In defense manufacturing, finishing processes often involve hazardous materials and environments classified as Class 1, Division 1 (C1D1) or Class 2, Division 1 (C2D1). These classifications traditionally necessitate manual operations in risky conditions.
Aerobotix is transforming that paradigm by adapting robotic systems to safely function in regulated environments. We achieve this through specialized conversions, NRTL-certified engineering, and collaboration with compliance officials—bringing automation to areas once off-limits.
Understanding Hazardous Environments
- Class 1, Division 1 environments are areas with flammable vapors or liquids under normal conditions—e.g., spray-paint booths and solvent-based processes.
- Class 2, Division 1 environments combustible dust, common in sanding, grinding, and polishing tasks.
- ATEX (Europe) environments use Zone classifications (0, 1, 2 for gases; 20, 21, 22 for dusts), based on the presence of explosive atmospheres.
Conversion and Certification Process
Converting robots for hazardous defense finishing requires specific engineering modifications including hermetically sealed electrical enclosures, positive pressure systems, temperature monitoring with automatic shutdown protocols, specialized conductive materials, and intrinsically safe circuits. Each modification is tailored to the specific classification—robots for C1D1 environments require different safeguards than those for C2D1 areas.
Deployment requires validation through a Nationally Recognized Testing Laboratory Entity (NRTLE) certification, ensuring all applicable safety standards are met. This process includes documentation review, laboratory testing, shop certification, and final field certification. Aerobotix collaborates with EHS and AHJ regulatory authorities throughout this process, delivering fully certified robotic systems capable of safely operating in environments previously limited to manual operations.
Benefits and Application
Implementing converted robots in hazardous environments dramatically reduces human exposure to dangerous conditions while helping defense manufacturers meet stringent safety regulations. These systems deliver consistent performance without breaks or shift changes, ensuring uniform coating thickness, consistent surface preparation, and reliable adhesion—critical for components meeting military specifications or MILSPEC.
Aerobotix’s hazard-converted robots excel in multiple defense manufacturing applications including precision sanding of composite material components, application of specialized low-observable and radar-absorbing materials, polishing in dust-generating environments, and finishing munitions in solvent-rich atmospheres. These implementations demonstrate how properly converted robotic systems transform traditionally manual processes while maintaining strict compliance with safety standards.
Conclusion
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, combined with our rigorous NRTLE certification process, enables defense manufacturers to automate previously manual finishing operations. The result is a manufacturing environment that prioritizes worker safety while enhancing productivity and quality consistency. As defense manufacturing continues to evolve, these specialized robotic conversions will play an increasingly vital role in meeting production demands without compromising safety standards. Partner with Aerobotix to explore how hazardous environment robots can revolutionize your defense finishing processes.