TL;DR Summary
NKT Photonics faced critical bond failures after internalizing their surface treatment process. With Brighton Science's BConnect technology, they have implemented a precise, data-driven approach to quality, resulting in:
- Zero bond failures
- 2x improvement in shear strength
- Consistent surface quality across complex geometries
- 100% inspection of high-value parts
- Real-time data integration for process control
When Surface Quality Goes from Assumed to Essential
When product quality hinges on flawless bonding, uncertainty in surface preparation isn't an option. That was the challenge NKT Photonics faced when a supply chain disruption forced them to bring aluminum etching in-house. Despite duplicating equipment and procedures, they encountered unexpected bond failures that threatened their reputation and financial stability.
Instead of relying on traditional surface testing methods, NKT transitioned to a data-driven approach, gaining real-time insights and precision through Brighton Science's advanced surface measurement technology - BConnect.
A Critical Transition Goes Sideways
NKT Photonics—known for high-performance fiber lasers and photonic crystal fibers—had previously outsourced surface treatment. When a key supplier relationship abruptly ended, the team rushed to replicate the process internally. Bond failures soon began appearing in the field, leading to costly rework, product returns, and damage to customer confidence.
Turning Point: Precision Surface Data with BConnect
To resolve the issue, NKT implemented Brighton Science's BConnect, the first and only surface intelligence platform, which offered:
- Sub-3-second measurements for real-time feedback
- Portability for in-line and at-line inspections
- Reliable contact angle data using patented Ballistic Deposition technology
- Access to complex geometries via a compact, customizable measurement head
- Data integration via API, feeding directly into quality systems
Root Cause Revealed by Surface Mapping
Using BConnect, NKT conducted detailed surface mapping. This revealed that surface quality varied significantly across part geometries. Water contact angle measurements were significantly higher around corners and tapped holes than across flat areas, indicating inconsistent cleaning in these harder-to-reach areas.
They also discovered that machining fluids varied between suppliers (oil-based vs. water-based), and their cleaning chemistry only worked effectively on one type, resulting in unpredictable surface energy and bond failures.
From Reactive Fixes to Data-Driven Control
Through systematic testing and measurement, NKT developed a new, validated surface preparation process:
- A universal cleaning protocol that is effective for all machining fluids
- 100% inspection of high-value parts
- Geometry-specific cleaning adjustments
- Statistical process control based on real-time surface data
Results That Matter
Since implementing the updated process, NKT has achieved:
- Zero bond failures
- Up to 2x improvement in shear strength
- Consistent contact angle readings across all part geometries
- Data-driven insights for ongoing process optimization
Building a Surface Intelligence Network
NKT has gone beyond fixing problems—they've created a scalable surface intelligence network. BConnect now feeds real-time surface data into their broader digital infrastructure, supporting:
- Automated pass/fail criteria
- Enhanced quality thresholds
- Future-ready manufacturing insights
Why It Matters
This case study illustrates how surface intelligence transforms quality control from reactive guesswork to a predictive science. With Brighton Science's BConnect, manufacturers can gain complete control over adhesion-critical processes, ensuring reliability, reducing rework, and protecting their reputation.
Frequently Asked Questions (FAQ)
What caused the bond failures at NKT Photonics?
Inconsistent surface preparation due to a change in machining fluids and inadequate cleaning processes. These issues weren't detectable using their old inspection methods.
How did Brighton Science's BConnect platform help?
BConnect provided fast, repeatable, and portable contact angle measurements. It enabled NKT to identify cleaning issues, validate their process, and monitor every high-value part.
What were the results of implementing BConnect?
- Zero bond failures
- 2x shear strength improvements
- 100% inspection capability
- Consistent quality across complex part geometries
What is contact angle measurement, and why is it important?
Contact angle measurement quantifies surface cleanliness and readiness for bonding. Lower angles typically indicate better surface energy for adhesion. It's essential for ensuring bond reliability.