Overview

When Gallagher set out to differentiate their new QuickSwitch product in a highly competitive market, they turned to a powerful but often overlooked tool: colour. Their vision was to create a printed circuit board (PCB) solder mask in Gallagher’s signature corporate orange. The goal was to reinforce brand identity, elevate perceived quality, and create an immediate visual signal that this is Gallagher.

This is the story of how design, engineering, manufacturing, and brand strategy came together to make it possible.

How It Started – A Strategic Brand Differentiator

The idea originated from Gallagher’s in-market sales team, who identified the opportunity to give the upcoming QuickSwitch product a stronger brand presence. Because QuickSwitch was a direct replacement for competitor offerings, they saw colour as a clear differentiator that would signal innovation, quality, and brand pride.

The initiative gained significance ahead of ISC West, the largest security trade show in the USA, where Gallagher wanted the product to stand out from competitors and be instantly recognisable.

Changing Minds – The Spark of Possibility

Momentum grew when Gallagher created a prototype using inkjet printing directly onto the board. This sparked broader conversations between PCB designers, electronics engineers, and product management. Precision was then engaged to explore what would be possible in production.

Technical Challenge – More Than Colour Matching

Precision confirmed that creating a new solder mask formula through the supplier was not feasible due to volume requirements. Instead, Precision engineers began mixing existing orange solder mask ink to achieve the closest match to Pantone 151C. More than 50 iterations were carried out to refine the consistency, tone, and manufacturability of the orange colour.

Innovation in Process

To achieve both visual accuracy and performance, Precision adopted a two-layer process:

-        White solder mask applied and set as a base

-        Custom mixed orange solder mask applied on top

This method ensured colour brightness, accuracy, and insulation protection. Process adjustments were required for etching, drying times, and cure cycles to maintain quality and consistency.

Ensuring Performance Integrity

While colour was adjusted, the solder mask still needed to fulfil its standard functions such as insulation, solder resistance, and durability. All standard PCB performance tests were completed and passed successfully. A golden sample was created to validate ongoing production accuracy.

Final Approval and Production Confidence

Gallagher reviewed and approved samples following several refinement stages. A jointly agreed inspection standard and tolerance range were established to ensure consistency in future batches.

Impact – Beyond Aesthetic

The first field installation demonstrated that colour has real value, even when the PCB is hidden inside an enclosure. Installers noticed, internal support grew, and the board colour became a symbol of quality, identity, and partnership.

Lessons Learned

Delivering a custom colour PCB was technically challenging but rewarding. The experience demonstrated the value of close customer feedback, persistence in testing, and pride in innovation.

Conclusion

The result is more than a coloured PCB. It is a manufactured expression of Gallagher’s brand, identity, and commitment to quality. This case study demonstrates how Precision and Gallagher turned a strategic brand idea into a technical reality.

This is brand alignment — engineered at the manufacturing level.