bfksolutions.com

Mixed substrates include

• complex assemblies made of multiple materials

• diverse product line, with common manufacturing equipment

Complex Assemblies

Complex assemblies may contain an assortment of metals, plastics, composites, elastomers, optics, even biologics or pharmaceuticals. 

Optimal critical cleaning processes are essential for quality, profitable manufacturing  of complex assemblies. BFK Solutions has decades of experience in designing precision cleaning processes for complex assemblies.  Balancing effective cleaning with favorable materials compatibility is a challenge – and we have addressed that challenge many times.  Our projects involving complex, multi-material assemblies include such applications as military systems, aerospace, medical, and job-shop fabrication.

Diverse product line

In other situations, the component or product is made of a single material, but cleaning is performed in a single batch or in-line cleaning system.  This is often referred to as a low volume/high product mix situation.  BFK Solutions efficiently evaluates your situation and suggests approaches to achieve more efficient cleaning and to avoid materials compatibility problems, including issues resulting from galvanic interactions.

Surface Preparation, Consumer Products

Another client had to clean an assortment of molded products to be used for a niche consumer application. The client wanted to decrease the failure rate due to unacceptable visible surface blemishes.  At a site visit, BFK Solutions reviewed the existing process flow and the yield records.  We identified a previously unrecognized but critical cleaning process.  Our solutions were readily adopted and were economically favorable. The failure rate decreased dramatically.

Precision Connectors

The product contained multiple materials of construction.  The initial cleaning agent selected proved unsuccessful.  The reason was that lot to lot variability of certain composites resulted in materials compatibility problems, specifically unacceptable dimensional changes.  BFK Solutions reviewed the problem and the cleaning requirements.  A relatively mild cleaning solvent in an airless cleaning system proved successful.

Military Systems

Manufacturing involved multiple fabrication and assembly steps; many of these steps involved suppliers and job shops.  While performance specifications for sub-assemblies had been spelled out, ruggedness during the cleaning that occurred in final assembly had not been considered.  Certain coatings were inadequately adherent during final cleaning.  After coordinating with the client, BFK Solutions worked with the job shop/subvendor to improve the pre-coating and coating process.  We also worked with the client to minimize contamination during final assembly, both inside the cleanroom and prior to cleanroom operations.

Surface Preparation, Aerospace 

The client had to remove all organic materials from a range of metals prior to application of engineered coatings.  The group had to meet strict military, aerospace, and avionic requirements and at the same time satisfy environmental regulations that sharply restricted process choices.  The process had to be effective and allow the client to remain cost-competitive.  BFK Solutions provided a range of options as well as guidance in downselect of the appropriate capital equipment. We also provided regulatory facilitation.