In defense manufacturing, finishing processes often involve hazardous materials and environments. These are classified as Class 1, Division 1 (C1D1) or Class 2, Division 1 (C2D1). Traditionally, these classifications necessitate manual operations in risky conditions.

Aerobotix is transforming this paradigm by adapting robotic systems to function in regulated environments safely. We achieve this through specialized conversions and Nationally Recognized Testing Laboratory (NRTL)-certified engineering. Additionally, we collaborate with compliance officials—bringing automation to areas once off limits.

• Class 1, Division 1:  areas with flammable vapors or liquids under normal conditions—e.g., spray-paint booths and solvent-based processes.
• Class 2, Division 1: contains combustible dust, common in sanding, grinding, and polishing tasks.
• ATEX (Europe): use Zone classifications (0, 1, 2 for gases; 20, 21, 22 for dusts), based on the presence of explosive atmospheres.

Converting robots for hazardous defense finishing requires specific engineering modifications. These include hermetically sealed electrical enclosures and positive pressure systems. Furthermore, they include temperature monitoring with automatic shutdown protocols. Specialized conductive materials and intrinsically safe circuits are also required. Each modification is tailored to the specific classification. Notably, robots for C1D1 environments require different safeguards than those for C2D1 areas.

Deployment requires validation through a Nationally Recognized Testing Laboratory Entity (NRTLE) certification. This ensures all applicable safety standards are met. The process includes documentation review, laboratory testing, shop certification, and final field certification. Aerobotix collaborates with EHS and AHJ regulatory authorities. Ultimately, we deliver fully certified robotic systems. These systems can safely operate in environments previously limited to manual operations.

Implementing converted robots in hazardous environments dramatically reduces human exposure to dangerous conditions. Meanwhile, it helps defense manufacturers meet stringent safety regulations. These systems deliver consistent performance without breaks or shift changes. As a result, they ensure uniform coating thickness, consistent surface preparation, and reliable adhesion—critical for components meeting military specifications or MILSPEC.

Our robots excel in multiple defense manufacturing applications. These include precision sanding of composite material components. They also include the application of specialized low-observable and radar-absorbing materials. Furthermore, they excel at polishing in dust-generating environments and finishing munitions in solvent-rich atmospheres. These implementations demonstrate how properly developed robotic systems transform traditionally manual processes. Simultaneously, they maintain strict compliance with safety standards.

Transforming standard robots to operate safely in hazardous environments represents a significant advancement for defense manufacturing. Aerobotix’s expertise in navigating the complex requirements of C1D1, C2D1, and ATEX standards enables defense manufacturers to automate previously manual finishing operations. This is combined with our rigorous NRTLE certification process. The result is a manufacturing environment that prioritizes worker safety. It also enhances productivity and quality consistency.

As defense manufacturing continues to evolve, these specialized robotic conversions will play an increasingly vital role. They meet production demands without compromising safety standards. Partner with Aerobotix to explore how our robots can revolutionize your defense finishing processes.