Case studies
Innovating and automating
large-scale manufacture
The startup needed to convert a manual PV cell handling process into automated operation. Cells are thin (
The manufacturer was ramping thin film solar production to meet strong market demand but needed an inline metrology system to monitor deposition. Their internal team had competing priorities and could…
The manufacturer aimed to produce five types of high-value fiber optic transducers but faced a nascent industry with almost no existing automation. Component loading, stripping, and bonding stations had…
The development team needed to validate tight-tolerance assembly processes—including adhesive dispense, vision-aided alignment, cable insertion, and sequence testing—without the expense of building…
Assembly of a critical module required components to be aligned to micron-level precision relative to a reference axis. The surfaces were difficult to image, and in-process quality control (IPQC) was complicated…
A next-generation tablet design required extremely precise alignment of the display to the back housing, a task the contract manufacturer was unable to solve with a passive alignment fixture. The process…
A leading manufacturer of laser processing systems for semiconductor advanced packaging needed to quickly offer automated film frame loading to customers who had previously purchased manual systems. The…
Existing solutions presented tradeoffs that limited performance:
A leading solar panel manufacturer needed to integrate proprietary, cost-reducing processes into production using custom equipment. Internal teams faced competing priorities, and any delay risked missing…
The CTO of a large thin film solar manufacturer wanted to reduce the cost of a critical electrical component by a factor of 10. The company lacked time and internal resources to validate and implement…
The customer required precise laser ablation of polymer and metallic components that were sensitive to thermal and oxidative degradation. They struggled to develop a laser process that could meet tight…
A medical device manufacturer was facing low yields and high rework costs on a catheter product line. Applying sealant adhesive to multiple radio marker rings within tight tolerances was difficult to perform…