Bullen Ultrasonics, which offers precision machining of advanced ceramics, glass, and specialty materials using proprietary ultrasonic and laser-based technologies, announced it has received a $23,100 grant through the Ohio Smart Manufacturing Program to support its Autonomous Process Optimization initiative, which applies artificial intelligence (AI) and machine learning to improve manufacturing operations. Bullen is working with industrial AI engineering company Phenx on the initiative. The companies will analyze approximately 2 billion data points collected from Bullen's customized manufacturing equipment to identify opportunities to improve process stability, efficiency and consistency.
"For several years, we have invested in the infrastructure needed to capture, organize, and understand the data generated by our equipment because we believed it would eventually help us make better manufacturing decisions," said Tim Beatty, President of Bullen Ultrasonics. "This grant allows us to turn that foundation into an actionable capability. We are applying AI to a specific manufacturing challenge with the potential to improve the value we deliver to our customers."
The project began with an analysis of Bullen's historical production data. Following encouraging initial findings, Phenx developed a digital twin, or virtual model, of the targeted manufacturing process.
The digital twin allows Bullen and Phenx to test different algorithms and process adjustments using actual production data before introducing changes on the manufacturing floor. The current phase is focused on validating the optimization algorithm within the digital twin. Once that work is completed, Bullen plans to pilot the algorithm on one of its machines and evaluate its performance during an extended prove-out period.
"Bullen had already completed much of the difficult foundational work required for a successful industrial AI project, including collecting high-quality data and developing deep knowledge of its custom machines and processes," said Saurabh Sarkar, founder and CEO of Phenx. "By combining that foundation with advanced modeling and machine learning, we can identify patterns that would be extremely difficult to isolate manually and safely test optimization strategies in a digital environment before moving them into production."
If successful, the project could help Bullen reduce process variation, shorten production cycles, and improve the predictability and consistency of its manufacturing operations. It could also establish a framework for applying similar AI-driven modeling and optimization capabilities to other manufacturing processes in the future.
The grant supports the project's initial phases. Bullen is investing additional resources in continued development, hardware integration, production testing, and long-term validation.
The Ohio Smart Manufacturing Program helps small and medium-sized manufacturers adopt advanced digital technologies to improve operational efficiency, productivity, and competitiveness. The program is supported by the U.S. Department of Energy's State Manufacturing Leadership Program and led in Ohio by the Ohio Department of Development. The University of Dayton Research Institute (UDRI) supported Bullen's participation by conducting technical discovery and helping prepare the project for state approval.
"UDRI is a key subrecipient supporting the Ohio Smart Manufacturing Program, providing technical project assessment and financial support to help companies like Bullen accelerate the adoption of digital technologies," said Mark McCormick, Senior Business Development Lead of the University of Dayton Research Institute. "Bullen's initiative is a strong example of how manufacturers can apply AI and machine learning to a clearly defined operational challenge with the potential to improve manufacturing performance and deliver measurable business value."
Bullen views the initiative as part of a broader strategy to combine the expertise of its engineers, machinists, and manufacturing professionals with emerging technology. The company intends to use AI to support human decision-making, accelerate problem-solving, and expand its precision manufacturing capabilities.
For more information contact:
Bullen Ultrasonics, Inc.
1301 Miller Williams Rd.
Eaton, OH 45320
937-456-7133
sales@bullentech.com
www.bullentech.com
Phenx
www.phenx.ai