Intertronics has successfully assisted an electronics manufacturer in the motorsport industry by automating encapsulation processes, which has resulted in the elimination of product scrap rates.

Streamlining Manufacturing Processes

Driven by the need for smaller components and tighter tolerances to achieve quicker lap times, motorsport manufacturers are upgrading their processes. An electronics manufacturer faced limitations with manual bonding and encapsulation, reaching its throughput and repeatability ceiling. Partnering with Intertronics, the company transitioned to automated dispensing and controlled UV curing, greatly enhancing production efficiency and consistency.

Addressing Challenges in Production

The manufacturer specializes in custom LED lighting and displays for top-level motorsport. As demands for lighter, smaller products grew, limitations in their encapsulation process became apparent.

“The bonding and encapsulation stages were heavily reliant on specifically skilled individuals, meaning our business model was vulnerable to disruption and limited from expanding,” explained the company’s managing director. “In our silicone potting step, around ten percent of products had to be scrapped due to human error. The impact on profits led us to seek Intertronics’ help in summer 2020.”

The partnership began with a demonstration and subsequent purchase of a three-axis dispensing robot from Intertronics’ Technology Centre in Oxfordshire. This robotic system can position adhesive within five microns and achieve dispensing accuracy of 99.9 percent.

“It became clear that the focus should be on consistently dispensing adhesive meeting the customer’s repeatability and accuracy requirements,” said Darren Rea, Lead Sales Specialist.

“Automating that process allowed the customer to remove operator error and reach their repeatability targets,” Rea continued, highlighting the benefits of standardized adhesive volumes and controlled flow rates.

Successful Outcomes from Automation

Six years post-engagement, Intertronics has supplied multiple robotic dispensing systems and bonding materials to the manufacturer. This collaboration has led to a stronger business model, improving profitability and operational efficiency.

“The simplicity that these robotics bring to the manufacturing process allowed us to outsource previously specialist work, like PCB assembly, making our expansion organic and natural,” stated the managing director. “The encapsulation step that once had a ten percent scrap rate has now achieved 400-500 cycles with zero waste.”

For more insights into how automated dispensing systems have enhanced the manufacturer’s business, read the complete case study on the Intertronics website here. Additionally, you can meet the Intertronics team at Robotics and Automation 2026 on June 16 and 17 at the MTC, Coventry.