At Generator at Sheridan’s Centre for Intelligent Manufacturing (CIM), innovation met a real-world manufacturing challenge when the team partnered with Vision Coatings Ltd., a GTA-based manufacturer known for delivering advanced coating and finishing services to extrusion companies, window fabricators, and others in the fenestration industry. Their shared goal: solve a major production bottleneck and help Vision Coatings meet rising demand for energy-efficient products.
Vision Coatings faced a persistent challenge in insulating its window frames. The process of manually inserting aluminum foam insulation was slow, inconsistent, and physically demanding. It also posed safety risks for workers and made it difficult to meet modern performance certifications such as Energy Star. Alternatives like spray coatings weren’t viable due to flammability, moisture sensitivity, and heat-induced deformation. To address this, Vision Coatings partnered with CIM on a collaborative research and development project to design a safe, efficient automation system. The work was supported by the Federal Economic Development Agency for Southern Ontario (FedDev Ontario), through SONAMI, whose funding played a critical role in bringing the concept to life.
High-quality output, transformative results
After a series of design iterations and rigorous testing, the team, consisting of students and researchers, developed a custom, mobile insulation insertion machine that transforms how aluminum foam is applied to window frames — even those up to 21 feet long. At its core is a smart automation system that pulls insulation through the frame cavities with high precision and minimal manual intervention. Key innovations include a bearing-assisted entry guide to reduce friction, smooth-gliding rails, and a redesigned non-slip material clip to keep the foam securely in place. Dual operator control panels and integrated safety sensors allow for consistent and secure operation, improving both efficiency and worker safety.
The results have been transformative. Vision Coatings now has a reliable, repeatable, and scalable solution that significantly increases throughput, ensures high-quality output, and reduces risk to workers. What was once a slow and inconsistent process is now streamlined and automated — enabling the company to grow its operations while meeting strict energy performance standards. Beyond the factory floor, the impact of this project extends into the community and the construction industry at large. The ability to efficiently produce energy-efficient window frames at scale supports the creation of greener homes and commercial buildings. These improvements lead to reduced energy consumption, lower utility bills for end users, and a meaningful reduction in greenhouse gas emissions.
“Our collaboration with SONAMI and Sheridan College’s Centre for Intelligent Manufacturing has been a very positive experience. Their support played an important role in helping us develop and build equipment for our newly developed product , bringing valuable technical insight and practical execution to the project. We appreciate the partnership and look forward to working together on future projects.”
— Farhad Zafari, Vice President, Technology & Sales, Vision Coatings Limited
This project is a clear example of how applied research and industry collaboration — backed by FedDev Ontario — can solve real-world problems, enhance regional manufacturing capabilities, and contribute to a more sustainable future. This applied research project is not only helping a local manufacturer thrive, but also driving progress toward a cleaner, more energy-efficient built environment.
About FedDev Ontario
For over 15 years, the Government of Canada, through FedDev Ontario, has worked to advance and diversify the southern Ontario economy through funding opportunities and business services that support innovation, growth and job creation in Canada’s most populous region. The Agency has delivered impressive results, which can be seen in southern Ontario businesses that are creating innovative technologies, improving productivity, growing revenues, creating jobs, and in the economic advancement of communities across the region. Learn more about the impact the Agency is having in southern Ontario by exploring our investment profiles, our Southern Ontario Spotlight, and FedDev Ontario’s X, Facebook, Instagram and LinkedIn accounts.