The Constraint: Clean It Without Stopping It
Manually wiping down each machined component would have required pulling units off the line, cleaning them and reintroducing them. That process simply couldn’t keep pace with production demands. The solution had to be in-line, meaning it had to clean the surface as the component moved through the assembly process without disrupting line speed or sequencing.
The manufacturer partnered with an equipment integrator to design the system, and that integrator brought in Designetics to solve the applicator side of the equation.
“They couldn’t take the component offline at any point, wipe it all down manually, and then push it back into the line. The solution had to work within the existing process.” -Jeff Schnapp, Regional Sales Manager
The Engineering Challenge: Surfaces That Destroy Standard Applicators
Designing an applicator for this application came with an immediate obstacle. The machined surfaces, while smooth in the critical interface area, still had rough edges from nearby upstream manufacturing processes. A traditional felt applicator — the standard choice for surface preparation — would have been shredded on the first pass. With production volumes at scale, an applicator that only survives one use isn’t a solution.
Designetics worked alongside engineers from the equipment integrator and the manufacturer’s assembly facility to develop an applicator that could withstand surface conditions while effectively performing the cleaning function. Testing was conducted at the Designetics facility, where engineers evaluated multiple applicator configurations and fluid delivery approaches. The manufacturer’s engineering team visited Designetics during this phase and participated directly in the evaluation process.
The result was a custom brush applicator, developed specifically for this application, with bristle firmness designed to displace oil and lift metal particles without compromising the surrounding surface geometry. The part design was modified in the process to optimize brush performance.
The Solution: A Turnkey, Palletized Cleaning Cell
The final system was built around a palletized cell: a self-contained unit that could be positioned line-side, taking up roughly 6 to 8 feet of floor space. It required no major fabrication to the existing line and could be moved, repositioned or redeployed to another facility without significant reconfiguration.
The Designetics components integrated into the cell included:
- Pumping system for fluid delivery
- Spring compliance mechanism to control the applicator's downward force
- Applicator track for consistent positioning
- Custom nylon brush applicator for surface cleaning
Every component was engineered to work together, simplifying integration for the equipment integrator and reducing the risk of compatibility issues between system elements.
“Initial concept discussions to a manufactured, ready-to-deploy system took approximately eight months to a year – including trials at the Designetics facility, iterative testing at the integrator’s site and the manufacturer’s internal approval process.” -Jeff Schnapp, Regional Sales Manager
The Results
Prior to implementing the cleaning cell, the manufacturer’s assembly line saw a defect rate of approximately 3%. At scale, that figure carried significant weight: teardown and rework costs, component waste and brand exposure from products reaching customers with assembly-related defects.
After the system was implemented, the defect rate dropped to approximately 0.2%. The improvement was significant enough that additional units were ordered for other facilities, not just within the manufacturer’s own assembly plants but also at the tier-one suppliers responsible for die-casting and machining the machined components before shipment.
The system is now operational at approximately eight manufacturing facilities in the United States and Canada, with additional installations underway in the United Kingdom and ongoing interest from suppliers across North America.
Beyond This Application
Designetics has built its reputation on fluid application: precisely delivering lubricants, sealants and coatings to surfaces in demanding production environments. This project represents an extension of that expertise into surface preparation and cleaning.
The underlying engineering is the same: controlling how an applicator interacts with a surface, managing fluid delivery and designing for durability at production speeds. Whether the goal is to put something on a surface or to ensure it’s clean before something else goes on, the core challenges — consistency, durability, and inline compatibility — are ones Designetics is built to solve.
For manufacturers in automotive, heavy equipment, marine, or any industry where assembly cleanliness affects downstream quality, this capability is now part of what Designetics brings to the table.
Have a surface preparation or fluid application challenge on your line?
Contact us to talk through your application. Our engineering team works directly with manufacturers and equipment integrators to develop solutions that fit within your existing process without stopping the line.