“In Australian manufacturing, we all have to be really good to each other. Have a really high level of collaboration. Because we know with all the innovation we've got and all the smart people we've got, we can be as cost-effective as anyone else.”
Come behind the scenes with us as we explore Sun Industries, our local WA industrial printing partner with over 74 years of expertise - a process defined by deep communication, shared expertise, and mutual respect.
Gavin and his team produced the first run of graphic fascia labels, decals, and overlays for our Cranio Pro-IO devices and were kind enough to bring us inside their Osborne Park facility to show us the process in person!
It was such a pleasure to witness the process and hear Ayrton and Gavin discuss the importance of open communication, strong collaboration, and innovative thinking in Australian manufacturing.
If you’d rather read than watch the video, read on to see how decades-old methods, cutting-edge technology, and unwavering attention to detail came together to produce labels that will stand the test of time!
The Beginning: Understanding What Cranio Needs
It all started with a conversation. Gavin Parker and his team at Sun Industries were approached by Ayrton and our team with the task. These labels needed to be more than just visually appealing—they had to be durable enough to withstand years of exposure to harsh environments, such as the scorching Australian desert under solar panels.
Understanding the use case was essential, as Ayrton and his team wanted a solution that could last at least 5 to 10 years in these tough conditions. Gavin’s experience in industrial printing helped identify a material that would provide the necessary durability: polycarbonate.
“The polycarbonate in your instance was specified because of its UV stability,” Gavin explained. “If you get the wrong base material, the wrong polycarbonate, the wrong polyester, the wrong adhesives, then you can have a breakdown very quickly.”
Choosing the right materials was just the first step. What came next was the intricate dance of designing, testing, and refining—a process made smoother through clear and open communication.
From Design to Print: A Blend of Tradition and Innovation
Once the specifications were agreed upon, the teams at Sun Industries got to work. This involved translating Element Engineering’s digital designs into printable formats using Adobe Illustrator, ensuring that all layers and colours were precisely set. Sun Industries could handle multiple file types, from DXFs to PDFs, and even work from raw samples if needed.
This adaptability proved crucial, as every decal had its own set of requirements. Some were branding solutions, while others served as interfaces, helping users understand what was happening inside the Cranio Pro-IO device.
The Screen Printing Process: Craftsmanship in Action
Screen printing is as old-school as it sounds. It involves using silk screen mesh and exposing it to a film with an emulsion to create a high-quality image. Sun Industries’ printing facility has a dedicated room for this process, complete with a vacuum frame and a powerful light to bake the emulsion onto the screen. This method results in perfectly straight lines and clean, crisp images—essential for maintaining accuracy and consistency.
Screen printing still has its place in modern industrial printing. Gavin described the process with pride, emphasizing how their technique could eliminate typical variations like sawtoothing and ensure that all lines were perfectly sharp.
“What it does is it creates a very high-quality image with perfectly straight lines,” he said.
Once the screen was ready, the team would push ink through the screen to produce the label. This traditional method is ideal for high-volume work and achieved a level of quality that digital methods alone couldn’t match. To further enhance the final product, the team employed hybrid techniques, digitally printing some components before screen printing over them with custom-mixed spot colours. This approach provided the vivid colours and durability needed for the Cranio decals.
Navigating Design Challenges Through Flexibility
Despite meticulous planning, not everything always goes smoothly in manufacturing. The Cranio decals posed some unique challenges, one of which was the design of specific holes in the labels. Initially, the team had specified a circular hole with a flap for an antenna. However, this design turned out to be too complex for traditional knife die cutting.
Rather than forcing the design through or making arbitrary changes, Gavin and Ayrton took a different approach. They sat down and had a face-to-face conversation to evaluate the necessity of the flap. After a brief discussion, they realized that the flap wasn’t essential since a washer would be covering that section anyway. By simplifying the design, they saved on costs and production time without compromising functionality.
“It was a conversation we had, but I just literally came down here yesterday on my way home from work,” Ayrton recalled. “We had a quick five-minute conversation. It was a non-issue, and it’s done.”
This moment highlighted the advantage of working with a local manufacturing partner. Small design adjustments could be discussed in person and resolved quickly, eliminating the back-and-forth that often plagues remote or international collaborations.
As Gavin put it, “That’s the advantage of having someone locally who can have that conversation. And we can be that flexible generally all the time.”
Quality Assurance: Attention to Detail at Every Step
Once the design and material issues were resolved, it was time to move into full production. At this stage, precision and quality assurance were critical. The team at Sun Industries had years of experience working with strict quality control protocols, including ISO 900 standards.
One of the final steps involved applying a specialized technique called subsurface printing. This method involved printing on the underside of clear polycarbonate, protecting the ink from scratches and environmental damage. To further ensure longevity, Sun Industries encapsulated the labels with high-quality adhesives, creating a robust, layered product that could endure harsh UV exposure and other challenging conditions.
Gavin stressed the importance of getting the details right, down to the knife dies used for cutting the decals. Each knife die was meticulously sharpened and embedded to within 0.1mm tolerances—a level of precision that ensured a clean, professional finish. The result was a product that not only looked great but also performed reliably in the field.
The Value of Hybrid Techniques
Gavin’s team faced another challenge: deciding how to best produce these labels using a combination of traditional screen printing methods and modern digital techniques. The Osborne Park facility was a blend of old and new, and Gavin wasn’t shy about showcasing this contrast. The team still used a guillotine from 1954 to cut raw materials—a machine that had made millions of cuts over the decades. Yet, they also boasted a brand-new Canon Arizona flatbed printer from 2024, capable of producing photographic-quality prints with exceptional detail.
“We now need to encapsulate that decal in with some adhesive,” Gavin explained.
“One of the most valuable parts of what we do with your decals is what’s called a subsurface print. So you’ve got your clear polycarbonate, and by us printing underneath, it means that our ink’s incredibly durable. You can’t get to it, you can’t scratch it off. It’s not going to peel off over time.”
This commitment to quality was evident throughout the facility, where traditional clamshell presses stood side-by-side with state-of-the-art laser cutters. Each piece of equipment served a specific purpose, from high-volume screen printing to intricate laser etching. This flexibility enabled Sun Industries to adapt to different production needs and deliver consistent results.
The Final Step: A Collaborative Future
The final step in the Cranio decal journey was quality control and finishing. Each decal underwent rigorous inspections to ensure that it met the high standards set by both companies. Sun Industries’ experience in this area meant that they could catch and correct any issues before the decals reached Element Engineering, saving time and money in the long run.
Reflecting on the entire process, Ayrton expressed his gratitude for the partnership and the shared commitment to excellence.
“There’s a stigma around local manufacturing, that we don’t do high-tech local manufacturing. We definitely do,” Ayrton said. “And seeing your business, 74 years old, having the old processes well defined and new processes being hybrid mixed in, choosing technologies which are specific to the customer—it’s just great to be able to support Australian manufacturers across whatever industry they want.”
For Gavin, the collaboration with Element Engineering wasn’t just another job—it was an opportunity to demonstrate the value of local partnerships and the power of combining tradition with innovation.
“I’m a very, very firm believer that Australian manufacturing is on the up,” Gavin said. “And I think with all the innovation we've got and all the smart people we've got, we can be as cost-effective as anyone else.”
The story of how the Cranio fascia labels were created is more than just a tale of industrial printing; it’s a testament to what local manufacturing can achieve when collaboration, communication, and innovation come together. From selecting the right materials and refining the designs to blending traditional and modern printing techniques, every step of this journey was shaped by the shared values and expertise of both companies.
And at the heart of it all was a commitment to being flexible, open, and supportive. As Ayrton summarized, “It was such a pleasure to see the process and hear Gavin discuss the need for open communication, strong collaboration, and innovative thinking in Australian manufacturing.”
The partnership between Element Engineering Australia and Sun Industries demonstrates that when local businesses come together with a shared vision, they can achieve outstanding results—results that reflect not just a job well done, but a step forward for the entire industry.
Australian manufacturing is growing stronger, fuelled by innovative minds and open collaboration.
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