5 Smart ways to achieve Zero Air Bubble in On Board Chargers Potting.
For the manufacturing plant in Vietnam Perfect Potting 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. And customer rejected a job with slightest bubbles.
For their latest project, they faced a critical challenge:
A tricky PU formulation which is extremely moisture sensitive requiring a precise 100:8 mixing ratio
A 400gm to 1kg is the Potting quantity variation, demanding extreme accuracy
100% bubble free is the target to win the customer’s heart.
The Reality: All variants gave bubbles after potting!
The company explored multiple options, but every solution came with serious drawbacks:
Lack of flexibility – Conventional machines weren’t adaptable.
High investment, high risk – Importing a system cost 3-4x more, came with 6-8 month delivery times, and still lacked flexibility.
Lack of Process knowledge with vendors they chose – Bubble formation and mixing inconsistencies risked the production output. And no one knew the right process.
They needed a total solution.- one that would guarantee 100% bubble-free potting, maintain Potting compound weight, and adapt effortlessly to future design changes.
Partnered with Twin, not just for a machine – but for a complete, future-proof potting process with one goal to achieve 100% Bubble free Potting and win the customer’s heart.
Fully Integrated Automation – A complete system with double head with independent axes, vacuum chamber for degassing 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 12 Weeks – A fraction of the time compared to imported solutions, with zero risk in implementation.
The Result: Zero air bubbles and a happy end customer!
Such smallest air bubble was rejected by the end customer.
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
Key Takeaway: A partner who knows the Process can give you the results that you want!
Most potting machines force manufacturers to adjust their process to fit the machine. But with Twin’s expertise, I 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 0.4kg to 1kg
- Constant rejection from their customers for the smallest air bubble
- Tricky 100:8 PU mix
- 100% bubble-free requirement
- Existing machines lacked flexibility, imported ones too rigid to make the change
Twin’s Solution: Flexible, result orientated to solve your problem!
- Double-head, independently controlled dispensing with post-dispensing vacuum
- Configurable for varying shot sizes, job sizes, and geometries
- Delivered in just 12 weeks, ready for future model changes
The Outcome: Zero Bubbles, Full Control
- Zero rejection- The end customer accepted the jobs happily!
- 100% traceable potting data for every OBC
- Seamless shift to new models without new machines or rework