

FireFly Automatix dates to 2008 when co-founder Steve Aposhian and a small group of fellow mechanical engineers decided to fabricate replacement parts for the sod harvesters used on Aposhian’s family’s turf farm in Salt Lake City. The parts were of such high quality that they began selling them to other sod farms, some of which encouraged them to build their own complete harvesters.
In 2011, Aposhian and his engineer buddies quit their day jobs and jumped into manufacturing of sod harvesters, but not the same-old-same-old.
"We were the first to implement a lot of electric technology on a piece of mobile equipment like this," said Aposhian in a recent TurfNet podcast interview with Dave Wilber and Peter McCormick. "Traditional machines used hydraulics and traditional control mechanisms. My background as a mechanical engineer is in automation, so we implemented a lot of factory-type automation on a sod harvester. Since then we've become the largest producer of automated turf harvesters in the world."
The Black Desert Championship launched the AMP L-100 into the industry limelight. Mark LeBlanc started with FireFly Automatix six years ago, doing mechanical design on those sod harvesters.
"Sod being an adjacent industry to golf, and knowing that a lot of our customers provide sod to to golf courses, we always envisioned ourselves expanding into that market," LeBlanc said in the podcast interview. "After a couple years Steve gave me a team and a blank board and said, go design an automated fairway mower."
LeBlanc's design team started by looking at what was out there in autonomous mowers at the time, and of course there was nothing other than early prototypes.
"We wanted to make an autonomous mower, but we didn't want to just make a fairway mower that's autonomous," LeBlanc said. "We decided to make the best fairway mower on the market from the standpoints of cut quality, drive system, and operational efficiency. Let's just make it as good as we can make it, and incorporate autonomous technology in the process."
Eliminating a combustion engine and operator station opened up design freedom for FireFly Automatix engineers. LeBlanc and his team started with a blank sheet of paper and redesigned a mower platform without a conventional combustion engine and operator station.
"When we took those two pretty big design constraints out of the equation, we realized that to make the best mower on the market for fairways, it would have to be electric. Designing it from the ground up to be autonomous gave us the design freedom to go back whenever we needed to and change the way things worked mechanically and electrically to better support the autonomy," he said.
Within three months they had a working prototype, but that was just the beginning. After mowing with it manually for a few months, they made it autonomous using software that they had developed for a previous, larger mower.
"We went back to the drawing board, erased the whole thing and started over. We took everything we didn't like about the first prototype and designed another one, and then we did that three more times. So, here we are."
Drive and control systems are one thing, but golf course superintendents want to know about the cutting units, where the mower meets the grass.
"The big mower companies have done a lot of homework for us," LeBlanc quipped." We didn't ignore all of the great things that they've done in the world of cutting units. But we saw some things that we thought that we could improve on. So we took a stab at designing one ourselves that that could make the the job of the mechanic easier, that could make the the job of the superintendent easier, and that that could make the course look better."
Simple knob HOC adjustment and locking down the bedknife and adjusting the reel to it simplify life for the mechanic and superintendent. LeBlanc and his team developed a simple hand knob adjustment where height of cut can be standardized across all cutting units in 45 seconds.
"We know that because our parts are designed and machined in a certain way that if we make the same number of clicks on both sides of the cutting unit to adjust that height, the cutting unit is still square," LeBlanc said.
Geometry of the bedknife within the cutting unit also came under scrutiny. The FireFly design locks the bedknife down and adjusts the reel to it, again with a hand knob and .00065" adjustment per click.
"We designed our cutting unit to lock the bedknife down in a really rigid way to make sure that bedknife never moves. And it's always square, and it's always as flat as possible, and there's no flex in that system," LeBlanc said. "We have gotten feedback from our customers that the bedknives hold their adjustment a lot longer and don't have to be adjusted as often."
Even with a current price tag of $160,000, the operational efficiencies of the AMP L-100 contribute to an ROI as low as two years or even lower in some cases. Efficiencies in capital expenditure, maintenance costs, energy and labor costs all contribute.
What's the lead time for one ordered today? "About 60 days," said Steve Aposhian.
Watch or listen to the complete conversation here or on Spotify or Apple Podcasts.
- Read more...
- 2,568 views