Overview
A leading Canadian UAV manufacturer approached Noreast in search of a reliable UAV epoxy potting solution after repeated failures in one of their assemblies. Under extreme temperature and environmental stress, their existing potting material was cracking, causing downtime, equipment failures, and reduced service life.
This case study highlights how Noreast engineered a durable epoxy potting approach that improved dielectric strength, eliminated cracking, and significantly extended the performance of the component in harsh environments.
The Challenge
The customer needed an epoxy material that could:
- Withstand extreme temperature and environmental variation
- Maintain strong dielectric protection
- Perform with a thin, uniform potting layer
- Deliver a smooth, consistent surface finish
- Prevent cracking and premature failures
Potting materials exposed to extreme temperatures and environmental cycling typically require specialized formulations that maintain dielectric strength under stress, as outlined in MG Chemicals’ epoxy potting guidelines.
This combination of performance requirements made the project highly specialized.
Noreast’s Engineering Approach
With over 47 years of expertise in vacuum impregnation and epoxy formulation, Noreast’s engineering team collaborated to explore material options and process enhancements.
We produced three epoxy test samples, evaluating each for:
The component tested during Noreast’s epoxy potting optimization process.
- Form factor
- Adhesion strength
- Dielectric performance
- Thermal and environmental stability
- Surface finish quality
These characteristics align closely with the dielectric performance expectations defined in industry research, such as EPO-TEK’s technical brief on the dielectric properties of epoxies.
Following hundreds of hours of environmental and stress testing, the optimized assembly:
✔ Exceeded performance requirements
✔ Demonstrated zero cracking under extreme conditions
✔ Achieved stable dielectric strength with a thin epoxy application
Even after approval, Noreast continued refining the solution by suggesting subtle design adjustments to the metal plates. This improved the aesthetic and overall uniformity of the potting.
The Result
The enhanced UAV epoxy potting solution delivered measurable, long-term benefits:
- Extended service life of the UAV assembly
- Eliminated the need for repairs or replacements
- Improved reliability in harsh environments
- More consistent visual finish
The customer has since placed additional orders and is now actively working with Noreast on next-generation drone components.
This project stands as a strong example of Noreast’s commitment to innovation, precision, and long-term customer partnership.
Why It Matters
This case marks the beginning of the Noreast Case Study Series, showcasing real engineering solutions that help customers solve complex problems and build more reliable products.
Our team will continue sharing insights that demonstrate how decades of experience, hands-on expertise, and a commitment to quality drive results for customers across aerospace, electronics, industrial manufacturing, and beyond.
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