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New Wave | Hugo Rauch | Substack

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🌊 The Invisible Problem Inside Every Factory

Why advanced manufacturing is still wildly inefficient — and how real-time sensing could unlock the next wave of climate tech.

We’re joined by Jared O’Leary, Co-founder of SirenOpt, a deep-tech company building real-time sensing systems for advanced manufacturing.

In this episode, we dive into why even the world’s most advanced factories operate with massive hidden inefficiencies, and what it really takes to move toward autonomous, self-optimizing manufacturing for climate technologies like batteries and beyond.

In our conversation, we covered:

→ Why manufacturing is inherently probabilistic, and why every product exists on a distribution of quality

→ The hidden cost of variability in battery factories, including massive scrap rates and conservative processes

→ Why “98% yield” doesn’t actually mean what people think

→ How missing data inside the manufacturing line creates huge blind spots

→ Why real-time sensing is the missing layer for Industry 4.0 factories

→ How cold plasma sensing works, and why it enables non-destructive measurement at millisecond speed

→ Why better manufacturing could unlock next-generation batteries like solid-state

Without the ability to manufacture advanced materials reliably, even the best lab breakthroughs never scale.

📬 Reach out to Jared O’Leary: [email protected]

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