Enterprise software
Ailoys brings AI-powered process monitoring to IMTS 2026
Industrial AI specialist Ailoys is showcasing its Edge technology at IMTS 2026, with applications ranging from wire drawing and tube production to CNC machining.
How can manufacturers increase the productivity of existing machinery without replacing it? Berlin-based Ailoys GmbH is addressing this challenge with an industrial AI and edge computing solution designed to detect changes in manufacturing processes as they happen.
At IMTS 2026, taking place from September 14 to 19 at McCormick Place in Chicago, Ailoys is presenting its Ailoys Edge device at booth 237629. The technology uses sensors to capture high-frequency signals generated by the interaction between machines, materials, and tools, effectively working as a “stethoscope” for production equipment.
AI analyzes these signals in real time to identify changes in process behavior at an early stage. The system can then alert an operator or communicate directly with the machine PLC, allowing an approved parameter to be adjusted while production continues.
The objective is to increase output, reduce scrap, and enable longer periods of unattended operation using existing manufacturing equipment.
From wire drawing to CNC machining
Ailoys reports applications of its technology across several manufacturing processes, including wire drawing, tube production, CNC machining, and welding.
In wire drawing, the company reports production speed increases of up to 30% and a 12% reduction in die wear on an existing line. Working with a European equipment manufacturer, Ailoys uses its technology to identify material conditions that could lead to wire breakage. The system can signal the PLC to reduce line speed while the affected section passes through the machine and subsequently return to the optimized setting.
In CNC machining, Ailoys has deployed its technology at a European aerospace manufacturer. During the first three months of operation, the system helped the company avoid more than $20,000 in potential scrap by detecting abnormal process behavior and separating suspect components before additional value was added.
The technology is also being applied to tube manufacturing. At a European tube producer, Ailoys continuously analyzes signals coming from the equipment and material, learns normal operating patterns, and detects deviations at an early stage. The resulting digital fingerprint of the manufacturing process can complement existing laser and ultrasonic inspection systems.
Ailoys expands into the US manufacturing market
IMTS 2026 also represents another step in Ailoys’ expansion in North America. The company has commissioned its first US project with an aerospace tubing manufacturer in the Philadelphia area and reports multiple rollout commitments with manufacturers in the Midwest.
The company began developing these relationships at US manufacturing trade shows in 2025 and has since established operations in the United States and joined the German American Chamber of Commerce of the Midwest.
“The United States has an enormous installed base of high-quality manufacturing equipment and a clear need to increase domestic production without rebuilding every factory from scratch,” said Sergei Altynbaev, founder and CEO of Ailoys. “Our proposition is simple: keep the machines that already work, add real-time process intelligence and give them the ability to respond before a small deviation becomes expensive scrap.”
Visitors to IMTS 2026 can meet the Ailoys team at booth 237629 to discuss production bottlenecks and explore applications of acoustic AI for existing manufacturing lines.
