Scale Your Machines Without Scaling Your Engineering Team

Controls engineering, UL508A panel manufacturing, software, motion, and automation - built to extend your team from concept through production.

Here’s How We Can Help

Controls for OEM Machinery

Custom UL508A controls engineered around your machine, production requirements, and OEM platform.

Plant Operations & Retrofits

Modernization, upgrades, and integration work tailored to your requirements.

Turnkey & Robotic Workcells

Fully custom automation and robotic systems built around your exact process needs.

Engineer-Supported Factory Direct Procurement

Factory-direct sourcing backed by our engineering support.

Their Challenges, Solved.

When an Outdated PLC Threatened a Product Line, They Found a Smarter Path

A portable machining OEM inherited a bore welder with an outdated PLC, bulky wiring, and razor‑thin margins. Automation Solutions replaced the PLC with a compact Raspberry‑Pi control system featuring an intuitive HMI, centralized controls, and robust safety features. The upgrade transformed a failing product into a global success.

Results:

3500+ machines upgraded across 28 countries
Major cost reductions
Improved reliability and user experience

Modern Motion Control — Without Replacing Their Test Equipment

An EMI testing manufacturer relied on legacy GPIB‑based actuators that couldn’t interface with modern Ethernet instruments. Automation Solutions built a rack‑mounted controller that translated Ethernet commands into precise servo control, enabling automated sequencing and accurate positioning without disrupting existing workflows.

Results:

Seamless Ethernet integration
Modernized motion control
Zero disruption to existing test systems

On‑Site Precision Machining for Wind Turbine Towers

A portable machine tool manufacturer required a control system for machining turbine tower flanges flat during on‑site assembly. Automation Solutions delivered controls for a portable rotary mill capable of delivering the precision needed for nacelle installation, eliminating the need for factory‑floor equipment.

Results:

Precise on‑site machining for turbine assembly
Reliable flange flattening before nacelle installation
Field‑ready control system

Scale Production Without Losing Quality — Automation Made It Possible

A fast‑growing cannabis brand struggled to meet demand using skilled hand‑rollers producing ~60 pre‑rolls per hour. Automation Solutions built a custom machine that rolls 600 pre‑rolls per hour with laser‑guided strain‑specific precision and real‑time monitoring — preserving quality while unlocking massive scale.

Results:

10× production increase
$500,000+ annual labor savings
Consistent strain‑specific quality

Reliable Testing for a Critical Medical Component

A medical manufacturer required precise, repeatable testing for mini-sponges used in life-saving applications. Automation Solutions engineered a custom mechanism that controls motion, force, and measurement to ensure every sponge meets strict performance criteria. The system supports regulatory compliance and delivers consistent, documented results.

Results:

Repeatable validated testing
Improved product reliability
Supports medical quality standards

Automating Forming, Cleaning, and Loading in One Flow

A manufacturer faced bottlenecks in forming, dedusting, and loading operations that relied heavily on manual handling. Automation Solutions delivered a robotic cell that forms parts, removes dust, and loads them into downstream equipment. The integrated system improves cleanliness, consistency, and overall production speed.