A major manufacturer of industrial paint sprayers contacted Carling Technologies to gauge our interest in modifying the length and shape of the bat style actuators used on our single and double pole F and G-Series toggle switches. Their present supplier was struggling with long lead times, price increases and poor service. The manufacturer, a existing customer of Carling, was familiar with our expertise in design and tooling and surmised that Carling could be a valuable solution to their problems. The specifications called for custom shaped 1 and 2 inch bat style toggles with Chromvet alloy plating. In addition, this project challenged our Carling design team to develop a switch to meet the stringent 28VDC load requirements for this application.

New tooling was designed and produced to not only lengthen the switch's toggle, but to also add symmetry from the top to the bottom of the bat to accomodate the custom panel design for the sprayer product. The customer absorbed the tooling costs through amortization of the piece price over a 1 year period. Carling had tested several different electrical contact combinations at our in-house test lab, before finally seting on a design combination suitable for 28VDC.

These modified toggles gave this industrial sprayer manufacturer the shape, length, and load carrying characteristics required for seamless integration into their product without need for costly design or tooling changes. Additional bonuses were the savings realized through Carling's competitive pricing, and the improved service levels provided by Carling Customer Care and our manufacturer's sales representative. This customization project resulted in a two-year contract for Carling. The sprayer manufacturer now purchases approximately 45,000 pieces of these modified F and G-Series toggle switches per year.

Potential markets for this F & G-Series toggle include: Appliance, Dental, Factory Automation, Medical, Audio Visual Equipment, Marine, Transportation, among others