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Ensinger and Loson have collaborated to successfully optimize a Delta robot’s performance in food packaging lines by replacing traditional metal inserts with high-performance polymers. A case study published by Ensinger demonstrates how TECAPEEK natural polymer can enhance robotic arm efficiency while solving multiple engineering challenges.
The original robotic arm design, weighing approximately 300g, included aluminum inserts that accounted for 27% of the total weight. These metal components added unnecessary weight and posed corrosion risks in food packaging environments where aggressive cleaning agents are used.
By replacing the aluminum inserts with TECAPEEK natural and implementing an innovative mechanical connection design, the engineering team achieved several key improvements:
- 15% reduction in total weight, enabling faster and safer robot operation.
- Elimination of galvanic and chemical corrosion risks.
- Enhanced performance-to-weight ratio compared to aluminum inserts.
- Improved durability through specialized undercut design that eliminates the need for adhesive bonding.
The solution involved creating machined undercuts in the TECAPEEK natural insert, which are filled with composite material during the lamination process. This mechanical connection prevents unwanted rotation while avoiding the limitations of traditional adhesive bonding.

King StarBoard® by King Plastic Corporation is pictured in use on a water treatement panel. Photo courtesy of King Plastic Corporation.
Manufactured using the company’s proprietary K-Stran™ process, which ensures superior flatness and consistency, King StarBoard® sheets are specifically engineered to withstand harsh operating conditions. The material’s resistance to UV exposure, chemicals and moisture makes it particularly well-suited for water treatment applications, where long-term performance is crucial.
Unlike traditional materials, King StarBoard® requires no painting or refinishing and is immune to rust, delamination, and rot, significantly reducing maintenance requirements in water treatment facilities. This application showcases how high-performance polymer materials continue to replace conventional options in industrial settings, offering improved durability and reduced maintenance costs. www.kingplastic.com.

A key advantage of these systems is their ability to maintain visibility during attack attempts — the materials won’t spider web or white out on impact, allowing security personnel to maintain visual control of situations. The glazing is approximately 50% lighter than comparable glass laminates, while PLASKOLITE’s TUFFAK AR hard-coat technology provides superior resistance to abrasion, chemicals and graffiti — crucial features in high-risk environments.
Beyond corrections applications, the technology is seeing increased adoption in other high-security environments including government facilities, banks, educational institutions, and retail locations such as gas stations and convenience stores. The materials can be implemented in many ways, from security windows and partitions to drive-up windows and ticket booths. www.plaskolite.com.