Inter-Ion, Inc. Delivers Mission-Critical Manufacturing Solutions for the Defense Industry
When reliability, durability, and strict military compliance are essential, manufacturers need a partner with the engineering expertise and manufacturing capabilities to deliver high-performance solutions. For more than 30 years, Inter-Ion, Inc. has supported the defense industry by providing precision manufacturing, military-grade coatings, engineering support, and custom fabrication for demanding applications.
From naval equipment to military vehicle components, Inter-Ion combines advanced manufacturing processes with specialized coating technologies to produce components that perform in some of the world’s most demanding operating environments.
Naval Hose Reels Built to Military Specifications
Inter-Ion partnered with defense contractors to manufacture and finish large naval hose reel assemblies designed for military applications. These oversized components required specialized handling, precision surface preparation, and coatings that met stringent military performance standards.
One of the most critical aspects of the project was achieving long-lasting coating adhesion on large aluminum components. To accomplish this, each part underwent an aggressive aluminum oxide blasting process that created the ideal surface profile for maximum coating adhesion.
Depending on the application, Inter-Ion applied one of two military-approved coating systems:
- DEVGUARD® Firefighting Primer for naval firefighting equipment
- Epoxy Polyamide Primer for fueling system applications
Despite the challenges associated with the large form factor of the components and demanding delivery schedules, Inter-Ion successfully developed a manufacturing process that maintained military specifications while helping control production costs.
Project Highlights
- Military specification surface preparation
- Aluminum oxide abrasive blasting
- Large-form-factor component processing
- DEVGUARD firefighting primer application
- Epoxy polyamide coating systems
- Precision quality control and inspection
- TWO-DAY turnaround time!
Military Vehicle Electronics Enclosures with CARC System Coatings
Inter-Ion also supported a different defense contractor in the production of electronics enclosures used on military vehicles. The project required both precision metal stamping and the application of a Chemical Agent Resistant Coating (CARC) system that complies with military specifications.
The enclosure consisted of a stamped steel cover and base that demanded extremely tight dimensional tolerances. During production, engineers encountered a flatness issue along the enclosure lip that affected assembly and pressurized leak testing.
Inter-Ion’s engineering team worked closely with manufacturing to refine the stamping process, ensuring the enclosure maintained dimensional accuracy while successfully passing leakage testing.
Applying the CARC coating system presented another challenge. Military coatings require exceptional adhesion while maintaining chemical resistance and long-term durability. Through process optimization and careful surface preparation, Inter-Ion developed a repeatable coating process that met stringent military requirements.
Project Highlights
- Precision steel stamping
- Military-specification CARC coating systems
- Pressurized leak-tested enclosures
- Engineering support for manufacturability
- Improved coating adhesion
- High-quality military component production
Engineering an Improved Coating Process for Military Air Shocks
Another defense-related project required Inter-Ion to solve a complex problem related to materials engineering, which involved protective coatings on metal components used in military air shock assemblies.
The assembly consisted of two circular metal components crimped around a rubber shock element. During the crimping operation, the metal experienced differential stretching that fractured plated finishes, exposing the underlying metal to corrosion.
Rather than relying on conventional plating, Inter-Ion engineered an alternative solution using a specialized nylon coating system.
The challenge was creating an adhesive bond stronger than the internal cohesion of the coating itself. Engineers developed a proprietary surface preparation process involving aggressive, controlled sandblasting that produced microscopic peaks and valleys across the metal surface. This increased the available surface area, drastically improving coating adhesion and preventing failures during the crimping process.
The result was a durable corrosion-resistant finish capable of maintaining protection even after significant forming and assembly operations.
Project Highlights
- Custom nylon coating development
- Advanced abrasive surface preparation
- Improved coating adhesion
- Corrosion-resistant finishing
- Manufacturing process development
- Enhanced durability after crimping operations
Comprehensive Defense Manufacturing Capabilities
Defense contractors require suppliers capable of maintaining quality, repeatability, and strict process controls throughout production. Inter-Ion delivers these capabilities through a combination of engineering expertise, precision manufacturing, and specialized finishing services.
Our defense manufacturing capabilities include:
- Military specification coating systems
- CARC coatings
- Surface preparation and abrasive blasting
- Precision metal stamping
- CNC machining
- Engineering and design support
- Fabrication and assembly
- Corrosion-resistant coating technologies
- Prototype development
- Production manufacturing
- Quality inspection and testing
Why Defense Manufacturers Choose Inter-Ion
Defense applications leave no room for compromise. Components must withstand harsh environments, chemical exposure, corrosion, mechanical stress, and demanding operational conditions while meeting rigorous military standards.
Inter-Ion’s multidisciplinary team works closely with defense contractors, OEMs, and government suppliers to solve manufacturing challenges before they become production problems. Whether developing a custom coating process, refining a stamped component, or producing large fabricated assemblies, our focus remains the same: delivering dependable, high-quality manufacturing solutions.
By combining engineering innovation with advanced manufacturing capabilities, Inter-Ion helps customers reduce production risks, improve product performance, and meet demanding military specifications.
Partner with Inter-Ion for Defense Manufacturing Solutions
If your organization requires a manufacturing partner experienced in military coatings, precision fabrication, engineered surface preparation, or complex defense components, Inter-Ion is ready to help.
From naval equipment and military vehicle enclosures to specialized corrosion-resistant assemblies, we provide complete manufacturing solutions designed to meet the demanding requirements of today’s defense industry.