Bullen Ultrasonics specializes in the precision machining of advanced ceramic components. We serve global companies in the Aerospace, Automotive, Life Sciences, Medical, MEMs, Telecommunications, and Semiconductor industries. Due to the variety of parts, machining challenges, and materials we work with, we have developed custom, precision machines to exceed customer expectations. Many customers turn to us because traditional machining methods cannot meet their material and feature requirements. Our specialized processes and machines enable us to offer high-quality solutions that may reduce long-term costs. 

Since not many companies meet the niche need that we’re able to provide through our unique solutions for hard and brittle materials, I want to dive deeper into the need, challenges, and trends for custom machines and explore the unique process that enables us to provide successful outcomes for our customers. 

Understanding Custom Machines in Manufacturing 

Custom machines fill unique market gaps where off-the-shelf machines fall short. The need arises when commercially available options lack efficiency or functionality. Businesses may adopt custom machines to reduce costs, automate manual tasks, or make unique products viable. Some companies offer custom off-the-shelf machines by modifying standard machines for specific applications, but fully custom machines are designed from the ground up for a specific product. 

Not one solution fits all when a new customer comes to the table. Unlike mass-produced solutions, custom machining requires flexibility. Each new request brings unique needs, and the machines they use are generally only of interest to that company for that specific product. The number of machines created is defined by the needs of that one customer. At Bullen, we let our customers drive the solution, avoiding restrictive designs that could limit efficiency. Our proprietary machining solutions maximize flexibility to meet diverse requirements. 

The Need for Custom Machines 

Why invest in custom machines? 

• Fill Technology Gaps in the Industry – Off-the-shelf and custom off-the-shelf machines do not meet every need. 

• Address Skill Gaps in the Workforce – Automation replaces specialized manual tasks that are difficult to staff. 

• Enhance Safety – Custom machines reduce dangerous or repetitive manual processes. 

• Efficiency & Cost Savings – Optimized machines streamline production, lowering costs over time. 

• Precision & Quality – Custom solutions provide higher accuracy than general-purpose machinery. 

Companies often use a combination of custom and commercially available machines to meet their unique needs. They may do this by starting with manual assembly and later investing in custom machines to improve efficiency. While custom machines are less versatile than commercial machines since they were created for specific uses, the advances they provide to different industries can make them worth the investment, especially in high-volume production cases. For example:  

• Aerospace & Automotive: Custom machines handle heavy components, precisely place delicate parts, and speed up assembly. 

• Medical Field: Automation accelerates diagnostics, enables non-invasive imaging, and supports robotic surgery. 

• Consumer Goods: High-volume products like food, beverages, and toiletries benefit from improved consistency and output. 

At Bullen, our customers face challenges that can no longer be accomplished effectively with traditional precision machines, which has led us to build custom, precision machines. Bullen has roots in ultrasonic machining, and we have adapted that technology to create custom machines to meet our customer’s needs. With our added capabilities in robotics, our development of new laser machining methods, and conventional machining and grinding, we’ve made it possible to bridge gaps that were close to impossible to cross before. 

The Process of Building Custom Machines at Bullen 

When considering new projects, we look at multiple key factors: 

1. Evaluation: Assessing customer print and its corresponding features, manufacturing challenges, quality requirements, and future production volumes. 

1. Feasibility: Reviewing the project parameters and expected production timeline in relation to available technologies, production capacity, and complexity of start-up. 

1. Cost & Efficiency: Ensuring competitiveness in the marketplace. 

1. Quality: Determining if our processes meet customer requirements. We are AS9100 and ISO 9001 Certified and Compliant with IATF 16949 standards, ensuring we generally meet or exceed the quality standards our customers provide. 

Each project includes material selection, budget constraints, and quality goals driven by market demands and production volume. 

Development Phases 

• Design For Manufacturing (DFM): Our highly qualified engineers discuss opportunities to improve manufacturability of the product with the customer. They work with other teams in our facility to develop goals, ensure quality, and design for manufacturing/assembly discussions related to the process itself. If this step is conducted well, a manufacturer can reduce production costs, improve quality, and accelerate time-to-market. 

• Proof of Concept (POC): Our team approaches projects with the fail fast methodology by testing ideas early and often. We pay attention to next-level ideas that could change our approach. Sometimes these ideas could have risk associated so we conduct proof of concept tests for evaluating and eliminating those risks. When we’re working on the design, we model in CAD and use computer-aided engineering tools to simulate these ideas when possible. To continue reading about why POCs are used to mitigate risks, read the section labeled “Technical Uncertainty” below. 

• Design Phase: The design phase is where we create the final plan for building the custom machine and process. This tends to be an iterative process, but we take the time to make sure we consider all the failure modes before we make the first piece. Getting more eyes on the design helps us get there. During design reviews, we ask, “How can this design fail?” We need to ask this question in terms of safety, quality, robustness, efficiency, repeatability, ergonomics, material flow, plant layout, and ROI.    

• Material Planning: We develop a bill of materials (BOM) that lists the raw materials needed for the custom machining process as well as any pre-made, off-the-shelf components that need to be purchased. A print package is generated and given to our in-house machine shop for all the custom pieces that go into the special machine. Safety-related provisions and spare parts lists are also being documented during this phase. 

• Machine Build: After receiving all components needed and preparing for assembly, our team can assemble the machine. Our machines have complex mechanical and electrical systems that control the machining process and Bullen is fortunate to have experienced technicians during this phase that take extra care of how the machine is built. 

• Testing/Debugging: Custom machines need an adequate testing period to ensure everything functions as it should. We often call this step debug because we want to do our due diligence to make sure there are no underlying issues that could arise after turning the system over to production. 

•  Final Run-Off – The equipment gets qualified by both our internal team and the customer to check its capability, run at rate, first article, etc. 

• Training & Documentation: We fully train personnel using safety procedures and operating procedures and review preventative maintenance schedules. 

Then, the production team will be free to ramp up to full production. If you have questions about our processes or solutions, you can reach out to our sales engineers at sales@bullentech.com  

Challenges and Considerations 

Initial Investment 

Custom machines often have high upfront costs, making justification to stakeholders challenging. However, the long-term benefits—efficiency, quality, and cost savings—can outweigh the initial expense. 

Technical Uncertainty 

Since custom machines are unique and may even be the first of their kind, designers may have to prove in advance if the machine design is possible.  This is done through developing a simple mockup version or proof-of-concept (POC) to lower the risk of failure in the end. While POCs mitigate risk, they are often limited by budgets and timelines. Working with experienced designers minimizes uncertainties and ensures success. The more unknowns a design has, the greater the risk. That’s why it is so important to ensure you have a designer with the necessary experience and skill set for your project. 

Maintenance & Upkeep 

Custom machines include both proprietary and purchased components. Over time, parts may wear out or become obsolete for a variety of reasons. For example, a special sensor might be required but will that sensor still be in use five years from now? What happens if the manufacturer of that sensor decides to discontinue it? There can be hundreds of such components in a special machine.  

A good machine designer needs to be able to foresee these things and create preventative maintenance guides along with a list of key spare parts. They may pay special attention to selecting components with long-term availability or recommend that a greater number of spare parts be purchased for items that may be hard to come by in the future to mitigate risks and last the life of the machine. 

Bullen gleans an interesting benefit from designing its own machines. Our designers get to build on past experiences. The machines that have been designed in the past are out there on our floor running production every day. The opportunities to improve become evident from shop floor uptime data, maintenance issues, quality statistics, ergonomic issues, and a slew of other feedback factors. Each new stride we take is not the last step but rather another stride in our constant drive to be better.   

Future Trends 

Technological Advancements 

Artificial intelligence (AI), the Internet of Things (IoT), and automation are shaping custom machinery. While these advancements can drive change and bring industry growth, they can be a challenge because engineers need to learn how to apply these technologies and get distance from their paradigms. AI can be used on shop floors to take in data and sort through, recognize patterns with, and make predictions for machine efficiency, schedule optimization, machine failures, and preventative maintenance. Tools for AI like machine learning and deep learning can potentially drive more understanding of the process so downtimes can be avoided and/or planned. It could show opportunities to control manufacturing variables that drive part quality or overall efficiency.  

IoT connectivity enhances real-time monitoring and performance tracking, creating a more connected facility. At Bullen, we embrace Industry 4.0, integrating digital technologies to boost productivity. 

Hybrid machining—combining additive and subtractive processes—further expands design possibilities. This equipment allows for parts to be machined layer-by-layer, using methods like 3D printing to add material to a component and methods like drilling or other forms of traditional machining to remove material. Utilizing this technology reduces machining costs and broadens feasible design options. 

Industry Experience & Insights 

Having worked in special machine design since the early 1990s, I have seen economic trends directly impact the demand for custom machinery. Employment rates, onshoring and offshoring, and supply chain disruptions influence automation investments and the volume of custom machines needed.  

Innovation is also a driver that affects machine automation in a positive feedback loop. Sunil Ranka at Forbes (2024) puts it like this, “Automation can trigger innovation by freeing up resources and providing data and insights, while innovation can serve as a spark for automation by leading to the development of new technologies and tools…Companies that invest in automation will be able to cultivate a culture of innovation and advanced thinking that would allow them to be better equipped to respond to the changes in their industry and scale their operations.” 

American Global talent explores this further in one or their 2024 articles stating, “By incorporating artificial intelligence and machine learning, industries can create intelligent innovation in automation that goes beyond following pre-programmed steps. Imagine self-optimizing algorithms in manufacturing that constantly refine production processes based on real-time data, or AI-powered design tools that assist engineers in creating innovative products by learning from past successes and failures.” 

These insights highlight the dynamic relationship between automation and innovation—one fueling the other in a continuous cycle of advancement. As economic factors shape investment in custom machinery, technological progress ensures that automation is not just about efficiency but also about adaptability and growth. Companies that embrace this synergy will not only navigate industry shifts more effectively but also drive the next generation of manufacturing intelligence. 

Top 3 Predictions 

1. Increasing Demand for Custom Machinery: Complex product designs and the desire for increased efficiency will sustain demand. 

1. Laser Technology Disrupting Traditional Machining: Our team has spent years working to develop an entirely new method of laser machining that we have named MicroLucentⓇ. If you’re interested in learning more, check out our article about it or view more information on the parameters associated with it on our MicroLucentⓇ page. 

1. AI Development in Coding: Smarter machines will enhance production intelligence and responsiveness to plat machinery and automation.

Custom machines, precision machines, and robotic machine tending will continue to drive innovation and efficiency for numerous industries. If you have a unique need and have considered custom machine options but have not found what you’re looking for, we may be able to create a unique solution for you. When you engage with our team, we promise to be upfront and provide a clear path to your production. If we’re not the best fit, we’ll help point you in the right direction.  

If you’re interested in learning more about our custom, precision machining solutions, you can reach out to our team via our contact form or email us at sales@bullentech.com with information about your project.      

Eric Norton 

Research and Early Innovation Manager, Bullen Ultrasonics 

 

Sources: 

Fortune Business Insights. (2025, January 6). Industrial Automation Market Size, share: Growth

report [2022-2029]. Industrial Automation Market Size, Share | Growth Report [2029].

https://www.fortunebusinessinsights.com/industry-reports/industrial-automation-market-

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How Innovation in Automation is Shaping the Future? American Global Talent. (2024, April 29). https://americanglobaltalent.com/innovation-in-automation/#:~:text=Automation%20is%20not%20just%20about,next%20generation%20of%20groundbreaking%20ideas. 

Precedence Research. (2025, January 22). Industrial Automation market size to surpass USD

569.27 bn by 2034. Precedence Research. https://www.precedenceresearch.com/

industrial-automation-market  

Ranka, S. (2024, August 13). Council post: How automation cultivates a culture of innovation. Forbes. https://www.forbes.com/councils/forbestechcouncil/2023/04/13/how-automation-cultivates-a-culture-of-innovation/