Accurate and reliable potting for automotive lighting

To support Venta Global with the efficient potting of PCBs for a high-power outdoor LED light, Intertronics supplied the IRS 3078 polyurethane potting compound and the 2-K-DOS metering, mixing and dispensing system.

The solution enabled a straightforward process that provided the required repeatability and accuracy, with reduced cost per gram of material due to bulk packaging.

Venta Global is a tier one supplier of lighting solutions to vehicle and machinery manufacturers, offering a complete service from custom design, to delivery. It has made significant investment into new technology for its UK production facility in Hampshire that deskills processes to enable consistent and reliable results, removes inconsistencies due to operator variance, and allows future scalability.

The company required a potting compound which could adhere to their choice of substrates and provide a seal to protect against environmental contaminants and water ingress. Venta Global discussed the requirements of the project with Intertronics, who they had previously collaborated with on a gasketing project.

Intertronics recommended that Venta Global trial the adhere IRS 3078 polyurethane potting compound, a semi-rigid, room temperature curing, electrically insulating black material. Its low viscosity meant it could flow into all required areas of the product and its 1:1 mix ratio makes dispensing it, or automating the dispensing process, simpler

To dispense the material, Intertronics recommended the 2-K-DOS, which can accurately meter, mix, and dispense all in one system. The 2-K-DOS is programmable from a simple control panel, and users can set mix ratio, dispensing rate, and dispensed quantity to provide consistent, error-free metering, mixing, and dispensing. The system is designed with a unique modular approach, and Intertronics built it custom to the material and process, with appropriate material reservoir sizes and dispensing hose lengths.

“A commercial advantage of the 2-K-DOS is that Venta Global could benefit from the cost savings of 5 kg bulk kits of IRS3078, over the 50g side-by-side cartridges that had been used initially for testing, further reducing the payback period,” said Matthew Baseley, technical sales executive at Intertronics.

“In addition, the 2-K-DOS eliminates the need for time intensive, manual processes like weighing and mixing. The system can also be simply reconfigured to work with robots or further automation, should Venta need to increase positional accuracy in future.”

Roderick Dible, production manager at Venta Global, said: “We’ve had the machine for over a year now, and it has been running perfectly. At the touch of a button, we can dispense a fully homogeneous mixed and metered shot exactly where it’s needed. The Intertronics team were on hand to support throughout, and we benefitted from their technical knowledge, support, and responsiveness. This coupled with the commercial support means I am sure it will not be our last collaboration.”


Station Field Industrial Estate
Banbury Road

+44 (0)1865 842842

More news
5 days ago
Southco launches a new wireless access system with the Keypaniontm app
Southco has launched a new wireless access system featuring the Keypanion app, a revolutionary smart access app that lets users wirelessly actuate latches from their smartphones.
6 days ago
Food Manufacturing Live – May 1st 2024 – National Motorcycle Museum
Specialist engineering publisher and exhibition organiser The Engineering Network (TEN) has just announced an all-new event for suppliers of engineering solutions to the food and drink manufacturing sector, Food Manufacturing Live.
1 week ago
Essentra’s Kidlington site switches to 100% recyclable packaging
Essentra Components has completed the switch within its UK manufacturing and distribution centre in Kidlington to using paper-based packaging. The new packaging contains recycled content and is widely recyclable after use, supporting both its own and its customers’ ambitions for a more sustainable future.
1 week ago
Intertronics launches adhesive and dispensing technology seminars
In a bid to help grow the adhesives, dispensing, and curing technology knowledge base of British manufacturing companies, Intertonics is offering seminars for customers under the adhere academy brand.
2 weeks ago
Coloured super glue enables automated QA in optical component assembly
A manufacturer of optical components was faced with an assembly challenge, needing an adhesive not only that could be applied around the complete diameter of the part, but one which also contained a pigment such that the application of the adhesive could be checked by camera before the next stage of the process. For a solution, the company turned to Advanced Adhesives.
3 weeks ago
Intertronics becomes UK distributor of Scigrip adhesives
Adhesives supplier Intertronics has partnered with Scigrip to distribute its methyl methacrylate structural adhesives (MMAs) in the UK.
3 weeks ago
SD Products now official UK distributor for King Slide
SD Products has announced an exciting new partnership with King Slide, Taiwan’s leading furniture hardware manufacturer. With over 30 years of experience in their industry sector King Slide has earned a strong reputation and trust among leading tech companies as well as high-end home furniture and appliance brands.
4 weeks ago
RS celebrates Formula Student team successes at milestone event
RS is celebrating the award-winning success of three of the teams it supported at the recent UK Formula Student 25-year milestone event. Sixty-one teams subjected their single-seat race car prototypes to rigorous testing at Silverstone race track in Northamptonshire, in the annual challenge organised by the Institution of Mechanical Engineers (IMechE).
1 month ago
Rolec enclosures get special mention in German Innovation Awards
Rolec’s aluDOOR industrial electronic enclosures have gained a Special Mention in the German Innovation Awards. Judges praised the “high added value for users”.
1 month ago
Live webinar to demonstrate LOCTITE value in assembly automation
LOCTITE is hosting a live webinar on 26 September at 11.30 am, focusing on its equipment assembly automation solutions for various market applications.

Login / Sign up