NDA Protected Application
Epoxy Encapsulation for High-Reliability Connectors
Executive Overview
Kirkco engineered an automated epoxy encapsulation architecture for a European manufacturer of high‑reliability connectors used in mission‑critical medical, military, instrumentation, and broadcast applications. The solution replaced a legacy polyurethane process with a higher‑viscosity, environmentally improved epoxy system while increasing consistency, quality, and automation throughput.
Business & Quality Drivers
The customer required vacuum‑sealed and IP68‑rated connectors where performance integrity is non‑negotiable. Failure risk directly impacts safety‑critical systems, driving the need for precise volumetric control, repeatable shot accuracy, and controlled material conditioning.
Process Requirements
The application required six discrete metered shot sizes ranging from approximately 0.07 ml to 0.8 ml. Multiple precision fixtures were integrated to hold connector variants while a three‑axis robotic system positioned the dispensing valve and static mixer for fully automated filling.
Material & Chemistry Considerations
The encapsulant was transitioned from a lower‑viscosity polyurethane to a two‑component epoxy resin with a mix ratio of approximately 100:90. Although more environmentally favorable, the epoxy introduced significantly higher viscosity and tighter thermal stability requirements.
System Architecture
The dispensing platform is based on a precision micro‑metering and mixing system configured for epoxy processing. To maintain process stability, the complete material path is temperature‑controlled, maintaining resin temperature between 50°C and 60°C throughout metering, mixing, and dispensing.
Automation & Controls
The system integrates robotic motion control with synchronized metering, valve actuation, and shot selection logic. This architecture enables rapid program changes across connector variants without mechanical reconfiguration.
Performance Outcomes
The upgraded encapsulation architecture delivered measurable improvements in product quality, shot‑to‑shot consistency, and process repeatability while simultaneously supporting environmental objectives through material selection and waste reduction.
Lifecycle & Engineering Support
Kirkco supported system validation through factory trials, application tuning, and commissioning. Ongoing support includes process optimization, material change evaluation, and automation scalability.
Adhesives & SealantsTwo-Component Adhesive Metering & Mixing Systems