The Challenge: A Precise Process Done by Hand
The manufacturer applies clear primers to large panel components ahead of assembly. The rectangular panels vary in size, and the application calls for very specific primer widths. Staff completed the process by hand for nearly a year.
Manual application wasted material and led to inconsistency in the primer lines – the kind of variability a precision manufacturing process can’t absorb. It also required a lot of skilled labor. The manufacturer began looking for a better way to apply the primer and sought fluid application expertise.
A Direct Line into a Typically Guarded Industry
Working in aerospace and defense usually means working through an intermediary. Designetics has previously supported aerospace-related applications through defense contractors who couldn't share much detail, even with an NDA in place.
"When a customer can only give you vague information about where a part is going or how it's used, it's often a real challenge to come up with the right solution."
–Gilbert Duran, Regional Sales Manager
This project was different. Once the NDA was signed, the manufacturer went further, sharing detailed information about their process, equipment and goals. That transparency allowed us to address the engineering challenge instead of guessing at requirements.
One Process Becomes Five
The manufacturer operates two manufacturing facilities, and our relationship started small with a single manual application at one location. Our team brought custom applicator tips to the facility for on-site testing, and the results were immediate, so we expanded our scope.
What began as a conversation with one process engineer grew into collaboration with five, spanning multiple processes at both facilities. Each engineer presented a different application challenge, which became an opportunity to learn more about how the manufacturer built its products.
Building the Solution: Dispensing Equipment and Custom Applicator Tips
Designetics built a dispensing system, and our team will install the equipment and run testing with applicator tips developed specifically for the aerospace industry. The manufacturer’s engineers will oversee setup and initial testing, instead of working through it on their own. Rather than relying on years of aerospace precedent, the solution was built around what the manufacturer's process required.
A Relationship Built on Trust, Not a Sales Pitch
One of the manufacturer's process engineers had prior experience with our products in another industry. Their confidence in the quality of our services helped move the relationship forward.
“At this point, you don't even have to sell me your product. I know your product. You have quality, and you know what to do.”
– Manufacturer process engineer
That level of trust carries weight. Designetics has built long-standing partnerships across other industries, and engineers who move between companies and sectors bring that history with them. It’s a reminder that a track record built in one industry can open doors in another.
A Team the Customer Can Count On
As the relationship grew from one contact to five, the manufacturer started seeing us as part of their team instead of a contractor. Every account manager has engineering support behind them, so if someone isn’t available, another team member can step in without the customer losing momentum or repeating themselves.
That structure matters most when a project is moving quickly, as this one did. Consistent, responsive communication has helped solidify the manufacturer's trust in our partnership.
The Result: Less Waste, More Consistency
According to one of the manufacturer's process engineers, the new approach improved their process by 100%, cutting material waste and adding a level of consistency the manual method couldn’t deliver. As on-site installation and testing move forward, the manufacturer is applying the same solution in different processes and facilities.
A New Industry, a Proven Approach
Designetics didn’t need years of aerospace-specific experience to solve this problem. The approach starts with discovery and understanding a customer's procedures before recommending a fix. That’s what continues to grow the partnership today. Branching into new industries is a deliberate part of how our company operates.
Have a fluid application challenge in a new or unfamiliar industry?
Contact our team to start building a fluid application solution that fits your specific requirements.