Enter any two known values and press calculate to solve for the others.
At Birk Manufacturing, we pride ourselves not just on delivering cutting-edge flexible heating solutions but also on being a true partner to our customers. A recent collaboration with a large aerospace manufacturer is the perfect example of that partnership, allowing us to display our innovative problem-solving, deep industry knowledge, quick response time, and agile development process to drive success, even when we’re up against a challenge.
The Challenge: An Unexpected Thermal Issue
After the initial delivery of prototype units to our customer, their team observed an issue during testing – overheating and charring in the neck-down area of the heaters. The company reached out to us and without delay, we quickly scheduled a conference call to analyze the issue together.
The Discovery: Insight through Collaboration
During the discussion, our customer provided valuable context, including comparison images of a heater from another manufacturer. While inspecting the images, our team immediately noticed a critical design difference. The previous parts were copper plated in the failure area, a detail that was not outlined in the original drawing and design documentation.
With this new information in hand, our engineers recognized an opportunity to remediate and refine the solution. We knew that time was of the essence on the project, so we jumped into action immediately.
The Response: Engineering a Quick and Smart Solution
Our response took a comprehensive approach…first, we audited all related designs going through the prototype phase to identify any other models potentially affected by the same condition. Our customer supported this process by putting those parts through thermal testing, which confirmed the overheating issue across a broader set of designs and model numbers.
From there, our team quickly moved into redesign mode. We increased the circuit width through the problematic area and incorporated copper plating into the new design. Given the unique nature of the parts, this required developing a custom copper plating method, a challenge we tackled and solved, cooperatively, with our plating partner.
The Result: Fast Turnaround, Reliable Performance
In just a couple weeks, we successfully developed the new copper plating process and delivered the first sample units to our customer for testing. The result…a reliable solution that not only met all of the company’s performance and delivery requirements but also reinforced our partnership, working together to solve any issues that arise.
Looking Ahead: Your Partner in Precision Engineering
This case is a testament to what sets Birk Manufacturing apart – expert technical knowledge, fast and responsive customer support, and the innovative mindset to quickly solve any issue. When projects encounter unexpected challenges, we’re ready to act, collaborate, and deliver solutions that perform at the highest quality.
