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ION SENSE®, an industry leader in advanced gas detection technologies, is proud to announce the introduction of its next-generation photoionisation detectors, the ION SENSE® PID 10.6eV 3 and the ION SENSE® PID 10.6eV 10, at the prestigious Sensor + Test 2025 exhibition in Nuremberg, Germany. This groundbreaking product line redefines the standards of volatile organic compound (VOC) detection, promising enhanced performance, accuracy, and reliability alongside low cost of ownership.

Next-Generation Detection Capabilities

The ION SENSE® PID 10.6eV 3 features an impressive detection limit of 0.5 ppb, with a measurement range of 3 ppm, while the ION SENSE® PID 10.6eV 10 offers a 1 ppb detection limit paired with a wide measurement range of 10 ppm. Both variants boast a remarkable 50% reduction in response time, 15,000 hours of lamp and filter life, robust EMI protection, and patent pending intelligent diagnostics aimed at ensuring operator safety. Additionally, the exceptional humidity resistance and superior lamp stability of these sensors equips users with confidence in their performance, even under challenging environmental conditions.

Investing in Innovation

The launch comes after four years of extensive research and development by industry leading talent, fuelled by feedback from industry professionals and a dedication to excellence. Designed for longevity and stability, ION SENSE® has developed and tested over 300 prototypes to ensure each product not only meets but exceeds performance expectations, providing superior air quality monitoring while significantly reducing maintenance costs.

"We are redefining what's possible in gas detection," said Peter Morris, Head of Sensors at ION SENSE®. "Our unique sensor technology enhances the monitoring of air quality, while simultaneously reducing operational costs and extending the lifespan of the equipment."

Seamless Integration

To complement the PID sensors, ION SENSE® is introducing a suite of integration boards: ION CONNECT and ION TRANSMIT. These integration boards allow rapid evaluation and provide seamless installation options, allowing for adaptation across diverse applications, from compact air quality monitors to comprehensive industrial systems.

The ION TRANSMIT board ensures effective long-range communication for remote monitoring, while the ION CONNECT board facilitates easy data interpretation by converting analogue signals into digital outputs. Advanced features such as MODBUS compatibility streamline system control, thereby enhancing operational efficiency across diverse applications.

Visit Us at SENSOR + TEST 2025

We invite all industry professionals to visit us on stand 1-300 during the Sensor + Test 2025 exhibition to experience live demonstrations of the new ION SENSE® PID sensors and integration boards. This event marks a bold step forward in our commitment to innovate and redefine PID technology for the evolving global market.

At ION SENSE®, our vision is clear: to leverage advanced sensing technology to safeguard lives, protect the environment, and transform industrial processes. The next-generation ION SENSE® PID sensors are a testament to this mission, combining greater sensitivity, long-term stability, and user-friendly integration.

Contact Us About ION SENSE® PID

For more information about the revolutionary new ION SENSE® PID sensors or to schedule a meeting at the exhibition, please email This email address is being protected from spambots. You need JavaScript enabled to view it. or call +44(0)1763 208503 or visit www.ionsense.com.

Want to inspire greater confidence in your workers? Need local indications of combustible gas concentration levels to satisfy user and application requirements? The PrimaX® IR+ Gas Detector could be the answer you’re looking for.

When you’re the person responsible for safeguarding people and places in the oil, gas, and chemical process industries, you naturally want to stay abreast of innovation in gas detection.

Advances in gas detection

But rapid technological developments over recent years mean there are now a wide range of  solutions. These range from conventional sensing methods like infrared detectors and catalytic bead sensors which have wide customer acceptance to newer technologies like ultrasonic detectors, open path infrared or laser-based detectors. Different technologies work in different ways – ultrasonic solutions ‘hear’ the ultrasonic sound from a compressed gas leak whereas other technologies ‘see’ a gas cloud using infrared absorption or ‘smell’ trace elements of a combustible gas.

Each of these solutions has its own strengths and weaknesses and are suited to particular applications and environments. For example, fixed point detectors like point infrared  detectors can help protect high risk locations from combustible gas leaks, including enclosed areas. They can also help in locations with potentially low oxygen content like ventilation ducts. Meanwhile, open path solutions can detect gas leaks in wide open areas providing integrated measurement of gas cloud. Ultrasonic detectors are suitable for high pressure offshore and onshore gas facilities where gas clouds can easily disperse, for example because of high winds.

The benefits of a layered approach

Choosing the right detection solutions for your site depends on many factors including the type of risk you’re trying to address, the placement, size and shape of your equipment, and the topology of your site. A layered approach in which several different detection technologies work together may be the best way for you to enhance safety and protect both people and plant. Using a combination of solutions helps to mitigate the limitations of single technologies and the risk that a system using the same method of detection will fail to detect a gas release.

Your first line of defence – point detectors

Fixed point detectors, including Point Infrared detectors, are likely to be your first line of defence. Infrared (IR) gas detectors rely on the ability of a hydrocarbon gases to absorb infrared energy (they’re therefore not suitable for hydrogen). They use two wavelengths – a gas-absorbing ‘active’ wavelength and a ‘reference’ wavelength not absorbed by the gas. With resistance to contamination and poisoning a long sensor life can be achieved, and minimal validation requirements help provide combined low cost of ownership. These detectors are suitable for environments where there’s continuous combustible gas presence, including oxygen deficient environments. They are positioned near potential leak sources such as pipe joints, valves, compressors, pumps and tanks.

Meet our PrimaX® IR+ Gas Detector

At MSA Safety, we’re now introducing a new point infrared gas detection solution, the PrimaX® IR+ Gas Detector. It is an extension to our PrimaX IR family that combines the trusted performance of the PrimaX IR® sensor with a user-friendly display providing real-time local gas concentration readings.

Tried and tested sensor performance

The reliability of the PrimaX® IR sensor will already be familiar to many health and safety decision-makers. With more than 45,000 units sold around the world, it offers the tried and tested reliability that inspires confidence in both health and safety professionals and workers alike. Its patented dual-source design helps provide excellent reliability and seamless monitoring in the event of one source failure. And heated optimised optics provide stability and accuracy even in humid conditions.

Now, with the addition of an LED display providing local gas concentration levels, the PrimaX® IR+ Gas Detector offers even greater confidence, enhancing your safety systems further.

Real-time local gas concentration readings and remote notifications

The addition of an LED display offers instant situation awareness and a local indication of gas concentration levels so workers can see at a glance that they’re working in a safe environment. There are four LED status indicators to signal normal operation (green), a fault (yellow), a low alarm (red) or a high alarm (also red). Two onboard alarm relays for low and high gas alarms and an additional fault relay can trigger desired safety actions.

Easy installation and operation

Users of our PrimaX® IR detector will know how easy it is to set up, calibrate and troubleshoot. And the same is true of the PrimaX® IR+. The factory calibration means it’s ready to use straightaway. But if you do need to recalibrate for different gases, the HART® technology and intuitive calibration cap complete with icon-driven interface make this a straightforward process.

Remote sensor option for maximum flexibility

Other notable benefits of the PrimaX® IR+ include the remote sensor option, enabling the sensor to be mounted up to 30 metres from the display unit. This allows you to position the display unit in the optimum location for your needs. The durable aluminium and stainless-steel enclosures add to user confidence and mean both sensor and display unit can be installed in the most demanding of environments.

Why you might want local indications

Offshore platforms, gas compressor stations and onshore terminals are complex environments and, in putting together a layered safety system and keeping it up to date, you will want to know you’re choosing the right solutions to meet today’s rigorous safety standards and expectations.Additionally, some sites may require a local indication of gas concentration levels to support safety protocols and provide workers in combustible environments with added reassurance.

To find out more about our PrimaX IR+ Gas Detector https://gb.msasafety.com/Fixed-Gas-%26-Flame-Detection/Gas-Detectors/PrimaX%C2%AE-IR%2B-Gas-Detector/p/000070001800001244 

Learn more about our Fire & Gas Detection Controllers https://gb.msasafety.com/detection-controllers

Teledyne Gas & Flame Detection (Teledyne GFD) is making its final preparations for a trio of forthcoming energy sector events taking place in Europe and Asia.

 Visitors to the Teledyne GFD booth at All Energy 2025 (Glasgow, UK, 14-15 May), World Hydrogen Summit 2025 (Rotterdam, Netherlands, 20-22 May) and World Gas Congress 2025 (Beijing, China, 19-23 May) will learn for themselves the advantages of tapping into sector knowledge and solutions that stem from decades of empowering safety in all forms of power generation. Key for these events will be Teledyne GFD’s hydrogen detection expertise and technologies.

The All-Energy exhibition and conference is the UK’s largest low-carbon energy and renewables event, with hydrogen among key focus areas regarding both grid integration and battery energy storage systems (BESS). Hydrogen is produced in BESS systems during the charging and discharging process of the batteries, or if a fault occurs that leads to thermal runaway. Once initiated, thermal runaway will likely result in a fire, but with the right detection technology it is possible to contain the consequences.

On stand B39, Teledyne GFD, which has its UK manufacturing facility just 8 km west of Glasgow in Renfrew, will be shining the spotlight on four key technologies.

The recently introduced Spyglass™ Xtend triple-infrared flame detector offers the simultaneous detection of both hydrogen and hydrocarbon fires. It boosts safety in environments where hydrogen flames can spread to co-located systems or nearby equipment and start fires involving hydrocarbon fuels that are invisible to a hydrogen-only detector. Integrated high-definition CCTV video delivers clear, rapid imaging of fuel fires like gasoline and jet fuel, while the near-IR video option detects fires caused by hydrogen and methanol, making it ideal for BESS applications. Five selectable sensitivity levels are available.

Other instruments of note at All Energy 2025 will include the tried and tested GD10P infrared (IR) gas detector, as well as the GS700-Hydrogen, a high-performance and highly flexible all-in-one instrument that is able to detect both hydrogen and natural gas in utility grid integration projects. Whether it is 100% hydrogen, hydrogen blends or natural gas, the portable GS700-Hydrogen simplifies gas detection in applications that include outdoor/indoor leak detection, purging, barholing and pipeline gas testing. Providing both safety and peace of mind, the fully ATEX-certified instrument means utilities can quickly determine the source of gas leaks, saving valuable time and reducing detection-related costs such as unnecessary excavations.

Also on show will be Teledyne GDCloud™, a user-friendly new cloud solution which enhances gas detection measurement by recording hazardous events. Users can take advantage of this technology to help ensure regulatory adherence and streamline safety programmes. Among Teledyne GDCloud’s most powerful capabilities is visualising detailed gas sensor readings from field sessions. Users can trace the route that a technician takes during investigations via advanced location mapping functionality. This capability enables breadcrumb mapping to identify the exact locations that correspond to gas readings logged by the detector. Users can also interact with dynamic charts and tabulated data displays to reveal further insights into field activity and events.

The same four technologies will also take centre stage at the World Hydrogen Summit 2025, where visitors will find Teledyne GFD at booth A93. In fact, such is Teledyne GFD’s expertise in the hydrogen arena that it has been invited to deliver a presentation at the event entitled ‘Regulatory Framework and Compliance along the Hydrogen Value Chain’.

At World Gas Congress, a flagship gas and energy industry event staged once every three years, Teledyne GFD will again present these technologies to visitors from booth Z12 in hall D. A team of local experts will be present to discuss current and/or future gas detection challenges.

Further reflecting its strong global presence, Teledyne GFD will also take booths at two events in the United States during May: AGA (American Gas Association) 2025 on May 4-8 in Aurora, Colorado; and OTC (Offshore Technology Conference) 2025 on May 5-8 in Houston, Texas.

For more information, visit www.teledynegasandflamedetection.com or contact This email address is being protected from spambots. You need JavaScript enabled to view it.

High Pressure Connectors Europe, a division of Parker Hannifin, the global leader in motion and control technologies, today announces the launch of two new intrinsically safe pressure sensors, the SCP10 and SCP11. These sensors are specifically designed for use in hazardous environments, particularly in applications involving hydrogen. Both sensors meet rigorous ATEX certification requirements, ensuring safety and reliability in critical settings.

The SCP10 pressure sensor is engineered for use with liquid and gaseous media in hazardous areas, while the SCP11 is specifically designed for hydrogen applications. Both sensors comply with ATEX certification standards for Zone 0 (II 1G Ex ia IIC T4 Ga) and Zone 1 (II 2G Ex ia IIC T4 Gb). The SCP10 additionally meets requirements for Zone 0 (II 1G Ex ia IIB T4 Ga).

Utilizing a digitally calibrated piezoresistive stainless steel measuring cell, the SCP10 sensor can detect pressures ranging from 1 bar to 1000 bar. The SCP11 handles pressures from 4 bar to 1000 bar.

A notable feature of the SCP10 and the SCP11 sensors is their monolithic design, which eliminates the need for internal seals, material mixes, and weld seams. This design reduces the risk of leaks, associated with material fatigue at internal seals, and enhances the durability of the sensors. Additionally, the sensors are vacuum-tight and elastomer-free, contributing to longevity and reliability. The materials used in their construction ensure broad media compatibility, making them suitable for diverse industrial applications. Importantly, the SCP11 sensor’s construction is designed to prevent embrittlement of the metal surface due to exposure to ionized hydrogen.

Both sensors have a compact stainless steel housing that allows for space-saving installation, even in challenging environmental conditions. They offer a range of pressure options, output signals, and connectors, making them suitable for various industrial and mobile applications.

The introduction of the SCP10 and SCP11 pressure sensors aims to enhance measurement technology for hazardous environments. By combining safety, durability, and precision, these sensors provide users with reliable solutions for operating in demanding conditions.

This launch aligns with Parker's commitment to advancing hydrogen technology, a key focus area, which is dedicated to developing innovative solutions that support the growth of clean energy.

For more information about the SCP10 and SCP11 pressure sensors, please visit: https://ph.parker.com/gb/en/pressure-sensor-scp10-sensocontrol

https://ph.parker.com/gb/en/pressure-sensor-scp11-sensocontrol

Extension of agreement means operator will continue to use Dräger’s portable gas detection and breathing apparatus systems.

 Dräger Marine & Offshore (DMO), a global leader in the field of safety technology, has secured a long-term deal with a major North Sea oil and gas operator.

Due to run for five-years, with a further two one-year extension options, the extension of the existing supply contract means more than 10 UK North Sea assets will continue to benefit from Dräger’s industry leading portable gas detection and breathing apparatus systems.

Building on an existing decade-long relationship - which has previously covered the provision of products and training services - this partnership cements DMO’s reputation as a leading provider of essential safety equipment for the offshore oil and gas sector.

Lawrie Kerr, UK Sales Manager, Dräger Marine and Offshore, said: “This contract win is a testament to the expertise, dedication, and collaborative effort of our team and of our industry leading products. It further solidifies our position in the offshore sector, and I would like to thank our client for putting their faith in DMO to deliver this vital service up to 2029 and potentially beyond.

“Health and safety should be of the upmost importance to any business, whether that be in offshore oil and gas or otherwise, and by engaging DMO’s services for a minimum of five-years the operator is underscoring its long-term commitment to upholding the sector’s high standards.”

In an industry where safety is paramount, but budgets are tight, cost-effective yet reliable gas detection is essential. DMO offers a comprehensive range of portable gas detectors and personal gas monitors to make safety, compliance, and asset management intuitive. The Dräger X-am® 2800 multi-gas detector measures up to four gases and is equipped with a particularly shock-resistant CatEx sensor, offering live data transmission and powerful fleet management. Meanwhile the Dräger X-am 2500, a one to four gas detector designed for use as personal protection, will be supplied on an ad hoc basis.

As DMO continues to expand its operations, this contract will serve as a foundation for business development and reinforces the company’s mission to provide cutting-edge safety-critical solutions to the industry.

www.drager.com

The global energy landscape is evolving at an unprecedented pace. With the increased adoption of renewable energy sources and the drive for a more sustainable future, the demand for efficient energy storage has never been greater.
 

Enter Battery Energy Storage Systems (BESS) the backbone of modern energy infrastructure, ensuring stability, resilience, and efficiency in power distribution.

In 2024, the US battery storage market saw record-breaking growth, with nearly 9.2 gigawatts (GW) of new capacity installed in late November alone, according to figures from S&P Global. But how is this supercharged leap into more stable power distribution fairing on a fundamental level?

Despite an estimated capacity increase in the United States of a staggering 89% in 2024, according to U.S. Energy Information Administration (EIA), there is still more to be done to ensure this rapid rollout of these mainly Lithium-ion battery systems don’t pose a threat to workers, communities and our energy infrastructure.

The global importance of Battery Energy Storage Systems
BESS plays a critical role in balancing power supply and demand, especially as more countries transition to renewable energy sources like solar and wind. Typically, renewable energy sources are inherently intermittent meaning they don’t produce electricity consistently throughout the day, due to a variety of uncontrollable environmental factors. BESS helps to bridge the gap by storing excess energy when supply is high and distributing it when demand peaks.

While the idea of shoring up our energy infrastructure to greater withstand periods of intense strain is a laudable (and indeed, logical) one, we must ensure that in our haste to erect new BESS sites, we don’t overlook vital safety concerns.

In addition to grid stabilization, BESS is instrumental in enhancing energy reliability. By storing surplus electricity, BESS ensures that power remains available even during blackouts or grid failures. It’s also an important element of reducing carbon emissions, as with stored renewable energy, reliance on fossil fuel-powered plants decreases, leading to a more sustainable energy mix. Let’s not forget how BESS underpins growing support for the electrification of transportation. As electric vehicles (EVs) gain traction, BESS can facilitate fast-charging infrastructure without overloading the grid.

The growing prominence of BESS installations can mean greater risks
In February 2025 alone, renewable energy producers added 10.5 GWh capacity to the global energy network, according to market intelligence firm Rho Motion’s Battery Energy Stationary Storage Monthly Database. But while BESS sites are a useful way to prevent overloading the world’s power supplies releasing stored energy at peak times when power generators come under greater strain they come with challenges.

One of the greatest concerns is thermal runaway, a dangerous chain reaction in which rising temperatures spread from one battery cell to another. Without proper monitoring and early detection of potential failures, thermal runaway incidents can easily snowball into devastating fires. These fires spread rapidly, passing from unit to unit, causing sizable financial losses, environmental damage, and, of course, safety hazards including releasing toxic substances such as hydrogen fluoride gas.

That’s why advanced thermal imaging solutions are becoming essential to keep BESS sites safe and operational. Fixed thermal cameras with advanced analytics are the go-to solution, as they can trigger alarms and suppression systems when temperatures pass a set threshold.

Learn more about solutions for early fire detection at BESS and other industrial sites.

The Pepperl+Fuchs Group, a pioneer in the field of mobile devices for hazardous areas, continues the success story of the globally certified and established Smart-Ex® series: The new, industrial-grade Smart-Ex® 203 smartphone is designed for use in Division 2 and Zone 2/22 hazardous areas and offers all the necessary certifications. This complements the smartphone portfolio around the proven Smart-Ex® 03 with another powerful device. The Smart-Ex® 203 enables continuous and reliable operation even in challenging industrial environments and offers a high level of user convenience thanks to a wide range of well-thought-out features. This makes it the perfect solution for addressing the increasing demands of digitalized process chains in the context of IoT and Industry 4.0 scenarios.

The new smartphone covers the most important public and private 5G and 4G mobile networks in a single hardware version and is suitable for worldwide use in areas with an increased risk of explosion. The Smart-Ex® 203 supports a total of 52 different frequency bands, including 24 5G and 28 4G bands. The dual SIM function simplifies the fast and flexible switch between private and public networks and their management by optionally using eSIM and nano-SIM. Thanks to the high-resolution 6.3-inch display, sophisticated augmented reality (AR) applications and other digital processes can be optimally used, ensuring maximum future-proofing.

Proven features optimize handling

In addition, the Smart-Ex® 203 has many other proven features that make mobile work and communication easier under demanding and harsh industrial conditions: Glove Mode, for example, increases the touchscreen’s sensitivity so that the device can be operated precisely even with gloves. This ensures more efficient and safer work processes. Another useful feature is Double-Tap, which allows to lock the smartphone by simply double-tapping on the home screen. This eliminates the need to feel for the on/off button on the side, making it easier to use the smartphone with gloves. In addition, both left- and right-handed workers benefit from this function. What's more, the Smart-Ex® 203 is equipped with the innovative feature Smart Call Handling, which enables intelligent call handling using hand gestures: to accept an incoming call, the device is brought directly to the ear. A simple shake, on the other hand, is all it takes to reject the call. If you want to mute the conversation, simply tilt the phone.

Additional features include a fingerprint sensor that allows unlocking without entering a code, thus enabling biometrically supported multi-factor authentication for maximum security. In addition, the smartphone has a rear camera with 48 megapixels, an autofocus and a LED flash, as well as a front camera with a resolution of 16 megapixels. The LED can also be conveniently used as a flashlight. The cameras can be used to take not only high-quality pictures but also videos in full HD resolution. The new accessory interface allows the Smart-Ex® 203 to be connected to the SM-Ex S203 SR scanner module, transforming it into a convenient 1D/2D barcode scanner. In addition, automatic identification of objects is possible with the smartphone.

Support for the latest communication standards

The Smart-Ex® 203 features Android 14, a cutting-edge operating system that optimally supports the latest communication standards. The pending Android Enterprise Recommended and Google ARCore certification make the smartphone ideally suited for demanding augmented reality applications such as remote support, training and other company-specific tools. And finally, the new accessory interface allows the use of additional accessories such as the SM-Ex S203 SR scanner module.

“With the Smart-Ex® 203, we are providing a powerful and cost-effective smartphone for use in Division 2 and Zone 2/22 hazardous areas, complementing our proven Smart-Ex® 03 portfolio. Users benefit from a wide range of features that take mobile work and communication to a new level in all industries with challenging production conditions. These include, in particular, the oil and gas, chemical, pharmaceutical, and food and beverage sectors,” explains Jörg Hartleb, Head of Product Management at the Pepperl+Fuchs subsidiary ECOM Instruments.

www.pepperl-fuchs.com

Situational awareness involves understanding a given circumstance, collecting relevant information, analyzing it, and making informed decisions to address any potential risks.

When applying this to perimeter security, it is common practice to see designs that fortify the perimeter; but once that alarm happens, it is uncommon to have a system that provides the continuous coverage and relevant information operators need to make an informed decision as the potential threat progress.

So, in thinking about a traditional perimeter design, you would expect to see some sort of intrusion detection system encompassing a variety of technologies. Often FLIR works with customers to set up a virtual barrier that includes a combination of thermal and visible cameras coupled with detection analytics. Together these systems can provide accurate information about people or vehicles at the perimeter.

However, it is the action that comes after a perimeter breach that determines how a security team should respond. This is, unfortunately, where we see gaps in security system designs and can ultimately mean the operator does not have total situational awareness.

This is where FLIR Nexus comes in. Nexus is a proprietary communication protocol that helps bridge the gap between devices and systems, ensuring a more complete understanding of the environment outside and inside a security perimeter.

Creating a detection system's tracking layer and providing complete situational awareness requires a system integrator to coordinate the communication between many different technologies. Without an overarching communication system, this type of coordination can be quite complicated, requiring the integrator to set up a series of rules to first identify the target, classify it as a threat, locate the physical location, and then track the target as it moves. It's unlikely this potential threat would stay in the field of view of a single sensor, so the integrator would further have to coordinate communications between different sensors to maintain continuity as the target moves.

Often, to execute this level of situational awareness, a customer would need some sort of advanced software that collects the geodata being presented by a variety of different sensors and then coordinate proper handoffs as the target moves.

FLIR Nexus provides customers with the situational awareness needed for exterior spaces by allowing edge devices to communicate in a server/client format without the need of software or server in the middle. There is no need for additional software or servers, reducing the cost of ownership when compared to similar solutions in the market. FLIR Nexus devices also allow for a simplified installation, since all of the edge devices are communicating in real-time and there is nothing to configure at the headend.

When combined with FLIR's camera analytics for detection, this total security system can identify, locate, and track targets all at the edge. As a potential threat moves through the scene, Nexus-enabled devices communicate the geodata to other Nexus devices and provide seamless handoffs for continuous tracking. This allows an operator to have the relevant information needed to make informed decisions on what is happening, thus providing complete situational awareness. Since all FLIR devices have ONVIF drivers, all of the video information can be recorded to any VMS.

Another advantage of Nexus is it allows customers to extend their coverage over large area using fewer devices. This makes providing complete situational awareness much more affordable.

For example, consider a commercial building parking lot. Trying to cover such a large area often presents many challenges such as low visibility at night and minimal infrastructure. With FLIR’s Nexus sensors we can cover 180 degrees from a building with just three devices. Two flat-panel radars can provide detection for a 180-degree field of a view, and a multi-spectral pan-tilt camera will provide visibility in both day and night. The devices allowing for alarm scheduling and zone configuration, so with three devices we can detect and track any potential threat who is in the area outside the desired hours.

See the FLIR Nexus Bundle and learn how it can improve perimeter security.

Today there is an abundance of options when it comes to analytics. If you want to receive a notification about some sort of detection, there is probably an analytic for that. When it comes to perimeter security, do these analytics help secure your environment, or do they end up creating nuisance alarms which makes the overall solution less effective? Nexus enabled devices from FLIR help customers create a simplified solution at a lower cost while ensuring that the information provided to the operator is not only relevant but accurate.

Lambda Resins isn’t a typical industry giant – and that’s precisely its strength. As a highly specialized resin manufacturer, the company has emerged over the past two years – under the umbrella of Nagel Technologies GmbH – as a sought-after technology partner for OEMs and innovation leaders. With powerful, thermally conductive casting resins, Lambda Resins GmbH (Germany) addresses some of the central challenges of electromobility, especially where conventional solutions reach their limits.

 Axial Flux Motors: Compact, Efficient, and Resource-Saving

A key application area is the axial flux motor – a forward-looking alternative to the traditional radial flux motor. Where compact design, high torque, and low power-to-weight ratios are essential, axial flux motors come into their own. They also offer a tangible economic advantage: significantly less copper, iron, aluminum, and magnetic materials are needed per kilowatt of output.

 Key advantages at a glance:

• Lightweight design
• High power density
• Optimal torque-to-weight ratio
• Improved energy efficiency
• Reduced raw material consumption

The Challenge of Scalability – and How Lambda Resins Provides a Breakthrough

Despite these technical advantages, many axial motor concepts have so far failed to reach mass production. The main hurdle: costly bonding and joining processes have hampered industrial scalability. This is where Lambda Resins steps in – with an innovative encapsulation material and an integrated system approach for thermal and structural optimization of electric motors.

Why Axial Flux Motors Aren’t Yet Mass-Produced – and How Lambda Resins Can Change That

Axial flux motors promise a new dimension of power density, spatial efficiency, and torque – all while consuming fewer materials. However, the complexity of their geometry demands precise alignment, extensive fixation, and a high share of bonding operations – often paired with thermal intermediate steps. The result: high energy consumption, long cycle times, and excessive production costs.

In the automotive industry especially, this represents a major barrier to mass adoption. "For any drive concept to be viable for series production, it needs a cycle time of less than one minute per stator – a benchmark that most axial motor concepts currently fail to meet," says Uwe Köhler, CEO of Lambda Resins.

Lambda Resins offers a highly practical solution. Through targeted material development, the company has created a thermally conductive resin system so structurally robust that it can eliminate the need for bonding processes entirely. Instead of maintaining dozens of hot-press stations for bonded joints, Lambda Resins enables the direct casting of entire functional units – faster, more reliably, and with drastically lower capital investment. This doesn’t just make axial flux motors technically attractive – it makes them economically feasible.

 Radical Simplification in Production: Fewer Parts, Less Effort, Greater Control

Lambda Resins' technology radically simplifies axial flux motor assembly. Instead of bonding, fixing, and thermally treating individual teeth, the innovative resin system enables the direct casting of complete functional units – including coils, tooth structures, and insulation. The result:

• Elimination of time-consuming bonding steps
• More robust components
• Shorter cycle times
• Higher process repeatability

A further technical benefit: the resins’ thermal expansion behavior is finely tuned to match the metal components used. Traditional weak points such as cracks and delamination are effectively avoided – even under the extreme lateral and torsional forces generated by high-frequency magnetic fields.

The encapsulation process also unlocks new design freedoms. By eliminating adhesives, mounting plates, and insulation layers, many components can be left out altogether – including intricate busbar holders and expensive GFRP or CFRP covers, which are prone to failure under vibration stress. Their removal allows the air gap between coil and magnet to be reduced by more than 60% – directly boosting efficiency through more torque, greater output, or lower energy consumption at equivalent performance.

From a production planning perspective, these advantages are significant. Traditional axial motor manufacturing might require over 100 hot-press stations to meet sub-one-minute cycle times. Lambda Resins' encapsulation approach achieves similar results with a fraction of the infrastructure – reducing floorspace, energy demand, and capital expenditure, while increasing flexibility for OEMs.

 More Than Just a Material: Lambda Resins as a System Partner for E-Mobility

Unlike traditional resin suppliers, Lambda Resins goes far beyond delivering materials and data sheets. In close collaboration with the internationally active Nagel Group and its sister company Gehring Technologies, the team has developed dedicated process and equipment technologies that enable reliable, fully automated integration of casting resins into both existing and new production lines.
“We don’t just supply a material – we deliver a solution,” explains Köhler. “From component design and prototyping to casting strategies and production line integration, we support our customers as true partners.”

This includes a modular machine platform that automates the encapsulation process, controlling critical parameters like fill volume, thermal management, and curing. Complementing the hardware is design consultancy: Lambda Resins works closely with clients to optimize designs for resin integration – such as wall thickness reduction, improved thermal pathways, or even complete part substitution.

 Proven Performance Gains – Across Applications

Lambda Resins’ resin systems are already being used in projects for motorcycle drives, commercial vehicle components, industrial drives, marine systems, and aviation – and since 2023, the company has supported several Formula Student teams as a development partner. One striking example: in a motorcycle motor application, Lambda Resins enabled a performance boost of up to 40% without any mechanical modifications.
The secret? Improved thermal dissipation, which reduced internal electrical resistance – translating directly into higher torque and greater efficiency. “We prove time and again that our resin doesn’t just work technically – it delivers measurable performance advantages. And word is spreading – we’ve become a bit of an insider tip,” says Köhler.

One Contact. One Process. One System.

Together with the Nagel Group and Gehring Technologies, Lambda Resins offers a fully integrated system for electric motor production – from resin development and process integration to complete line planning. By combining materials, machinery, and application expertise, OEMs receive a solution-focused, all-in-one package that minimizes coordination overhead, interface risks, and friction losses – while maximizing market readiness and investment security for innovative motor concepts.

 Enabling the Axial Flux Motor for Mass Production

The future of drive technology isn’t just about new motor architectures – it’s about the materials and processes that make scalable production possible. Lambda Resins delivers exactly that: high-performance resin systems, combined with deep process and manufacturing know-how, specifically tailored to the needs of modern axial flux motors.
For OEMs and suppliers seeking efficiency and readiness for mass production, Lambda Resins and the Nagel Group offer a reliable and visionary partnership.

www.nagel.com