NDA Protected Application
Epoxy Encapsulation for Industrial Electronics and Controls
Executive Overview
Kirkco engineered an epoxy encapsulation architecture for industrial electronic and control assemblies requiring stable electrical performance, environmental protection, and long-term reliability in demanding operating conditions. The architecture applies proven encapsulation quality principles to ensure consistent results across production programs.
Business & Quality Drivers
Industrial control manufacturers face reliability expectations driven by uptime requirements and warranty exposure. Variability in manual potting processes introduced risks related to voiding, inconsistent cure, and thermal stress. A controlled encapsulation architecture was required to stabilize quality and reduce lifecycle risk.
Process Requirements
The application required two-component epoxy encapsulation with controlled ratio management, stable material temperature, defined shot volumes, and repeatable fill behavior across multiple enclosure geometries.
System Architecture
The encapsulation platform utilizes precision metering and mixing equipment with temperature-conditioned material handling. Point-of-application mixing minimizes residence time and supports void-free encapsulation across varying part sizes.
Controls & Validation
PLC-based controls manage recipe storage, ratio monitoring, automated flushing, and process interlocks. Defined process windows were validated to ensure consistent encapsulation quality across production runs.
Encapsulation Quality Framework Alignment
This application is executed within Kirkco’s encapsulation quality framework, which standardizes ratio stability, thermal control, void mitigation, and process validation across encapsulation systems. For a system-level view of how encapsulation quality is engineered across applications, reference: Encapsulating Quality – Application Architecture (Rev C).
Operational Performance
The architecture reduced rework, stabilized encapsulation quality, and minimized operator dependency while supporting predictable production throughput.
Lifecycle & Scalability
Designed for long-term service, the system supports future material changes, additional recipes, and throughput increases without architectural redesign.
Adhesives & SealantsTwo-Component Adhesive Metering & Mixing Systems