Custom Cavity Clinching Jig

This custom clinching jig was designed to dramatically improve the assembly speed, accuracy and safety of producing custom door cavity frames. The system allows operators to quickly set the required cavity width and height, position all components and complete a full cavity build with significantly less effort. By introducing guided setup, controlled clamping and a two hand activated clinching tool, the jig increased production throughput by approximately 4.5 times compared to manual assembly.

The adjustable modules support a wide range of cavity sizes from 620 mm to 1600 mm wide and up to 3000 mm tall. During loading, backposts, spreaders and gal angles or split jambs are positioned using clear measurement points and integrated safety locks. After everything is clamped, the operator uses the weight assisted clinching tool to secure each connection with reduced physical strain. The completed cavity rotates for ergonomic unloading, improving workflow and reducing manual handling risks.

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Custom Narrow-Format Pallet Scissor Lifter

This compact scissor lifter was engineered to operate within extremely tight geometric constraints while providing reliable pallet lifting for an automated conveyor system. Designed to fit inside a 1,000 mm × 350 mm footprint, the mechanism raises from a collapsed height of 300 mm to a working height of 925 mm, enabling pallets to be stored above the conveyor and lowered only when required.

The restricted envelope demanded detailed mechanical analysis to optimise scissor arm geometry, pivot locations and actuator travel. A reinforced platform supports pallet loads while remaining narrow enough to sit between conveyor rollers, allowing seamless integration with existing pallet transport. The result is a precise lifting system capable of handling high loads in a confined space without affecting conveyor performance.

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Bobbin Rewinder

Developed to streamline the handling of carbon fibre tow, this machine rewinds partially used bobbins into fully consolidated, production-ready spools. The system manages both unwind and rewind bobbins simultaneously, guiding the tow through a series of pulleys, width and binder sensors, and into a precision-controlled rewinding assembly.

An integrated tow-joining station automatically connects successive bobbins, using a heated press with programmable timing and temperature. The machine monitors bobbin diameter, tow width, binder orientation and material presence throughout the cycle, enabling a stable and continuous rewinding process. Automated tension testing, servo-driven oscillation control and guided HMI workflows support repeatable spool formation and consistent tow quality.

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Pod Sealing Machine

This machine was designed to validate and control the sealing of membranes onto pods using tightly regulated heat, pressure and timing. Pods are loaded into a guided sliding drawer, where...

Pod Sealing Machine

This machine was designed to validate and control the sealing of membranes onto pods using tightly regulated heat, pressure and timing. Pods are loaded into a guided sliding drawer, where the sealing head applies a programmed thermal and pneumatic cycle.

Operators set the required parameters through an HMI interface — including seal temperature, pressure, down-time and tolerance windows — allowing the machine to replicate sealing conditions consistently for testing or production verification. Integrated safety interlocks, heater status monitoring and guided PID temperature control maintain stable and repeatable sealing performance across multiple pod batches.

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Automated Peach Stone Cracking Machine

This machine was engineered specifically for agricultural seed preparation, where peach kernels must remain completely intact for successful germination. Off-the-shelf nut crackers or roll crushers apply inconsistent force and often...

Automated Peach Stone Cracking Machine

To handle this challenge, the system combines dual vibratory feeders with a centring mechanism that aligns each stone before cracking. A custom-designed electric cracking actuator controls speed, force and travel distance, using live current feedback to detect the exact moment the shell should fracture. This allows the blade to crack stones of varying sizes while protecting the delicate kernel inside.

Runoff trays with air-assist jets separate shells and pips cleanly for downstream planting or processing.

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Accelerated Wear Testing Machine

This machine was developed to carry out controlled wear testing on large-format materials under repeatable, monitored conditions. Designed to handle samples up to 1500 mm long and 150 kg in...

Accelerated Wear Testing Machine

This machine was developed to carry out controlled wear testing on large-format materials under repeatable, monitored conditions. Designed to handle samples up to 1500 mm long and 150 kg in weight, the system uses a servo-driven linear axis to move the scrub carriage across the test surface while managing table height, pad pressure and cycle count with high precision.

Setup is guided through an intuitive HMI interface, including height adjustment indicators, scrub pad alignment, water-lubrication control and cycle preparation prompts. During operation, the machine maintains accurate positional feedback, consistent scrub force and programmable cycle parameters, giving operators reliable and repeatable test results across different material types.

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Syringe Conveyor

To improve flow control, reliability and throughput in syringe packaging lines, this conveyor system manages the transport of syringes between upstream processes and the blister-packing stage. The design uses eight...

Syringe Conveyor

To improve flow control, reliability and throughput in syringe packaging lines, this conveyor system manages the transport of syringes between upstream processes and the blister-packing stage. The design uses eight individually controlled conveyor sections to regulate spacing, accumulation and delivery, ensuring smooth transfer even at variable production speeds.

Width-adjustable conveyor rails, main and micro adjustment systems and polycord belt handling allow precise alignment for different syringe formats. Integrated sensors monitor accumulation, detect gaps and manage timing logic between conveyor sections and the downstream equipment. Operator access is supported through a structured HMI interface with automatic and manual modes, counters, alarms, and speed settings.

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Dropper Insertion Machine

To improve accuracy, reliability and throughput in dropper handling, this machine automates the entire cut-and-insert process for droppers used in high-volume production. Bulk droppers are orientated through a hopper, bowl...

Dropper Insertion Machine

To improve accuracy, reliability and throughput in dropper handling, this machine automates the entire cut-and-insert process for droppers used in high-volume production. Bulk droppers are orientated through a hopper, bowl and linear feed system before being picked by a robotic arm and placed onto an eight-position index table.

A servo-driven accretion pad feeding system scores, cuts and folds material before the pad insertion module places it precisely inside each dropper. Integrated vision inspection verifies correct pad placement, while a second robot manages pass/fail sorting and transfers completed units directly onto the outgoing conveyor.
Safety is supported by interlocked guarding, emergency stops, and a structured operator interface for setup, monitoring and routine adjustments.

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Pita Bread Rotary Die Cutter

To improve efficiency and consistency in pita bread production, we developed a rotary die-cutting system to accurately cut 60–65 mm triangles from large pita discs up to 350 mm in...

Pita Bread Rotary Die Cutter

To improve efficiency and consistency in pita bread production, we developed a rotary die-cutting system to accurately cut 60–65 mm triangles from large pita discs up to 350 mm in diameter. Discs are fed two-wide with offset spacing before being precisely cut and transferred back onto the oven line.

The machine is built on a stainless-steel frame with food-grade components, a rotary die-cutting cassette, variable-speed infeed conveyor, and a fully enclosed, interlocked guarding system. Mounted on castors, the unit is designed for improved workflow, easy access, fast cleaning, and seamless integration into an existing bakery process.

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Valve Assembly Machine

This custom automated assembly machine was designed for stopcock water valve assembly, testing & packing. The operator loads a pre-assembled stopcock valve into the location fixture and the machine slides...

Valve Assembly Machine

Assembly includes screwing the screw on cap to a pre-defined torque (via Deprag Pneumatic screw driver), and leak testing by creating a silicon seal and using a ATEQ F420 series leak tester. Parts that pass the test are removed and placed directly into shipping cartons.

This implementation combines the assembly and testing into one machine and improves the efficiency of assembling the product as well as increasing the quality & reliability of the product.

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Bagged Ice Conveyor

This full turnkey indexing conveyor was designed and manufactured right here in Melbourne at Applied Automation....

Bagged Ice Conveyor

This full turnkey indexing conveyor was designed and manufactured right here in Melbourne at Applied Automation.

With a dedicated flight pitch the conveyor is able to move bagged ice at 1 index per second for high speed sorting and packing, and to date has moved with over 1.5million trouble free indexing movements.

The equipment includes a Siegling Prolink plastic modular belt with fixed flights, constructed with 316 stainless steel for all mechanical parts and driven with SEW Helical-bevel gear servo motor.

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Indexing Conveyor

One of the many projects completed for Pfizer; this automated indexing conveyor is part of a process to count, check, sort and place pharmaceutical vials into trays....

Indexing Conveyor

One of the many projects completed for Pfizer; this automated indexing conveyor is part of a process to count, check, sort and place pharmaceutical vials into trays.

Our unique design for the system includes precision servo control with an indexing star wheel tray loader that allows it to accommodate various vials sizes being fed through the infeed conveyor.

The end result is optimal singulation and efficient packing into the tray shipper.

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High Speed Sorting Conveyor

This conveyor project was completed for Mondelez, one of Australia's leading confectionery food manufacturers (with brands such as Cadbury, Pascall and BelVita). The high speed conveyor is capable of processing...

High Speed Sorting Conveyor

This conveyor project was completed for Mondelez, one of Australia’s leading confectionery food manufacturers (with brands such as Cadbury, Pascall and BelVita). The high speed conveyor is capable of processing 80 cartons per minute and supports product cartons of varying sizes.

The design implemented by our engineers includes eight conveyors using automated scanning and sorting to direct cartons to the correct lane and onto the robot palletiser conveyors.

Technology utilised in the project includes Sick sensors, Rockwell 1kW MP Servo Motors, Apex planetary gearboxes, Forbo Belts, Rockwell Control System and Intralox Dynamically Activated Roller Belt (DARB).

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Conveyor Transfer Slide

One common requirement of conveyors in automated systems is the need to transfer products between various stations and conveyors, and between multiple conveyors....

Conveyor Transfer Slide

One common requirement of conveyors in automated systems is the need to transfer products between various stations and conveyors, and between multiple conveyors.

To make this transition smooth and ensure no damage to the product we can combine 5-Axis CNC machining and 3D printing to produce complex shapes that would otherwise be difficult or expensive to make. Such parts can be incorporated in new systems or added to existing systems to improve efficiency and quality.

The large 500mm component attached to the conveyor shown was 3D printed in HP PA 12 Polymide black, and combined with a machined aluminium mounting component allowing for a smooth transition.

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Modular Syringe Transfer Conveyor

This conveyor project was completed for a pharmaceutical client to transfer syringes between stations. Custom designed by Applied Automation, with concept and final design produced in SolidWorks....

Modular Syringe Transfer Conveyor

This conveyor project was completed for a pharmaceutical client to transfer syringes between stations. Custom designed by Applied Automation, with concept and final design produced in SolidWorks.

The final conveyor size for this project was 4m x 1.5m x 1m, however the modular design allows this conveyor to be produced to suit any length. The design also allows for changes in incline and a 90 deg change in direction.

Accommodating a variety of syringe sizes, the single drive Twin O-Ring system transfers syringes un-marked at 100mm per second. Twin clutches are used in the final stage of the conveyor for control and accumulation.

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Indexing Conveyor and O-ring Conveyor Transfer

This conveyor is part of a pharmaceutical cleaning & filling machine for a client to transfer tubes between stations. These conveyors are just one part of the complete machine that...

Indexing Conveyor and O-ring Conveyor Transfer

This conveyor is part of a pharmaceutical cleaning & filling machine for a client to transfer tubes between stations. These conveyors are just one part of the complete machine that was custom designed & manufactured by Applied Automation.

The magazine is loaded with tubes which are gravity fed onto the indexing conveyor. The indexing conveyor plays an important roll to ensure each tubes lines up at the corresponding station (cleaning, orientation & filling).

The o-ring conveyor is used for the outfeed, and a transfer station is used to move the product from the indexing conveyor onto the o-ring outfeed conveyor.

Conveyor systems such as this require custom design to suit the product which always varies in size and orientation. The design of the conveyor transfer station plays a critical role to ensure that transfer operates seamlessly for efficient operation of the machine.

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Scientific Instrument Manufacturing

Working with Melbourne based manufacturer Earth Sciences we designed and manufactured a distinctive range of scientific equipment enclosures and associated components, ready for assembly with the electronics....

Scientific Instrument Manufacturing

With a limited amount of space available to house all the necessary electronics, PCB’s LCD screen, push buttons and connectors the housings were manufactured from 6061 T6 on our multi-axis machining centres.

The design was carefully planned to allow for an efficient assembly process even with the limited space available. Our precise CNC machining techniques resulted in a high quality product ready for assembly by our customer.

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Health & Fitness Equipment Manufacturing

Working with Melbourne based health & fitness assessment company SBN (Strength By Numbers) we provided design assistance and manufacturing for equipment in their AxIT system. The resulting products offered by...

Health & Fitness Equipment Manufacturing

The project was developed upon initial CAD designs provided by the customer. Materials including 6061 T6 and acetal were selected to meet the necessary strength and functional requirements.

Our experienced CNC operators performed the challenging machining operations on our multi-axis machining centres to output aesthetically pleasing products of an exceptional quality, ready to be assembled by the customer.

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Vacuum Extraction System

This industrial extraction system was designed to extract particulates for a yoghurt filling machine and was integrated into an existing machine being used for production....

Vacuum Extraction System

This industrial extraction system was designed to extract particulates for a yoghurt filling machine and was integrated into an existing machine being used for production.

The tubs are indexed through the machine where the extraction system uses a series of custom designed nozzles that lower into the tub, removing particulates via vacuum into a filtered chamber above the machine. The process was able to perform this task on six tubs every 2 second cycle (supporting a 1.7 – 2.0 second cycle).

The systems were manufactured in accordance with food manufacturing standards for a total wash down scenario, and utilised a Rockwell MPAI Axis with 300mm stroke for the vertical movement, and Simco equipment for deionizing of tubs prior to cleaning.

This implementation combines the assembly and testing into one machine and improves the efficiency of assembling the product as well as increasing the quality & reliability of the product.

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3D Printed Conveyor Slide

This upgrade for a syringe conveyor was designed in-house at Applied Automation to facilitate the transition of product between two conveyors....

3D Printed Conveyor Slide

This upgrade for a syringe conveyor was designed in-house at Applied Automation to facilitate the transition of product between two conveyors.

The large 500mm component was 3D printed in HP PA 12 Polymide black and fastened to an aluminium mounting component.

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Engineered Transport Skid

This custom transport skid fabrication included complete project management from start to finish and was designed & manufactured to the build specifications....

Engineered Transport Skid

This custom transport skid fabrication included complete project management from start to finish and was designed & manufactured to the build specifications.

The skid is manufactured from carbon steel tube ASTM 500 GRB with folded fabrications from ASTM B209 alloy plate, and all welds qualified and tested to AWS D17.1/17.1M:2017.

This project highlights the engineering expertise and capabilities of the team at Applied Automation & Engineering.

Items used in the project such as fasteners and fittings were certified to MIL spec standards, along with MIL spec electroplating and epoxy priming.

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Automated Precision Conveyor

This conveyor system completed for Robert Bosch is part of an automated assembly line for measuring and testing of diodes used in automotive components....

Automated Precision Conveyor

In order to meet the high throughput demands required by automotive industries, automated conveyor systems are often used with vision systems for quality control and electrical testing.

This conveyor system completed for Robert Bosch is part of an automated assembly line for measuring and testing of diodes used in automotive components.

Utilising standard motor gearbox combinations with encoder feedback, this assembly is constructed using precision CNC machined components for accurate movement & testing of delicate products. Festo pneumatics are used in the design the singulation mechanism.

The Proof is in the Projects.

Custom Solutions, Built Right​

Automated Conveyor Systems​​

CNC Product Design & Development​

Custom Engineering Solutions​

Food Grade

Medical Grade

Custom Cavity Clinching Jig

Custom Cavity Clinching Jig

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Custom Narrow-Format Pallet Scissor Lifter

Custom Narrow-Format Pallet Scissor Lifter

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Bobbin Rewinder

Bobbin Rewinder

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Pod Sealing Machine

Pod Sealing Machine

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Automated Peach Stone Cracking Machine

Automated Peach Stone Cracking Machine

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Accelerated Wear Testing Machine

Accelerated Wear Testing Machine

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Syringe Conveyor

Syringe Conveyor

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Dropper Insertion Machine

Dropper Insertion Machine

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Pita Bread Rotary Die Cutter

Pita Bread Rotary Die Cutter

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Valve Assembly Machine

Valve Assembly Machine

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Bagged Ice Conveyor

Bagged Ice Conveyor

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Indexing Conveyor

Indexing Conveyor

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High Speed Sorting Conveyor

High Speed Sorting Conveyor

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Conveyor Transfer Slide

Conveyor Transfer Slide

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Modular Syringe Transfer Conveyor

Modular Syringe Transfer Conveyor

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Indexing Conveyor and O-ring Conveyor Transfer

Indexing Conveyor and O-ring Conveyor Transfer

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Scientific Instrument Manufacturing

Scientific Instrument Manufacturing

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Health & Fitness Equipment Manufacturing

Health & Fitness Equipment Manufacturing

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Vacuum Extraction System

Custom Solutions, Built Right

Automated Conveyor Systems

CNC Product Design & Development

Custom Engineering Solutions