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:
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.
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.
To resolve the issue, NKT implemented Brighton Science's BConnect, the first and only surface intelligence platform, which offered:
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.
Through systematic testing and measurement, NKT developed a new, validated surface preparation process:
Since implementing the updated process, NKT has achieved:
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:
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.
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?
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.