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Industry Background
Interconnect systems such as switches, connectors, sensors, and harnesses are essential to modern automotive electronics, enabling real-time data transmission for control, safety, and performance. Exposed to harsh environments, these components require robust protection to ensure long-term reliability. Potting with two-component (2K) epoxy adhesives is a widely adopted solution, offering excellent resistance to moisture, dust, vibration, and thermal cycling.
However, precise dispensing of 2K epoxy adhesives pose technical challenges, including strict mixing ratio control, mixing, and dispensing within its pot life. Addressing these factors is crucial to maintaining the durability and functional integrity of components being potted.
Potting Application in Switch Harness
Customer Introduction
A leading automotive interconnect systems manufacturer in Chennai is into the business of producing Automotive switches and harnesses for vehicle applications. To ensure long-term performance in harsh outdoor environments, they used a two part epoxy adhesive for potting which was supplied by their supplier in a 20-litre plastic pail.
Understanding the Problem
Because the epoxy was supplied in a large bucket the manufacturer faced critical challenges in their assembly process due to small size and intricate geometry of parts that needed to potting areas. The manual methods of transferring into small containers, measuring, mixing and dispensing the adhesive were proving inadequate, leading to significant inconsistencies and material waste.
Challenges faced:
ADoST Solution
Seeking improvement, the company partnered with the ADoST team, who introduced the ADoST CDS PRO—a semi-automated Cartridge dispensing system designed for accurate and consistent epoxy potting in small parts. This innovative solution replaced manual mixing and dispensing processes by enabling bulk epoxy adhesive to be transferred into 400ml dual cartridges and dispensed with precision.
The implementation of ADoST CDS PRO significantly improved production efficiency, eliminated human error, and reduced adhesive wastage, ensuring optimal fill in every sensor and switch.
Most importantly, it enabled the customer to maintain consistent quality across batches, enhancing the reliability of their critical automotive components while optimizing material usage and production costs.
Customer Experience
Prior to the implementation, the customer conducted a full-day production trial run using the ADoST CDS PRO system with epoxy-filled 400ml cartridges. The results exceeded expectations—dispensing was accurate, clean, and repeatable, even in small potting cavities.
From the initial discussions to on-site support, the ADoST team worked closely with the customer to understand their process, challenges, and production needs. The team not only delivered a reliable dispensing solution but also ensured that the ADoST CDS PRO could be seamlessly adapted into the customer’s production line.
Recognizing the significant improvement in quality, efficiency, and material usage, the customer approved the deployment of the ADoST CDS PRO on assembly setup, making it a standard solution for all future potting applications.
Potting with ADoST CDS PRO ensures controlled, accurate, precise, and neat adhesive dispensing.
Conclusion
By adopting the ADoST CDS PRO, the customer transformed their potting process from a manual, error-prone operation into a streamlined, reliable, and efficient workflow. The ability to handle bulk epoxy by refilling it into 400ml cartridges gave them flexibility of application and a low cost metering system without compromising precision. With accurate metering, consistent mixing, and controlled dispensing, the system not only improved product quality but also helped reduce material waste and operational costs.
