Breaking News: The NTS & UPC business divisions of NITREX, a manufacturer of industrial furnaces focused on nitriding solutions, will be acquired by the AICHELIN Group, a global provider of industrial heat treatment solutions. For clients, this means access to a broader range of technologies and stronger local support.
Headquartered in Canada, NITREX has around 250 employees in five countries. The business unit Heat Treating Services is not included in the scope of the acquisition.
The transaction represents the largest acquisition in AICHELIN Group’s history. For employees, the acquisition opens up new perspectives within a strategically focused industrial group. The Group notes in their press release that it “will become the largest global furnace manufacturer in its industry of heat treatment solutions,” with a reach of combined sales at more than EUR 230 million and employing over 1,350 people across 23 locations in 11 countries throughout Europe, Asia, and North America. The Group is also represented by a global network of sales partners.
Christian Grosspointner CEO AICHELIN Group. Source: AICHLELIN Group
The acquisition brings together two highly complementary portfolios: NITREX adds renowned expertise in nitriding furnaces to AICHELIN’s broad technology offering. The geographic fit is equally noteworthy, with NITREX’s operations in the U.S., Canada, Poland, Germany, France, and China integrating seamlessly into AICHELIN’s regional structures.
The acquisition marks an important milestone in the implementation of AICHELIN’s Strategy 2030, which focuses on sustainable growth through regional proximity, diversification, and technological progress.
“This acquisition marks a new chapter for AICHELIN. By combining forces with NITREX, we are unlocking innovation potential and global synergies that will benefit our customers, employees and stakeholders alike,” says Christian Grosspointner, CEO of AICHELIN Group. “We are proud to welcome NITREX into our Group.”
AICHELIN is expanding into new markets and client segments, both through internal innovation and targeted acquisitions. With this acquisition, the Group is thus advancing its goal of becoming a lifecycle partner for heat treatment clients worldwide, supported by digital services and localized operations.
Press release is available in its original form here.
Heat Treat Today has gathered the four heat treat industry-specific economic indicators for August 2025. July industry-specific economic indicators showed predictions for mixed slowdown and growth; industry suppliers expect stagnation in August, with hope for a future upswing.
July’s industry-specific economic indicators showed one index with no change, one continuing in contraction, and two slipping into contraction. The Inquiries index shows some improvement, jumping out of contraction to 50 (from 49.3 in July). Bookings dropped down to 47.2 (below July’s 53.6). The Backlog index rose to 46.3 (from 41.7 in July). Finally, the Health of the Manufacturing Economy index dipped slightly into contraction at 48.0 (compared to 50.0 in July).
The graphs overall suggest that though suppliers are preparing for a slowdown there is an undercurrent of hope, with half of the indexes improving over last month.
The results from this month’s survey (August) are as follows: numbers above 50 indicate growth, numbers below 50 indicate contraction, and the number 50 indicates no change:
Anticipated change in Number of Inquiries from July to August:50
Anticipated change in Value of Bookings from July to August: 47.2
Anticipated change in Size of Backlog from July to August: 46.3
Anticipated change in Health of the Manufacturing Economy from July to August: 48
Data for August 2025
The four index numbers are reported monthly by Heat Treat Today and made available on the website.
Heat TreatToday’sEconomic Indicatorsmeasure and report on four heat treat industry indices. Each month, approximately 800 individuals who classify themselves as suppliers to the North American heat treat industry receive the survey. Above are the results. Data started being collected in June 2023. If you would like to participate in the monthly survey, please click here to subscribe.
A plant is expanding its heat treatment capacities with a dual-chamber vacuum furnace equipped with an oil quenching system and an advanced vacuum carburizing system.
The new device for Bodycote, a heat treater with U.S. locations, is for their Siechnice, Poland location. The furnace will expand its range of services and will be provided by SECO/WARWICK, a furnace provider with locations in North America.
Maciej Korecki Vice President of Business of the Vacuum Furnace Segment SECO/WARWICK
“These multi-chamber furnaces combine heat treatment in a vacuum with traditional oil quenching in dual- or triple-chamber configurations, enabling high efficiency, and delivering clean, oxide-free (IGO) parts. The Bodycote Group is a key partner for us, thanks to our shared commitment to advanced heat treatment technology,” said Maciej Korecki, vice president of the Vacuum Segment Group at SECO/WARWICK.
Dariusz Podgórski Vice President Bodycote Polska
“The dual-chamber [furnace] was the correct choice to meet the requirements for implementing sustainable development strategies and reducing CO₂ emissions. The new furnace will allow us to conduct cleaner carburizing processes without an endothermic atmosphere,” said Dariusz Podgórski, vice president of Bodycote Polska Sp. z o.o.
The features of the furnace include an oil quenching system ensuring fast and uniform cooling of the charge, as well as the FineCarb vacuum carburizing system, which allows for precise control of process results.
Press release is available in its original form here.
In this Technical Tuesday installment Christoph Bollgen, industry manager for Thermal Processing Technology, JUMO GmbH & Co.describes how global industries accelerate towards greener, smarter manufacturing. Thermal processing is at a pivotal crossroads of advances in industrial furnace technology, energy efficiency, and sustainable operations set to transform how materials are hardened, strengthened, and perfected.
This feature presents these important developments in thermal processing — from technological developments and energy efficiency measures to digitization, sustainability, regulation, and market growth — supported by current analyses, statistics, and case studies.
This informative piece was first released inHeat Treat Today’s August 2025 Automotive Heat Treating print edition.
Introduction
Thermal processing technology, specifically industrial furnaces and heat treatment processes, are the backbone of numerous industries from steel and ceramics to automotive and electronic components. Over the last five years, this sector has developed rapidly. Driven by new technical possibilities and increasing requirements relating to efficiency and sustainability, significant trends have arisen in industrial furnaces, heat treatment processes, and the market as a whole.
Industrial process heat is essential for many industries, which is why increasing energy costs, regulatory requirements, the shortage of skilled professionals, and international competition pose challenges for companies.
Electrification is increasing in importance, as it offers high process efficiency, emissions reductions, and tried-and-tested technologies. Nevertheless, there are technical and economic obstacles for high temperature processes where limited heat flux densities and high operating costs make complete electrification more difficult.
Hydrogen is being investigated as a possible option for decarbonization in industries that currently use natural gas. However, for the switch to take place, changes to process conditions and material properties are required, while the availability and cost of hydrogen remain decisive factors.
Future decarbonization strategies must be developed for specific industries, as not all processes can be electrified. Both hydrogen and electrical energy require significant changes to the infrastructure to ensure supply security in the long term. The choice between electrification and hydrogen depends on underlying technological, economic, and infrastructure conditions.
Advances in Industrial Furnaces and Heat Treatment Processes
State-of-the-art industrial furnaces and heat treatment systems have made huge advances in a short period of time. Key examples are the new, altered material and product requirements in the automotive industry; more lightweight components and electromobility place higher demands on components, such as rolling bearings. This has resulted in process innovations.
Carbonitriding of bearing steel has therefore experienced somewhat of a renaissance, as it facilitates higher levels of power density and temperature resistance. At the same time, low-distortion steels are being developed for lightweight construction, and modular heat treatment processes (e.g., nitriding and low-pressure carburizing) are being introduced to adapt processes more flexibly to different workpieces.
Progress has also been achieved when it comes to the furnace technologies themselves. New furnace designs combine multiple process steps in a single plant and make better use of energy. For example, pre-heating, heating up, and melting are combined in a single furnace shaft in modern shaft furnace designs. This makes maximum energy yield possible, thanks the smart geometry and burner technology. Due to the installation of these types of new melting furnaces, gas consumption and therefore energy costs can be reduced significantly.
Figure 1. Comparison of old and new industrial furnace technologies
In addition, compact furnace constructions are gaining in importance, as space-saving, modular furnaces enable integration in confined production environments, without compromising capacity or temperature homogeneity.
Finally, induction technology is also increasingly being used in heat treatment — for example for inductive hardening of complex components — as it combines precise local heating with high energy efficiency. Overall, technical progress aims at achieving higher product quality with lower side effects (e.g., distortion, energy consumption, scrappage).
Measures for Improving Energy Efficiency
In light of increasing energy costs and strict climate targets, energy efficiency in thermal processing plants is once again in the spotlight. Over the past five years, various measures have been established to reduce the energy consumption of furnaces and heat treatment processes.
Optimized Furnace Insulation and Construction
Manufacturers are increasingly relying on improved insulating materials and energy-efficient furnace constructions to minimize heat loss. State-of-the-art industrial furnaces have highly effective insulation and sophisticated flow guidance, meaning less unused energy escapes. This therefore significantly reduces the specific energy demand per processed piece.
Heat Recovery
Nowadays, unavoidable waste heat is better exploited. New technologies (e.g., high-temperature heat pumps or ORC systems) can raise waste heat to a usable temperature and guide it back into the process or use it for electricity generation. This waste heat recycling reduces the use of primary energy and, accordingly, emissions. McKinsey & Company (2022) estimates the global waste heat potential that can be exploited to be at least 3,100 TWh annually, which could mean savings of up to €140 billion (US$164 billion) per year if used in full. In practice, recuperators, regenerative burners, and heat exchangers are part of the standard equipment of many furnaces to reuse energy from hot exhaust gases for pre-heating processes.
More Efficient Burners and Process Control
Progress in burner technology also plays a role in achieving savings. Industrial gas burners currently operate with improved air pre-heating or flameless oxidation (FLOX) modes, which increase efficiency and reduce losses. Precise digital control systems (with PID controllers and recipe programs) also ensure that furnaces remain in the target temperature range with increased accuracy. Avoiding overshoots (overheating) in heating-up and cooling-down phases saves energy and shortens process times. Intelligent control algorithms and sensor technology ensure that the temperature distribution is more even, meaning fewer readjustments are required.
Figure 2. How various measures help boost energy efficiency (Data from Future Market Insights, Inc. 2025, McKinsey and Company 2022, and Neal Systems Incorporated)
Modernizing and Replacing Old Plants
Many companies are investing in replacing outdated furnaces with new, energy-optimized systems. These types of modernization efforts — often funded by state energy efficiency programs — boost productivity and reduce energy consumption by double digits in no time. Retrofits (e.g., improved insulation, speed-controlled drives for fans, automatic door locks) also noticeably boost the efficiency of existing furnaces.
These measures pay off both economically (thanks to reduced operating costs) and environmentally (thanks to reduced emissions). Efficient thermal processing technology has therefore become a core concern for the industry.
Digitization and Automation in Thermal Processing Technology
Industry 4.0 has reached thermal processing technology over the last few years. Automation and digitization are now the most important drivers of growth in this sector. Specifically, a range of state-of-the-art technologies are used in furnaces and heat treatment systems.
IoT-Capable Furnaces and Interconnected Sensor Technology
New industrial furnaces are equipped with sensors (e.g., temperature, pressure, atmospheric composition, wear monitors) and communicate their operating data in real time. These types of smart furnaces enable the process to be continuously monitored and fine-tuned. The data gathered is evaluated in control systems, which boosts operating efficiency and reduces downtimes. For example, trends in temperature curves or burner parameters can provide early indication that maintenance is required. Operators can therefore achieve interruption-free production processes thanks to predictive maintenance.
Predictive Maintenance and Digital Twins
Instead of reactive maintenance, many companies rely on predictive maintenance. Upcoming plant failures can be predicted using machine learning from sensor data. Digital models (twins) also simulate the furnace behavior and facilitate parameter optimization, without interrupting real-time operation. According to a market analysis, these types of virtual simulations are used to plan preventative maintenance and optimize processes. This boosts plant availability and extends maintenance intervals.
Consistent Automation and Reliable Control Systems
Today, thermal processing plants use PLC/CS systems to automatically control operations and can coordinate multiple connected furnaces or burners centrally. State-of-the-art control systems meet high safety standards (e.g., according to EN 746-2 or ISO 13577 for burner safety), meaning that even complex plants can be operated in compliance with standards and fail safety. This trend toward safely automated thermal processing plants has been further advanced thanks to new standards and digital control technology, among other things.
Integration of AI and Autotuning Systems
The first AI-based optimization systems are being implemented to improve thermal processing in real time. Systems like this learn from process data and adapt parameters (e.g. furnace atmosphere, power control) automatically to further reduce energy consumption or throughput time.
Robots and Automation of Handling
Alongside furnace control itself, the material handling process is also increasingly being automated. In modern hardening plants and foundries, robots deal with the loading and unloading of furnaces and transport workpieces between process steps, thereby boosting process reliability and reproducibility. This reduces errors due to manual interventions and enables low-personnel or lights-out operating concepts.
Overall, digitization results in higher flexibility, quality, and availability in thermal processing technology. Companies that make use of heat treatment 4.0 can respond to new production requirements more quickly and operate their plants more cost-effectively as a whole. The industry is transitioning toward data-driven, intelligent systems that are transforming traditional furnaces into high-tech interconnected systems.
Developments in the Field of Sustainable and Environmentally Friendly Technologies
Against the backdrop of climate change and environmental requirements, thermal processing providers are increasingly promoting sustainable technologies. A key aim is to decarbonize industrial heating processes — in other words to drastically reduce CO₂ emissions and other pollutants. Multiple developments over the last few years should be highlighted here.
Electrification of Heating Processes
Wherever possible, fossil fuel-fired furnaces are being replaced by electric heating processes. Electric heat (e.g. induction furnaces, resistance heating furnaces, or electric arc furnaces) does not cause any direct emissions locally and can be operated practically CO₂-neutrally using green electricity. Electric high-temperature heat pumps, electric boilers, and furnaces are increasingly gaining in popularity, particularly for low temperature ranges or discontinuous processes.
However, there are challenges. In some industries, gas-fired furnaces are still more cost-effective due to higher electricity prices — even though electric furnaces often operate more efficiently. Although fully electric melting furnaces in the glass industry may be more energy-efficient, they cannot yet achieve the capacities of larger gas furnaces and may result in higher operating costs depending on the region. Nevertheless, the proportion of electric heat treatment systems is continuously rising, especially as the investment costs are often lower (no fuel storage, no exhaust gas cleaning required).
Hydrogen and Alternative Fuels
High hopes are resting on green hydrogen as a replacement for natural gas or oil in industrial furnaces. Hydrogen burns without producing any CO₂ if it originates from renewable sources — the only product that is created is water vapor. However, hydrogen requires a modified furnace design and safety precautions due to different combustion properties (faster flames, higher temperature peak). Nonetheless, initial pilot plants such as those in the steel and brick industry, successfully demonstrate operation with hydrogen burners. Ammonia is also being trialed as a storable hydrogen carrier (in particular in Japan) in order to provide carbon-neutral process heat.
Emission-Free Combustion Technologies
Regardless of the fuel, there is a focus on reducing harmful gases such as NOx. Technologies such as flameless oxidation (FLOX) and staged combustion drastically reduce NOx formation by smoothing combustion peaks. Some manufacturers are making their names as pioneers in low-emission technologies in furnace construction. Improved filter and afterburning systems are also being integrated to remove particles, VOC, and CO from exhaust gases. State-of-the-art thermal processing plants therefore often significantly fall below current limit values and minimize local air pollutants.
Energy Management and Renewable Integration
Sustainability is also reflected in plant energy management. Many companies are integrating their furnaces into energy recovery cycles or using excess heat to heat other plant components or buildings. Some heat treatment companies are investing in their own renewable energy sources (photovoltaics, wind) or are purchasing green electricity to lower the CO₂ footprint of their processes.
For example, in the aluminum recycling industry, AI systems (as mentioned above) are used to reduce the use of new aluminum and melt more scrap, which saves a significant amount of energy. These types of holistic approaches — closing the material cycle, using waste heat, employing green electricity — play a role in ensuring environmentally friendly thermal processing technology.
As a whole, the industry is making significant strides toward climate neutrality and resource conservation. Numerous providers and industrial companies have set voluntary targets or commitments to reduce their process-related emissions by large percentages by 2030 or 2040. The course is set in terms of technology (electric processes, hydrogen as an option, highly efficient furnaces) to make this transformation possible.
Regulatory Developments and Underlying Legal Conditions
The trends described are strongly impacted by laws and regulations. Over the last few years, legislators around the world have enacted an increasing number of rules which also impact thermal processing technology.
Environmental Regulations and Emission Limits
Figure 3. Impact of regulations on thermal processing technology (Data from BMUV 2021 and European Commissions 2026)
There are now strict limit values for exhaust gases from industrial furnaces (NOx, CO, particulate matter, etc.) in many regions. For example, the permitted emissions have been tightened up further in the EU with the Technical Instruction on Air Quality Control 2021 and the Industrial Emissions Directive. Manufacturers are responding to this with the low NOx technologies mentioned above as well as more efficient combustion in order to adhere to the strict environmental regulations. The permitted CO₂ emissions are also being limited indirectly — by such means as national CO₂ prices or emission trading schemes which make fossil fuels more expensive. This creates an economic incentive for switching over to more efficient or CO₂-free technologies (electric heat, H₂).
For example, China’s state “dual carbon” strategy aims at reaching peak CO₂ early and then becoming climate-neutral – which is pushing the local heat treatment industry to upgrade to energy-efficient and environmentally friendly plants quickly. Similar climate protection programs in Europe (Green Deal/Fit for 55) and the U.S. (Industrial Heat Shot, 85% emission reductions by 2035) exert pressure globally to make thermal processing plants greener.
Energy Efficiency Requirements and Promotion
Many countries have legal targets for reducing industrial energy consumption. For example, the Energy Efficiency Directive in the EU means large companies are obligated to carry out audits which often uncover potential for greater efficiency in thermal processing. Germany and other countries are funding investment in energy-efficient interdisciplinary technologies — explicitly including industrial furnaces.
Companies receive subsidies or tax breaks if they replace old plants with efficient ones or introduce utilization of waste heat. For example, in the case of Hattori in Japan, a state funding program helped it to finance the purchase a new melting furnace. This type of funding significantly speeds up the market penetration of state-of-the-art technologies.
Safety and Quality Standards
These underlying legal conditions not only relate to the environment, but also to safety and quality. The EN standards series 746 (or ISO 13577 et seqq.) for thermal processing plants has recently been updated to represent the current state of technology — for example with respect to the functional safety of burner controls. Operators are instructed to equip their plants according to these standards, which makes the use of advanced control technology necessary. In safety-critical industries (e.g., aerospace), standards and customer requirements also require each heat treatment process to be documented in detail (AMS2750 or Nadcap in heat treatment). This promotes digitization (for example electronic batch reports, traceable sensor technology calibrations) and ensures that new technologies operate reliably and in a reproducible manner.
All in all, regulations both put pressure on companies and create incentives: on the one hand, stricter laws force companies to make changes (any company which operates inefficiently or produces a high level of emissions, risks penalties or competitive disadvantages); on the other hand, funding programs mean that making the switch is easier. The thermal processing technology industry is current operating in an environment which is strongly influenced by climate and industrial policy objectives — and therefore responds with innovations to meet these objectives.
Market Growth and Predictions for the Years Ahead
The thermal processing technology market is characterized by solid growth thanks to the above-mentioned trends. Around the world, the market volume of industrial furnaces and heat treatment systems is expected to grow further. According to a current analysis (Future Market Insights), the global market grew to a volume of around USD 10.26 billion in 2024 and is expected to grow to above USD 17.1 billion by 2035; this corresponds to an average annual growth rate of around 4.8% (2025–2035).
Figure 4. Distribution of energy sources in thermal processing technology (Data from Future Market Insights, Inc 2025 and Leicher, Giese, and Wieland 2024)
Industries and regions: almost all user industries contribute to market growth, in particular the automotive industry. Significant markets such as Europe and North America are experiencing somewhat more moderate growth but are increasingly carrying out high-tech upgrades to existing plants.
Market character and outlook: the thermal processing technology market is highly diversified, spanning large continuous furnaces for mass production to specialized laboratory furnaces. Customized solutions are gaining in importance, as manufacturers are increasingly having furnaces tailored precisely to their process requirements.
Conclusion
The thermal processing industry has noticeably changed over the last five years. Modern industrial furnaces and heat treatment processes are more efficient, digitally networked, and significantly more environmentally friendly than their predecessors. Companies are investing in energy-efficient, automated plants to both reduce costs as well as meet regulatory and climate-relevant requirements. These trends will continue over the upcoming years.
Further market growth can be expected, while the technologies also evolve toward sustainability and smart manufacturing. The combination of innovation and adaptability mean that thermal processing technology will secure a central position in the industrial value chain in the future.
Leicher, Jörg, Anne Giese, and Christoph Wieland. 2024. “Electrification or Hydrogen? The Challenge of Decarbonizing Industrial (HighTemperature) Process Heat.” J 7 (4): 439–456. https://doi.org/10.3390/j7040026
Over the last eight years, Christoph Bollgen has made an incredible journey from a college teaching assistant to the Market Segment manager at JUMO Process Control. Along the way, Christoph earned a bachelor’s degree in automation and robotics from the University of Applied Science Fulda, Germany, and received a master’s degree in industrial engineering from the University of Texas in Arlington. After joining JUMO, Christoph successfully participated in the CQI-9 Process Auditor training in 2019 and in the 2019 SECO/WARWICK Heat Treatment 4.0 Seminar, gaining expertise about topics such as theoretical and practical issues of heat treatment 4.0 concerning aircraft, automotive, mass production, and hardening industries.
Christoph was also an honoree in Heat Treat Today’s40 Under 40Class of 2024.
Advanced Heat Treat Corp. (AHT) has completed a building expansion at their Monroe, Michigan facility. The new 6,000 sq. ft. addition increases production capacity and enhances operational efficiency.
The climate-controlled addition will provide an area for additional equipment and services for Advanced Heat Treat Corp. (AHT), free of existing production space, and provide a new office and modern breakroom.
Chad Clark Plant Manager Advanced Heat Treat Corp.
Groundbreaking for the project took place on November 27, 2024 and their certificate of occupancy was awarded on July 29, 2025.
“Seeing this expansion completed is incredibly rewarding—it reflects the hard work and dedication of our entire team,” said Chad Clark, Plant Manager. “The additional space allows us to streamline operations, support more equipment, and enhance service to our customers. We’re excited to begin the transition and fully integrate the new area into our daily workflow.”
Heat Treat Todayreported on a new gas nitriding unit at the Monroe facility last month. The new unit will be utilized in heat treatment for industries such as automotive, government and defense, plastics, power generation, and others. It will utilize UltraGlow® Gas Nitriding, which is a case-hardening process whereby nitrogen is diffused into the surface of a solid ferrous alloy by holding the metal at a suitable temperature in contact with a nitrogenous gas, usually ammonia.
AHT has four locations: one in Monroe, Michigan; two in Waterloo, Iowa; and a fourth in Cullman, Alabama. AHT Michigan has the unique capability to nitride parts up to 31-feet in length.
Press release is available in its original form here.
Founded in 1975, this Mexico-based furnace manufacturer has 50 years of expertise in thermal processing equipment and has delivered more than 2,000 units across 48 countries.Heat Treat Today’sIndustry Company Highlights is dedicated to shining a light on major players within the heat treatment industry.
In today’s edition, learn more about ceramics, proprietary technologies, and technical services that set NUTEC Bickley apart. Read to the end to catcha unique interview of NUTEC Group CEO Daniel Llaguno by Heat Treat Today Publisher Doug Glenn.
With a mission to provide industrial kilns and furnaces to North American and international markets, NUTEC Bickleyis celebrating its 50th anniversary as a company. Through its 50 years of growth NUTEC has made a global impact and continues to look ahead with a vision of wide-reaching impact, including strategies and initiatives which prioritize efficiency in industrial heat treatment.
NUTEC Bickley designs and manufactures kilns for the ceramic industry, furnaces for steel, aluminum and specialty alloys, ovens and dryers, combustion and control systems, and preheaters and dryers. They service the automotive, aerospace, sanitaryware, refractories, abrasives, and steel industries, and are known for their aluminum heat treating furnaces.
The company has several proprietary technologies, including:
ECOmbustion™: An advanced combustion control system that reduces fuel usage and carbon emissions
IMPS™ (Integrated Monitoring & Pulse System): A control technology that enhances process precision and uniformity
Jointless® Insulation Modules: A patented ceramic fiber design that extends furnace lifespan and reduces heat loss
Energy Recovery Systems: Solutions that maximize fuel efficiency by reusing residual heat.
Shuttle kiln Source: NUTEC Bickley
In July 2025, NUTEC Bickley announced an exclusive manufacturing license in North America for Regenerative Thermal Oxidizers through a strategic alliance with Spain-based Kalfrisa. This partnership enhances its environmental technology offerings and expands its North American footprint.
Alberto Cantú, NUTEC Bickley’s vice president of Ceramics and New Business Development, said, “The effective and safe removal of VOCs is vital for a wide range of industries and is something we are asked to address on a regular basis. Kalfrisa is a highly respected name in emissions treatment and control and so I’m delighted that we have been able to announce this new collaborative agreement. There is strong potential for the deployment of high-performance RTOs in the North American market, and I’m very excited about working closely with Kalfrisa to deliver the best available technology.”
The company continues to invest in R&D with recent innovations including a high-precision shuttle kiln for ceramic core sintering and advanced drop-bottom furnaces for aluminum heat treatment. These developments will be featured in upcoming events like UNITECR 2025 in Cancún and the FIA Light Alloy Conference.
Drop bottom furnace Source: NUTEC Bickley
Doug Glenn, publisher at Heat Treat Today, interviewed NUTEC Group CEO Daniel Llaguno for the 50th anniversary of the company and discussed its current operations and future plans.
Daniel Llaguno CEO NUTEC Group Source: NUTEC Group
US Dollar and Pesos (00:01): Daniel discusses how the strength of the U.S. dollar and the Peso relate for the sale of NUTEC’s thermal processing equipment. He shares why “a strong U.S. dollar is very beneficial for us.”
Increasing Capacity at Charlotte Facility to Mitigate Tariffs (3:00): The effects of the current economic and political situation between the United States and Mexico directly impact NUTEC’s business. However, to mitigate tariff impacts, Daniel shares how they are increasing capacity at their Charlotte facility with a goal that 90% of their fiber division production may occur within the United States.
The Path Forward For NUTEC’s Divisions (9:10): NUTEC’s R&D is split across the U.S. and Mexico, and they partner with a research center in Spain; they are pro-active in developing new technologies. Daniel believes that furnaces have to be smarter and more helpful to the client, and the company is geared toward improving efficiency. Daniel adds that NUTEC primarily specializes in customized furnaces.
Inaugurating AI Technologies (13:38): Daniel commented on how NUTEC is in the early stages of exploring applications of AI in their products and business. They currently see many applications on the business side and are actively discerning how to apply it to their furnace technologies.
A company in advanced metal casting technologies has shipped its first commercial additive manufacturing evaporative casting (AMEC) machine to the University of Tennessee, Knoxville (UTK). The system will be installed at UTK’s manufacturing research facility, where it will support continuing education, casting research, and workforce development in next-generation manufacturing.
Lightning Metal LM-16 is Skuld LLC‘s flagship machine for additive manufacturing evaporative casting (AMEC). The machine is a tool-less, net-shape casting process capable of producing aerospace grade aluminum and other high-performance alloys with minimal post-processing. The system enables rapid prototyping, reduced lead times, and flexible alloy compatibility, making it ideal for both industrial and academic environments.
The Lightning Metal LM-16 AMEC machine by Skuld Source: Skuld LLCSarah Jordan Founder & CEO Skuld, LLC Source: Author
“This milestone represents…a signal that advanced casting is entering a new era,” said Sarah Jordan, co-founder and chief executive officer at Skuld. “The University of Tennessee is a national leader in manufacturing innovation, and we’re proud to support their mission with a system that bridges research and real-world application.”
Adam Penna Director, Sales and Marketing Skuld Source: Linkedin
UTK will use Lightning Metal LM-16 platform to expand its materials science curriculum, conduct applied research in casting and alloy development, and provide hands-on training for students and professionals entering the manufacturing workforce.
“This is exactly the kind of partnership we envisioned when we launched the Lightning Metal platform,” said Adam J. Penna, director of sales and marketing at Skuld. “It’s a platform that empowers innovation in evaporative casting utilizing 3D printing for improved features like edges and surfaces while also reducing the need for tooling cost…whether you’re solving supply chain challenges or training the next generation of engineers.”
The Technology
Skuld’s AMEC technology merges lost foam with polymer 3D-printing. Heating up to around 2000°F, the machine operates as an automated micro-foundry. The Lightning Metal LM-16 removes the safety issues of handling molten metal and is perfect for small, custom, one-off aluminum parts fasteners. It makes products in a 7″ cube, melting approximately 16lbs of aluminum, and can also process brass or bronze.
The machine is sized to be able to move through standard doorways and utilizes single-phase power, like a dryer plug.
The casting works by utilizing a hollow polymer shape in place of lost foam, where the molten metal vaporizes the polymer. This is a subset of the casting field called lost foam, which is a variation on lost wax investment casting, and eliminates around 90% of process steps, making for fewer costs and a faster process. The mold is insulated with a thin ceramic shell, ceramic beads, a metal container called a flask, and unbonded beads.
Gear produced by Lightning Metal LM-16 Source: Skuld LLCProduct of Lightning Metal LM-16 Source: Skuld LLCProduct of Lightning Metal LM-16 Source: Skuld LLC Source: Skuld LLC
Heat Treat Today asked what difficulties Skuld faced in developing this technology. The development process faced several unique hurdles, such as heat retention due its small size (compared with a large furnace), as well as crafting the machine’s automation while not allowing it to be hackable.
Applications
SBIR awarded to Skuld LLC Source: Skuld LLC
The Lightning Metal LM-16 is for those without an in-house foundry. It works well for replacement parts for in-house heat treatment, for example: hooks, baskets, or rollers. The machine can also produce spare parts or be utilized for prototyping pieces that can be used by higher volume machines. The Lightning Metal LM-16 operates well at around one hundred pieces per year.
The AMEC technology eliminates machining (which reducing costs for clean machining), and drives down the cost substantially associated with cooling for lost foam. The process also avoids HIPing, reducing the need for powder bed fusion parts.
The system enables reverse-engineering for discontinued items, and could be particularly applicable for heavy equipment, agriculture, compressors, and railroads.
The Lightning Metal LM-16 deployment marks a major step in Skuld’s commercialization strategy, following over $9 million in Department of Defense contracts and successful pilot programs with the U.S. Air ForceandDefense Logistics Agency. The company was recently awarded an SBIR for additive manufacturing.
For more information on this technological innovation, please contact Adam Penna at apenna@skuldllc.com.
Atlas Holdings has announced the formation of Orion Steel following the completion of the acquisition of EVRAZ Inc. North America and EVRAZ Inc. NA Canada with their respective subsidiaries. The newly formed Orion Steel will be led by former U.S. Steel executive, Doug Matthews, who will serve as chief executive officer. Orion Steel is poised to become a central player in the North American steel market due to its focus on engineered steel products intended for rail, energy, infrastructure, and industrial.
Atlas announced the agreement in June of 2025 to acquire EVRAZ North America, a leading producer of engineered steel products in the United States and Canada for rail, energy, infrastructure, and industrial end markets. The new company, Orion Steel, includes Rocky Mountain Steel Mills in Pueblo, Colorado; Oregon Steel Mills in Portland, Oregon; and Interpro Pipe and Steel in Regina, Saskatchewan, and locations across Alberta, Canada.
Orion Steel’s website Source: Orion Steel
Collectively, Orion Steel employs 3,400 skilled associates across two electric arc furnace steel facilities, 12 steel product mills, and 17 scrap recycling facilities. They have a steelmaking capacity of 2.3 million tons and a finished steel capacity, including tubular products, of 3.5 million tons. Orion Steel products regularly contain more than 98% recycled scrap material, and Rocky Mountain Steel is the world’s largest solar-powered steel mill and the largest rail supplier in North America.
“As a well-capitalized strategic supplier, Orion Steel is poised to become a central player in the North American market, helping to ensure economic and security interests of the United States and Canada are advanced through significant, local production,” said Doug Matthews, CEO of Orion Steel. “I’ve been in this business for three decades and I am completely energized by this unique opportunity. This is a historic operation heading into a bold new chapter.
“I’ve seen the look in steelworkers’ eyes when they push an operation to new heights. We are going to see that same look from our team members across all Orion Steel facilities as we write the next chapter of this essential North American steelmaker,” added Matthews.
“Doug offers more than just decades of experience in operations, sales, marketing, and supply chain management. He brings a forward-thinking, hands-on approach that helped transform U.S. Steel’s commercial strategy and operations, and he has the deep belief that the heart of this business is the people on the ground, running the mills day in and day out — and he works to empower them to perform at their best.” Atlas Partner Sam Astor commented. “This is a critical time in the global steel market. We’re ready to meet the challenges and seize the opportunities, and we are excited to be playing a role in ensuring the long-term future of strategic steel production in the United States and Canada.”
Matthews began his 33 years with U.S. Steel rising through the ranks from plant leadership in Pittsburgh, Pennsylvania, to operations leadership as a member of the executive team.
Former CEO of EVRAZ, Skip Herald, will continue his service as a member of the Orion Steel Board of Directors.
Press release is available in its original form here.
Whether you need insight on enhancing your energy utilization, managing induction systems (troubleshooting), or prolonging equipment longevity, today’s Technical Tuesday original content feature will keep you well-informed.
Heat TreatToday has coalesced technical information across articles from key experts, including tips to improve your energy efficiency, a walk-through guide for troubleshooting your induction system, and ten practical tips for improving your equipment longevity.
Induction and Sustainability Tips Part 2: Efficient Power
As energy efficiency becomes a driving force in modern heat treating, manufacturers are turning to smarter induction technologies to cut waste and lower costs. In this second installment of Heat Treat Today’s sustainability series, explore how AC-to-DC conversion, intelligent power feedback systems, and advanced diagnostics can transform your induction heating setup into a cleaner, more consistent, and cost-effective process.
“Furthermore, transformers operate at optimal efficiency when under a reduced load – i.e., less than 70% output in steady-state heating – rather than ramping up to the full operating temperature. Another advantage of the DC-type transformer is that its operating power factor is very close to 1.0, which lowers the utility company’s calculation of peak demand surcharges.”
Facing erratic heating, poor consistency, or unexpected shutdowns in your induction system? This comprehensive guide walks heat‑treat operators through a ten‑step diagnostic framework for identifying and resolving common induction issues.
Figure 2. Induction
system components Source: Contour Hardening, Inc.
“The induction process involves many characteristics such as: position of the piece within the induction coil, load positions, cooling positions, cycle times, applied electric power, and others. It is important that the professional can identify the failure and the particular situation at the moment in which it is occurring.
On some occasions, the failures are not evident and therefore it is essential to analyze the part that has been treated. This analysis can be key to understanding situations such as poor depth due to electrical power or decrease in output frequency, among other possible scenarios.”
New and Improved Tips for Induction Equipment Longevity
Heat treaters are always looking for ways to extend the life of their induction tools, but what methods are proven maintenance strategies? Focusing on the durability of coils, bus bars, inductors, and quench components, this technical article will give you practical and reliable tips to promote longevity in your equipment.
Figure 2. Break-Away bolts designed to fail beneath the washer if over tightened
“More than coils — When working to optimize the life of induction equipment, don’t focus solely on the coils. Bus bars, inductors, and quenching equipment are also key to success.
Austenitic stainless steel — Use austenitic stainless steel for fasteners, fittings, and hose clamps, and remember, non-ferrous is the way to go.
CNC machining — Manufacturing with a 5-axis CNC machine ensures quality and consistency.
“Break-Away” bolts — For fasteners, use “Break-Away” bolts on contact surfaces. These bolts are designed to fail beneath the washer if they are overtightened, a design that prevents damage to the threaded insert inside the copper contact.”
