From napkin sketch to prototype reality: InDro Forge does it all

From napkin sketch to prototype reality: InDro Forge does it all

Aug 8, 2024 | InDro Forge, InDro Solutions, RealLife Robotics, Scott Simmie

By Scott Simmie

 

What’s in a name? Let’s take a look at InDro Forge – our custom fabrication and prototyping facility operated by InDro Robotics in collaboration with Invest Ottawa.

The “InDro” part obviously comes from InDro Robotics. But what about that second word?

One of the most common definitions of “forge” is to “produce a fraudulent copy or imitation.” Think currency, signatures, or maybe a work of art. We don’t do that.

Another is to “make or shape (a metal object) by heating it in a fire or furnace and hammering it.” While we don’t have a blast furnace, we do like the imagery here – of taking raw materials and producing useful and functional end products. It’s also easy to picture our engineers and technicians as high-tech blacksmiths, using state-of-the-art tools to achieve similar transformations.

And that also meshes nicely with  the third definition: To “create something strong, enduring or successful.” At InDro Forge, we do both. We also forge solid relationships with clients during the production journey. Whether it’s a single part, a fully functioning prototype or even a limited production run, the Forge team does it all.

“InDro Forge – as a whole – is an integration facility for robotics and other client projects where those clients don’t have in-house manufacturing capabilities or expertise,” explains Joel Koscielski, Lead Manufacturing Engineer. InDro Forge has a wide range of high-end tools at its disposal, and the expertise to take something from a concept in someone’s head to a fully functional product in their hands.

“So if they know what they need at a high level, but don’t necessarily know what material to make it out of, or what the right process is, or how to design for those processes to reduce cost – we can provide that expertise to support their prototyping journey, whether that be in robotics or in any other field.”

In other words, InDro Forge turns ideas into reality.

Below: Production Engineer Stephan Tzolov operates the facility’s OMAX water jet table, which can slice through metal and other materials using a focussed, high-pressure slurry. Photo by Scott Simmie

PLUS AND MINUS

 

When it comes down to basics, there are really two ways to build something. You can do so by adding things together, or taking things away. Someone building a shed takes wood, adds more wood, adds windows and a roof and a door (and, presumably, a floor unless they’re on a really tight budget). That’s a backyard version of additive manufacturing (AM).

On the oppositve end, a sculptor takes a cube of marble and removes the excess material to reveal the inner vision. That’s subtractive manufacturing (SM). The water jet table in the image above is a subtractive tool.

InDro Forge has wide array of AM and SM tools at its disposal, including CNC machines, industrial 3D printers, lasers and more. Many of the projects we work on involve both of those techniques before we integrate the various parts (including electronics and software) to arrive at the final prototype or product.

“We even do things like casting, where we’re taking a mold we’ve created of what the client wants and pouring in a liquid so that either cures as it cools or is cured by ultraviolet light or whatever other kind of process is required,” says Koscielski.

Tools at InDro Forge includes SLS – or Selective Laser Sintering. This is a specialized type of 3D printing particularly suited to parts with complex geometries. Starting with a heap of powder (and there are many types of powders to choose from – including plastics, composites, metal, glass and ceramics), and a laser precisely fuses (sinters) those tiny particles into a solid.

TOOLS, TIMELINES

 

With such a wide variety of tools available – and the expertise to operate them – Forge has become the one-stop shop for many clients. As Koscielski mentioned, very few companies have these kinds of AM and SM tools in-house. That’s why companies like InDro Forge exist.

One of the differentiators of InDro Forge is its agility. On Friday, August 2 – right before the long weekend – a robotics client called up. They were in a bit of a panic; they had a demo coming up the following week. They needed custom parts printed in a hurry.

“They needed a bunch of parts and didn’t have a printer capable of handling them. They said: ‘Hey, we’re in a bind, we need some help,'” recalls Koscielski. “They asked if we have printers available and if there was any possible way we could spin these up in a couple of days.”

Sound impossible? Not to the InDro Forge team.

“We burned through the weekend and got them what they needed so we could support them as a fellow member of the robotics community. The order came in Friday; the parts were ready to ship on Tuesday.”

Below: Mechatronic engineer Matthieu Tanguay programs InDro Forge’s CNC machine. Photo by Scott Simmie

 

MAJOR PROJECTS

 

While the example just cited illustrates our ability to take on smaller, urgent projects with a tight timeline, InDro Forge also executes much larger projects. Much, much larger.

In fact, we’re nearing completion of an entire delivery robot for client Real Life Robotics. The Ontario company specializes in zero-carbon cargo and last mile delivery. Earlier this year, RLR was one of eight Canadian startups selected by the Canadian Food Innovation Network to receive funding through its FoodTech Next program. FoodTech Next offers funding for early-stage Canadian technology firms who seek to be part of – or sell to – the wider food industry. With this funding, RLR will be putting its delivery robot through real-world testing and validating ROI for the Canadian food sector.

One of its core delivery robots is named BUBS. It has been demonstrated across the country, using wireless teleoperation and autonomy to show off its delivery capabilities. But the time had come to upgrade to a sleeker and smarter robot, with a plethora of new features and capabilities. InDro Robotics is RLR’s contract manufacturer, so the company came to InDro Forge to build the next-gen BUBS from the ground up.

“RLR is growing lightning fast and our solution is a customizable platform to fit our client’s exact last-mile delivery needs,” says RLR Founder and CEO Cameron Waite.

“This client had some pretty unique sizing and design requirements – and knowing that the fabricators at Forge have the same depth of engineering experience as our own team builds the trust you need to move fast and meet budgets for a project like this….. The fact they are also a Canadian tech startup and not far away is a bonus,” he adds.

We don’t want to steal their thunder, but this is one of those “everything” projects. InDro Forge worked in tandem with the engineering team from RLR to build, assemble and test the entire robot – on time, on spec and on budget. It incorporates multiple advancements from the first iteration.

“We’ve built a full skeleton electronic system based on RLR’s designs and a suite of sensors to be able to do the autonomy, as well as an exterior shell that allows them to do remote, last-mile delivery,” says Koscielski.

And BUBS 2.0 will have much more on board than its predecessor.

“This next version of BUBS takes much of the learnings from the last year and brings them to reality. We’ve done countless customer demos and interviews to learn and iterate as a result,” says Waite. “BUBS has a number of new features that our engineering team is really proud of – and we look forward to sharing those soon.”

The skeletal structure for BUBS is all aluminum, and was cut using the water jet table. Those parts were then welded and powder-coated. Smaller brackets used to affix electronics (and this machine has a lot of electronics) were produced by the Prusa MK3.5 3D printers (Forge has three of them).

Like all 3D printers, the Prusa has limitations to the dimensions of the objects it can produce. It can manufacture very strong, high-resolution parts using a number of different plastics and composites, but it can’t print anything huge. Because BUBS is a large robot, it needed some very large parts for its outer shell. Forge had the solution.

 

BIGREP ONE

 

 

BigRep is a German company, known for its award-winning industrial 3D printers. The BigRep ONE is capable of printing objects up to one cubic metre. It is one of the key tools at InDro Forge for large-scale projects like BUBS. The machine is compatible with eight different types of printing material, depending on the application requirements. (One of those materials is water-soluable and perfect for support structures – those lattice-like bits that help support the complex main structures as they’re being printed. When complete, water turns that plastic into something with the consistency of thick syrup and it can be easily removed by hand.)

Because the side panels of BUBS are large, BigRep ONE was the perfect solution.

“We used the BigRep to print the side panels in two pieces and glued them together to make those large parts – and in a fraction of the time that it would take using any of the other methods,” says Koscielski. “In doing the two sides we went through just over 13 kilos of material over the span of about six days.”

For Real Life Robotics, the capabilities and machines at InDro Forge were a perfect fit.

“InDro Forge accelerates my ability to take our designs and get my product to market; we’d have to spin up an entire manufacturing department to do these things,” says Waite. “The team at Forge is professional and exceptionally talented. They’ve been able to take our vision and designs and turn them into reality.”

There’s a lot we could say about the capabilities of BigRep ONE – including the fact there are but 350 worldwide and only a handful in Ontario. But we’ll let the company give you a more complete picture with this video:

INDRO’S TAKE

 

September will mark the first anniversary since what was formerly known as the Bayview Yards Prototyping Lab became InDro Forge. A lot has happened since then, including additional staff with engineering and design expertise, the hiring of a sales and client relations specialist, and – in February – a new strategic roadmap for the future.

“In addition to prototypes, we are now equipped to take on clients with projects at any point along the Technology Level Readiness (TLR) scale,” says InDro Robotics Founder and CEO Philip Reece. “There are some very good prototyping labs in Ontario. But what elevates our value proposition is that InDro Forge, when required, has the full engineering support of the InDro Robotics team at Area X.O. That’s a winning combination, and we have proven that with increasingly complex projects over the past year.”

So whether you’ve got an idea floating around in the back of your head – or fully formed specs for a new robot or other technology – InDro Forge is ready.

Are you? Get in touch with Account Executive Callum Cameron here.

 

 

InDro Forge prepped for next-phase expansion

InDro Forge prepped for next-phase expansion

Feb 8, 2024 | InDro Forge, InDro Solutions, Industry News, Scott Simmie

By Scott Simmie

 

Have an idea for a prototype? InDro Forge has got you covered.

The company can take a napkin sketch, turn it into a full-fledged design – and then produce a single prototype or limited manufacturing run.

But the Ottawa-based facility, equipped with multiple machines for additive and subtractive manufacturing and an A-level team of engineers and support staff, is now capable of much, much more.

If you happened to miss this story, here’s the headline: Back in September, InDro Robotics took over operations of what was known as the Bayview Yards Prototyping Lab. Previously run by Invest Ottawa, InDro could see the synergy of running this in conjunction with its R&D headquarters (based at Ottawa’s Area X.O).

But the acquisition has involved much more than a name change. Under the guidance of Stacey Connors (Head of Strategic Innovations) and Joel Koscielski (Senior Manager, Design and Fabrication), a longer-term plan for growth quickly began to form. Soon, there were new hires in engineering and sales. There was a comprehensive review of the existing market to identify gaps.

And, ultimately, a new roadmap for the future. Though prototypes will still be an important part of the core business operation, InDro Forge now has the expertise and capacity to be of service to companies with products anywhere along the Technology Level Readiness (TLR) scale.

“I was initially excited about the synergies with robotics,” says Luke Corbeth, Head of R&D Sales with InDro Robotics.

“But after seeing the all-star cast, I’m also excited for its potential as a standalone alongside InDro Robotics. There are so many other industries we can touch. I feel so confident, talking to anyone and knowing that wherever they are in their journey we’re going to be able to help. I know we can take it on – and that’s super exciting.”

It is. Now, let’s find out why – and how.

Below: The water jet table at InDro Forge. Using a fine slurry under immensely high pressure, it can slice through steel up to 2″ thick

Advanced Manufacturing

NEW STAFF

 

It was clear at the outset that InDro Forge would be able to tap into the expertise of InDro engineers who work at the Area X.O site. But it was equally clear that InDro Forge would also benefit from additional full-time engineers at its own location.

We were fortunate in finding Matthieu Tanguay, a Mechatronics Engineer with a deep background in robotics, along with experience in forestry and oceanography. Tanguay also worked for four years with another Canadian robotics leader, Clearpath. He helped design, validate and deliver multiple different robots to clients during that period (including a robot custom-built for Antarctica).

“I’ve always described myself as a ‘Jack of all trades'” he says. “I’ve always been a curious person with a wide variety of interests. At InDro Forge I think I will be able to tap in these skillsets acquired through the years to help InDro Forge push through to another level.”

Stephan Tzolov was eager to make the jump from Area X.O to join the growing team at InDro Forge. Tzolov has a degree in Industrial Design – and design is integral to the InDro Forge process. Tzolov also loves learning new skills, and saw a perfect fit with InDro Forge.

“I made the jump to InDro Forge when I wrapped up a large, long-term project,” says Tzolov. “Timing worked out perfectly in that we had just announced the new expansion into Forge and the cool new opportunities for a dedicated mechanical engineering/design team. With the new skills and technical know-how I’d acquired via that large project, I decided to push my abilities even further by helping build up the team.”

Tzolov already had experience with a range of production tools. For the past few months, he has immersed himself in learning new ones.

“There were already quite a few machines and tools I’d familiarized myself with via my university education. However, in recent months it’s been quite the deep dive on these machines and processes – including operating the waterjet cutter and CNC.”

Below: Stephan at the controls of the waterjet cutter

 

THE PATH TO PRODUCTION

 

Prior to becoming InDro Forge, the lab specialised in designing and producing prototypes. And while that will still be part of its business model, the company is positioning itself to take on clients with products that are anywhere along the TRL scale. Perhaps you’ve already got a prototype – but it doesn’t have quite the look and feel desired. Maybe you have a functioning product that has some bugs. Or perhaps you’re looking for a polished, finished product that can be shown to your own clients or displayed at a conference. InDro Forge does it all.

“Our initial conversations with industry partners have helped us identify, these are the things that matter,” explains Connors. “We can help customers wherever they are on the TRL.” Offerings include:

  • Design
  • Production
  • Builds
  • Prototypes
  • Testing/validation
  • Engineering

Whether it’s a new client, a new concept – or a completely new application – InDro Forge can shape the path to a finished product. And while there are other companies out there (and some doing very good work), we believe that the synergy of InDro Forge’s leadership and staff – combined with the R&D expertise of InDro Robotics and our state-of-the-art production tools – sets us apart.

“We are leading with technical expertise – that’s our strongest differentiator,” says Stacey Connors. “We work closely with clients – with recommendations, collaboration and consultation – every step of the way. And we really have a wide array of equipment.”

Below: How the relationship between InDro Forge and InDro Robotics works for clients

Prototyping Lab Canada
Rapid Prototyping Canada

NEW SUPPORT

 

Companies need clients. And clients need knowledgeable staff who truly understand their needs – people who understand both the technical requirements and the customer journey. InDro Forge is fortunate to have newly hired Account Executive Callum Cameron. With a Bachelor of Commerce degree from the University of Ottawa – and a passion for understanding the technical side of things – Callum isn’t simply after sales. He is dedicated to helping customers find the precise solution to their needs, along with keeping them in the loop throughout the process.

“InDro Forge provides clients with end-to-end prototyping services that can turn any idea into a ready-for-market product,” he says. “Our services help businesses of all sizes accelerate their time to market and pathway to profitable growth.”

As part of getting settled into the role, Callum researched other companies offering similar services, drilling right down to the capabilities and machines at those facilities. And he’s reached some conclusions.

“InDro Forge offers a range of specialized services that competitors simply can’t replicate. We have the technical expertise and a state-of-the-art facility that allows clients to choose different levels of involvement along their prototyping journey. Furthermore, our team has years of experience in every phase of rapid prototyping, which allows us to guide our clients in the right direction every step of the way.”

 

INVESTMENT

 

In the transition to InDro Forge, great emphasis was put on identifying areas – and hires – that would allow for greater capacity going forward. Senior Manager of Design and Fabrication Joel Koscielski, who was previously with the Bayview Yards Prototyping Lab, sees that as a significant step forward.

“InDro made an immediate investment in building the Forge team by adding new capacity. We now have an Applications Engineer to help clients develop a solution tailored to their needs, plus a Mechatronics Engineer to bring a greater technical expertise in the integration of mechanical, electrical and code into a single solution.”

The other significant difference is the new ability to tap into the broad expertise of the InDro Robotics engineering team, based at Area X.O.

“The InDro Robotics engineers being included in design reviews or in a design consulting capacity during projects ensures higher quality output from Forge – and the opportunity for more creativity in solutions.  The InDro team also has a large number of industry contacts including trusted suppliers and partners which pre-date the InDro Forge. These contacts have served to bolster the list of partner companies which Forge draws from to deliver great prototypes when the needs exceed our in-house capacity or current equipment capabilities.”

In addition, the InDro Forge team all share a trait that’s reflected in their work ethic, and ultimately the finished product: Passion.

“The best part of starting a project from scratch is being able to breathe life into something that was originally just an idea, maybe just a sketch on a piece of paper,” says Stephan Tzolov.

“Taking that spark of innovation from an idea to reality never gets old. So, I’d say those beginning steps of concept development and iterative design are the most rewarding.”

 

Below: InDro Forge’s new Mechatronics Engineer, Matthieu Tanguay

INDRO’S TAKE

 

We obviously felt there was a synergy in developing InDro Forge. And while the Bayview Yards Prototyping Lab was known for its excellent work, we wanted to both expand in-house capabilities and leverage the expertise of our Area X.O engineering team. The result, we believe, is a solution we intend on refining until it is unrivalled in the country.

“Expanding the core team at InDro Forge, and creating a roadmap under the guidace of Stacey Connors, was the first step,” says InDro Robotics CEO Philip Reece.

“We now have outstanding in-house capabilities, with more hires to come. That, in combination with the ability to tap additional expertise from our Area X.O team, positions InDro Forge for a truly exciting path forward – both for InDro Robotics and for InDro Forge clients.”

Interested in learning more? Feel free to contact Account Executive Callum Cameron here.