Smart way to achieve 100% flexibility in OBC (On Board Chargers) Potting.
This Auto-electronics manufacturer needed precise, bubble-free potting with full flexibility for future models. And it had to be done in less than 16 weeks.
When Precision Potting Becomes Key Target
For the manufacturing plant in India, precision isn’t just a requirement—it’s the foundation of their reputation. As a world-class manufacturer, they supply high-quality on board chargers globally.
But with every new variety, the game changed.
Circuit designs kept evolving. Potting quantities varied. Component geometries changed.
For their latest project, Otter faced a critical challenge:
A tricky epoxy formulation requiring a precise 100:8 mixing ratio
A 300gm to 1kg is the Potting quantity variation, demanding extreme accuracy
100% bubble free is the target.
The Reality: All Potting trials gave bubbles after potting
The company explored multiple options, but every solution came with serious drawbacks:
Lack of flexibility – Conventional machines weren’t adaptable to changing component designs.
High investment, high risk – Importing a system cost 3–4x more, came with 6–8 month delivery times, and still lacked flexibility.
Uncertain quality – Bubble formation and mixing inconsistencies risked defects and rework.
They needed a total solution.—one that would guarantee 100% bubble-free potting, maintain absolute precision, and adapt effortlessly to future design changes.
Partnered with Twin, not just for a machine—but for a complete, future-proof potting solution.
Twin Dispensing Technology – Proven for ultra-precise applications, Zero air bubbles.
Fully Integrated Automation – A complete system with double head with independent axes, vacuum chamber after dispensing ensuring perfect repeatability and no operator dependency.
100% Flexibility – Designed to reconfigure easily for different sizes of the jobs, shot sizes, and component geometries—future-proofing investment.
Delivered in Just 14 Weeks – A fraction of the time compared to imported solutions, with zero risk in implementation.
The Result: Zero air bubbles and saving complete clean up time
First-time-right production – Easy to understand and use. Training and support from Twin definitely helped.
100% data maintained for every OBC – Twin’s precision control eliminated bubble formation and mix ratio inconsistencies and gathered data for customer audit for each job with Potting quantities dispensed
No risk, even with future component changes – Customer could switch models, modify shot sizes, —without needing a new machine.
Key Takeaway: Automation Should Adapt to You, Not the Other Way Around
Most potting machines force manufacturers to adjust their process to fit the machine. But with Twin’s expertise, Otter got a solution designed around their needs—one that works today and adapts effortlessly for tomorrow.
This company made the right call. Ready to make yours?
The Challenge: Potting That Keeps Up With Change
- Constant changes in OBC designs, shot sizes from 300g to 1kg
- Tricky 100:8 epoxy mix and 100% bubble-free requirement
- Existing machines lacked flexibility, imported ones too costly and slow
Twin’s Solution: Flexible, Future-Proof Potting System
- Double-head, independently controlled dispensing with post-dispensing vacuum
- Configurable for varying shot sizes, job sizes, and geometries
- Delivered in just 14 weeks, ready for future model changes
The Outcome: Zero Bubbles, Full Control
- First-time-right production with no clean-up delays
- 100% traceable potting data for every OBC
- Seamless shift to new models without new machines or rework