Why Tolomatic? Personal Protective Equipment

When the pandemic hit New York City, Charles Boyce, President of Boyce Technologies, Inc. (BTI), he heard the grim news day after day and knew he needed to do something. BTI makes life safety, security, and communications equipment for New York's mass transit system. As information about the pandemic grew, it became clear there was an immediate need for personal protective equipment (PPE) and Boyce knew BTI was uniquely positioned to help. BTI specializes in going from concept to product rapidly.

Because emergency ventilators were in short supply across New York City, BTI joined the Emergency Ventilator Response Team (EVRT). The EVRT group designed and produced the Spiro Wave, a low-cost, easy-to-produce and FDA approved emergency ventilator in 5 weeks. BTI retooled its factory and made thousands of the ventilators for use in New York City and State.

Challenge:  Producing Personal Protective Equipment (PPE)

When wearing masks became mandated, it was apparent that there were not enough masks being made fast enough. BTI wanted to get involved and took the same approach they took with the Spiro Wave: respond quickly, think creatively, and design innovatively.

"All the mask-making machines we looked at were based on 20-year-old designs; they are large, single purpose machines," said Tom Powell, VP of Business Development. "They are expensive, they need lots of space, and you can't get one in the near term. With innovative technology, we knew we could make a nimble machine with high-capacity throughput on a small footprint for a much lower cost of ownership compared to the big machines. Real estate is important on New York. We needed something highly configurable that would fit in as small a space as possible."

BTI took the challenge and after a short development cycle BUT launched a new generation of mask making machines based on the automated work cell concept to improve efficiency, quality, and throughput. BTI's primary goal was to maximize output with the smallest footprint and fewest workers as possible. BTI partnered with component manufacturers that could work fast and offered flexible product solutions.

Tolomatic provided the linear motion control components (electrical actuators) that move, form, index, cut and assemble the fabric into masks. Because both Tolomatic and BTI have similar operating philosophies, Tolomatic was able to provide a wide variety of motion control actuators quickly and in the required configurable lengths and options. Another major benefit was that Tolomatic is in the United States leading to better quality, delivery, and technical support.

Solving the Problem:  Small, fast, and flexible machines

BTI knew it wanted a machine that was small, fast, and flexible. They wanted their design to be able to make assorted sizes of masks, masks for both children and adults, different face sizes and different mask styles. In addition, the machine needed to work with varied materials (cotton or synthetic), strap materials and lengths. "There's no point in making a one-size-fits-all machine," said Powell. "We've built the machine so people can get what they want."

BTI's design has a small footprint and uses state-of-the-art motion control components - Tolomatic actuators, robots, PLCs, servo motors and drives, conveyors, and Ethernet IT-based communication - to provide the nimbleness and speed for fast and accurate throughput.

More than a dozen different Tolomatic actuators create the required linear motion for the machine to feed, cut, shape and index the materials.  The actuators were selected based on their force, load, speed, orientation and flexible mounting and configuration options. "Customers turn to Tolomatic for our reputation for quality and robust products, customer support and some of the fastest deliveries for build-to-order products in the industry, said Andy Zaske, VP of Sales and Marketing.

"We are a very much inclusive company, " said Powell. "We work in a collaborative-partner relationship. That is why we chose Tolomatic. They are in the room helping us make the machines. They make their own product and control their own supply chain. We did not have to go through a lengthy procurement process. Tolomatic's catalogue products are stroke-configurable which allows us the flexibility we need. Plus, if we need something customized, we can get that too."

Mask Making Linear Motion Components

The mask making machine has three primary stages: material feed; form and cut; assemble and finish. Each stage requires specific motion control requirements and axes of motion. From the initial material infeed and transfer station, the machine performs operations for form pressing, cutting and fabric welding. From there, the formed masks move to the assembly stations, where straps and nose pieces are cut, shaped, and added to the mask molds. The final stations are for quality control inspection and packaging.

BTI uses Technic servo motors and Tolomatic has a system to integrate these motors with their actuators. Tolomatic's 'Your Motor Here' configurator makes ordering and delivery of this combination of motor and actuator quick and easy.

At the first station, a Tolomatic B3W rodless belt-drive actuator moves and supports the material. The actuator pulls in the sheet of heavy material and then supports a heated form press that comes down on top of the sheet. It is a large platform requiring the actuator to provide high moment loading capabilities as well as support the 100-pound press. The entire unit is completely sealed to prevent fabric particulate from getting inside the actuator and affecting the performance of the required motion.

A Tolomatic B3W rodless belt-drive actuator provides fast positioning at the second station that supports a press that cuts and welds the masks. The B3W actuator can move at speeds up to two hundred inches per second and support large moment loads to help facilitate production cycle times.

At the third and final station, a Tolomatic B3W actuator moves the pre-formed masks to an ABB robot which moves the masks to a new location. Robots then cut and apply straps and nose pieces. Two Tolomatic GSA linear slide actuators assist in the ultrasonic welding function that applies the ear loops to the masks. The masks are then unloaded, packaged, and shipped.

The Future for BTI and Tolomatic

BTI bypasses traditional manufacturing methods:  The company's vertical structure relies on onshore manufacturing and collaborating with partners with similar strategies. "If anybody is going to make ventilators or mask machines in a fraction of the usual development time, it is going to be us," said Powell. "We think a next-generation robotic mask machine work cell that is highly configurable makes sense. We did not do market studies or focus groups; we listened to the front-line healthcare professionals and just came to that conclusion on our own. In our business, time really does equal money. It is important to us to have good local partners and U.S. made equipment. We can make better systems and products this way."

Tolomatic has a similar philosophy about manufacturing and response to these types of challenges. "We felt like we were uniquely positioned as an essential business, with fast and configurable products, to partner with BTI and create solutions needed for making masks, ventilators, new testing machines and other medical devices," said Tolomatic's Zaske.