Case Study: Solving Outdoor Lighting Seal Failures & Cutting Warranty Costs by 40% with Custom Pre-Cut Gaskets

Meta Description: See how a German lighting manufacturer eliminated leaks, slashed assembly time by 99%, and reduced warranty costs by 40% by switching from liquid sealants to our custom pre-cut EPDM foam tape gaskets. A detailed project case study.

Introduction

In the competitive world of high-end outdoor lighting, product longevity is the ultimate test of quality. A persistent failure point? The seal between glass and metal. This case study details how a German lighting manufacturer transformed its production and product reliability by partnering with us to replace messy, unreliable liquid sealants with a precision-engineered, custom pre-cut foam tape gasket solution. Discover the tangible results: 40% lower warranty costs and assembly line revolution.

1. Client Profile: Precision and Heritage Under Pressure

• Location & Market: A family-owned manufacturer based in Bavaria, Germany, supplying architect-specified lighting across Europe.

• Product Focus: High-design integrated outdoor wall and ground lights. Their reputation was built on aesthetics and “Made in Germany” durability.

• Initial Challenge Context: Their flagship product line required a permanent, waterproof bond between a tempered glass lens and a powder-coated aluminum housing. The existing process was a bottleneck and a quality risk.

2. The Core Problem: Inefficiency and Costly Field Failures

The client initially used a two-part silicone sealant. While effective when perfect, the process was fraught with issues:

• Production Bottleneck: Manual application was inconsistent. Required 24-48 hours of curing time, occupying valuable space and halting assembly flow.

• Invisible Quality Defects: Minor application errors (air bubbles, uneven beads) only manifested months or years later as condensation and water ingress inside the light fixture.

• High Lifetime Cost: Field failures led to expensive warranty claims, involving site visits, unit replacement, and reputational damage. Their own analysis showed over 15% of warranty costs were tied to this single sealing issue.

3. Our Collaborative Solution: From Liquid to Solid, from Manual to Precision

Our engineers conducted a joint analysis, focusing on material compatibility, environmental stress (-30°C to 80°C), and assembly line realities.

The Provided Solution:

• Product Configuration: A custom-formulated, closed-cell EPDM foam double-sided tape. The EPDM foam core provides excellent long-term compression set resistance and environmental sealing. The high-strength acrylic adhesive is optimized for bonding to both glass and coated aluminum.

• Process Innovation (The Game-Changer): We moved beyond supplying rolls of tape. Instead, we provided a “Ready-to-Apply Gasket Frame.”

  • Using our digital flatbed die-cutting technology, we precision-cut the tape into perfect rectangular frames that matched the client’s housing groove dimensions exactly.

  • The parts were kiss-cut and supplied on easy-release liners, in organized stacks.

• Logistics & Support: Provided initial samples for testing within 5 working days. Established a Kanban-style replenishment system for just-in-time delivery to their assembly line, ensuring no production delays.

4. Measurable Results & Long-Term Impact

The new system was implemented 28 months ago. The outcomes have been transformative:

• Assembly Efficiency:

  • 99% Reduction in Bonding Process Time: The “peel-and-place” process takes under 2 minutes per unit, eliminating the curing bottleneck entirely.

  • Elimination of Rework: No more waiting for cure or cleaning up excess sealant.

• Quality & Reliability:

  • Zero Seal-Related Warranty Claims: Since full implementation, not a single unit has been returned for water ingress related to the primary seal.

  • Consistent Seal Quality: Every unit receives an identical, perfectly applied gasket, removing human error.

• Financial Impact:

  • 40% Reduction in Annual Warranty Costs: A direct result of eliminating this failure mode.

  • Increased Production Capacity: The freed-up space and time allowed for a higher output rate without capital investment.

• Partnership Expansion: Based on this success, the client has standardized this solution across all outdoor product lines and awarded us status as a Preferred Development Partner for new projects.

5. Client Testimonial: The Voice of Experience

“We approached them with a chronic quality headache. They delivered a complete process revolution. The pre-cut gasket frame wasn’t just a component change; it was a mindset shift. It gave us 100% reliability, took a major cost off our books, and simplified training for our team. They truly understood our problem beyond the datasheet.”
— Production Director, Bavarian Lighting Manufacturer

(Published with client permission. Specific name withheld for confidentiality.)

Conclusion

This case underscores a critical principle: often, the most impactful innovation isn’t in the core product, but in the enabling components and processes that surround it. By moving from a generic material to a custom-engineered, application-ready solution, we helped a quality-conscious manufacturer turn a weakness into a definitive competitive advantage.

Is your process hindered by adhesive or sealing challenges? Let’s translate your problem into a measurable success story. Contact our engineering team today to start a conversation about your specific application.