

Today, the companys LibertyPak line of battery products is still widely used by the film and photography industries. In one notable example, SimpliPhi technology enabled much of the special lighting in the film Tron: Legacy, in which safe portable batteries were necessary to power bright colored lights inside a wide array of plastic costumes and props, all sensitive to heat and in close proximity with actors bodies. In the big picture, the technology provided by SimpliPhi has contributed strongly to the overall displacement of fuel-based generators and wet acid batteries in remote and location environments in the film industry. Also used by research teams like those from National Geographic and many other scientists plying their trades in challenging environments, SimpliPhi technology, as represented by products

In SimpliPhis architecture, the lack of impedance translates to an over 98% input to output efficiency and eliminates thermal loss.

Some specific products have even been designed custom for the military, including high output batteries that are safe in ambient temperatures of over 120 degrees and generate no heat.

like the LibertyPak plug and play portable products, when coupled with a fold-out solar charger, has gone a long way in providing reliable energy outside the boundaries of the transmission lines. Additional applications currently include mobile battery packs used for off-grid power on oilrigs and wells, as well as a host of applications for use in the field by the U.S Army and Marine Corps. .

In making batteries that are ideal for use in many of these applications, the companys designs stand as some of the only in their class that can function safely in high ambient temperature environments. Some specific products have even been designed for the military, including high output batteries that are safe in ambient temperatures of over 120 degrees that do not generate heat. These products, which enable soldiers in the field to store their own power from green sources, have at times reduced fuel usage on

27Visit: eeweb.com

EEWeb FEATURE

During those early days as a rugged field innovator, Lennox was also one of the first to work with the now-common lithium-cobalt oxide chemistry in rechargeable lithium-ion batteries. At this nascent stage in the energy storage game, however, three particular issues remained to push the innovative drive that would ultimately take form with SimpliPhis current work. First, persistent thermal runaway stood as a barrier to efficiency and generated a stubborn heat profile. Then, the relatively short cycle life of lithium cobalt provided a barrier to longevity and, therefore, cost. Finally, the heat profile generated by this particular chemistry also demanded additional costs in terms of necessary ventilation and cooling. Clearly, there was much room for improvement.

In the mid-1990s, a newer, safer chemistry emerged in the form of what is now commonly known as lithium iron phosphate. In short, this chemistry eliminated thermal runaway and provided a major extension of cycle life,

lowering costs significantly. With these advantages in hand, and plenty of room left to maximize their effectiveness, SimpliPhi began the work it continues today, looking to provide safe, simple, reliable energy storage for both residential and commercial customers, all with a focus on renewables.

Much of what defines SimpliPhis impressive work involves the companys proprietary battery architecture, in which the flow of charged electrons is optimized to eliminate the common problems of impedance. In SimpliPhis architecture, the lack of impedance translates to an over 98% input to output efficiency and eliminates thermal loss. The lack of a heat profile also provides a host of cost savings for the user as well, making considerations of cooling and ventilation virtually unnecessary. To meet the many possible needs of size, weight, cycle life, and adaptive discharge, SimpliPhi designs are not only cell agnostic, but chemistry agnostic as well. This allows the company to present an

unusually diverse array of power storage solutions, and thereby, a broad portfolio of products that is only continuing to grow to meet the world of energy and its consumerson mutual terms.

Today, the companys LibertyPak line of battery products is still widely used by the film and photography industries. In one notable example, SimpliPhi technology enabled much of the special lighting in the film Tron: Legacy, in which safe portable batteries were necessary to power bright colored lights inside a wide array of plastic costumes and props, all sensitive to heat and in close proximity with actors bodies. In the big picture, the technology provided by SimpliPhi has contributed strongly to the overall displacement of fuel-based generators and wet acid batteries in remote and location environments in the film industry. Also used by research teams like those from National Geographic and many other scientists plying their trades in challenging environments, SimpliPhi technology, as represented by products

In SimpliPhis architecture, the lack of impedance translates to an over 98% input to output efficiency and eliminates thermal loss.

Some specific products have even been designed custom for the military, including high output batteries that are safe in ambient temperatures of over 120 degrees and generate no heat.

like the LibertyPak plug and play portable products, when coupled with a fold-out solar charger, has gone a long way in providing reliable energy outside the boundaries of the transmission lines. Additional applications currently include mobile battery packs used for off-grid power on oilrigs and wells, as well as a host of applications for use in the field by the U.S Army and Marine Corps. .

In making batteries that are ideal for use in many of these applications, the companys designs stand as some of the only in their class that can function safely in high ambient temperature environments. Some specific products have even been designed for the military, including high output batteries that are safe in ambient temperatures of over 120 degrees that do not generate heat. These products, which enable soldiers in the field to store their own power from green sources, have at times reduced fuel usage on

28 Visit: eeweb.com

PULSE

forward operating bases by up to 80%, lowering reliance on fuel supply lines and minimizing the associated risks. With efficiency comes security and resiliency.

In 2010, Lennox made the first strides toward applying the proprietary architecture, circuitry and Battery Management System (BMS) that he had created for the film industry to the worlds of homes and businesses. Today, at a time when many local governments are deciding to end so-called net energy metering programs that allow privately-generated energy to be fed back into the public grid for mutual benefit, the necessity to store self generated power seems more present than ever before. People who have invested in solar arrays for homes or businesses find that suddenly storage is much more significant in leveraging the capital expenditure, company officials say, and if they arent benefiting from feeding clean energy into the grid through the net energy metering program, then they need to capture what theyre not using during the day from their solar generation to use at night when the sun goes down. Whether for personal

use or for maximizing stored energy as capital for arbitrage, SimpliPhi is making energy work for their customers on their terms and in truly progressive ways.

SimpliPhi also deservedly prides itself on the level of safety that theyve achieved with their decidedly non-toxic and low-voltage approach. While lithium-ion batteries are generally considered as one homogeneous chemistry by policymakers, safety and certification standards, SimpliPhi hopes to provide the basis for differentiation between their LFP chemistry and products and the many competing toxic and potentially hazardous chemistry and products produced by other manufacturers that fall under the generic heading of lithium ion batteries. SimpliPhis proven performance and track record across diverse industries and use-cases since 2002 demonstrates beyond the shadow of a doubt that their technology performs in places that similar technology has never been able to perform before without the risk of thermal runaway and overheating. Currently, the companys products stand as some of the only lithium-ion products that are specially

licensed for air transport by the FAA, a distinguishing characteristic that presents some impressive evidence of the companys attention to safety and comes as a result of extensive government testing by the U.S. Army Aberdeen Proving Grounds and Marine Corps.

SimpliPhi certainly expresses a goal to continue providing products that are non-toxic and safe at low-voltages, allowing customers, as company representatives relate, to think of our services and power storage technology as helping to not only encourage the use of renewables, but to create a community resource for times of emergency or failure that is safe and accesible. Such non-txic and low voltage technology doesnt require a specialized technician or safety equipment to operate. Working with utility companies to create micro-grid systems that function entirely at the 48-volt level or lower and which include such attention to detail as built-in 80-amp breakers that effectively provide an on-off switch during shipping, installation and in times of emergency, SimpliPhi sees advanced safety as a big step to getting their technology working for communities as well as individuals. Naturally, it also earns them entry into places where the competition often just cant reach.

A relatively small operation compared to most of its direct competitors, SimpliPhi has seen its dedicated research and development push its prices down almost 30% in the last two years. As we ramp up in scale, our prices will come down even more significantly, says SimpliPhi CEO Catherine Von Burg.

Whether for personal use or for maximizing stored energy as capital, SimpliPhi is making energy work for their customers in truly progressive ways.

...SimpliPhi sees advanced safety as a big step to getting their technology working for communities as well as individuals.

In the big picture, one of the critical issues for customers is the difference between the upfront price point and the long-term cost of energy over time. While the companys technology is slightly more expensive upfront per kWh compared to other solutions, it offers significantly more advantages that justify the cost. Von Burg relates: If you look at our extended cycle life, our ten year warranty, our depth of discharge and efficiency rate, and the fact that you dont have to add ancillary cooling and ventilation equipment, we are very price competitive and can currently offer between $0.15-$0.17 savings per watt, and the price will only continue to come down.

In making these points clear to policymakers and potential customers, cultivating an educated public is a major goal at SimpliPhi. We want people to be actively participating in their power utilization, Von Burg told us, and it takes a discerning customer to cut through the surface details to look more deeply at the issues behind the basics, to really understand how well a particular product works, how safe it is, and how these factors influence the true costs for home and business owners, including the growing costs of insurance coverage for distributed assets. Were trying to engage in a kind of marketing effort that helps to create an educated, discerning consumer. With a bright horizon ahead of them, guided by a desire to meet real needs and create a better world, SimpliPhi is poised to make some impressive strides in revolutionizing the way the world thinks about energy.

29Visit: eeweb.com

EEWeb FEATURE

forward operating bases by up to 80%, lowering reliance on fuel supply lines and minimizing the associated risks. With efficiency comes security and resiliency.

In 2010, Lennox made the first strides toward applying the proprietary architecture, circuitry and Battery Management System (BMS) that he had created for the film industry to the worlds of homes and businesses. Today, at a time when many local governments are deciding to end so-called net energy metering programs that allow privately-generated energy to be fed back into the public grid for mutual benefit, the necessity to store self generated power seems more present than ever before. People who have invested in solar arrays for homes or businesses find that suddenly storage is much more significant in leveraging the capital expenditure, company officials say, and if they arent benefiting from feeding clean energy into the grid through the net energy metering program, then they need to capture what theyre not using during the day from their solar generation to use at night when the sun goes down. Whether for personal

use or for maximizing stored energy as capital for arbitrage, SimpliPhi is making energy work for their customers on their terms and in truly progressive ways.

SimpliPhi also deservedly prides itself on the level of safety that theyve achieved with their decidedly non-toxic and low-voltage approach. While lithium-ion batteries are generally considered as one homogeneous chemistry by policymakers, safety and certification standards, SimpliPhi hopes to provide the basis for differentiation between their LFP chemistry and products and the many competing toxic and potentially hazardous chemistry and products produced by other manufacturers that fall under the generic heading of lithium ion batteries. SimpliPhis proven performance and track record across diverse industries and use-cases since 2002 demonstrates beyond the shadow of a doubt that their technology performs in places that similar technology has never been able to perform before without the risk of thermal runaway and overheating. Currently, the companys products stand as some of the only lithium-ion products that are specially

licensed for air transport by the FAA, a distinguishing characteristic that presents some impressive evidence of the companys attention to safety and comes as a result of extensive government testing by the U.S. Army Aberdeen Proving Grounds and Marine Corps.

SimpliPhi certainly expresses a goal to continue providing products that are non-toxic and safe at low-voltages, allowing customers, as company representatives relate, to think of our services and power storage technology as helping to not only encourage the use of renewables, but to create a community resource for times of emergency or failure that is safe and accesible. Such non-txic and low voltage technology doesnt require a specialized technician or safety equipment to operate. Working with utility companies to create micro-grid systems that function entirely at the 48-volt level or lower and which include such attention to detail as built-in 80-amp breakers that effectively provide an on-off switch during shipping, installation and in times of emergency, SimpliPhi sees advanced safety as a big step to getting their technology working for communities as well as individuals. Naturally, it also earns them entry into places where the competition often just cant reach.

A relatively small operation compared to most of its direct competitors, SimpliPhi has seen its dedicated research and development push its prices down almost 30% in the last two years. As we ramp up in scale, our prices will come down even more significantly, says SimpliPhi CEO Catherine Von Burg.

Whether for personal use or for maximizing stored energy as capital, SimpliPhi is making energy work for their customers in truly progressive ways.

...SimpliPhi sees advanced safety as a big step to getting their technology working for communities as well as individuals.

In the big picture, one of the critical issues for customers is the difference between the upfront price point and the long-term cost of energy over time. While the companys technology is slightly more expensive upfront per kWh compared to other solutions, it offers significantly more advantages that justify the cost. Von Burg relates: If you look at our extended cycle life, our ten year warranty, our depth of discharge and efficiency rate, and the fact that you dont have to add ancillary cooling and ventilation equipment, we are very price competitive and can currently offer between $0.15-$0.17 savings per watt, and the price will only continue to come down.

In making these points clear to policymakers and potential customers, cultivating an educated public is a major goal at SimpliPhi. We want people to be actively participating in their power utilization, Von Burg told us, and it takes a discerning customer to cut through the surface details to look more deeply at the issues behind the basics, to really understand how well a particular product works, how safe it is, and how these factors influence the true costs for home and business owners, including the growing costs of insurance coverage for distributed assets. Were trying to engage in a kind of marketing effort that helps to create an educated, discerning consumer. With a bright horizon ahead of them, guided by a desire to meet real needs and create a better world, SimpliPhi is poised to make some impressive strides in revolutionizing the way the world thinks about energy.

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