Built for Harsh Environments: How Defence Manufacturing Expertise Supports Mining Innovation

Mining operations are under constant pressure to become safer, more efficient and more profitable. As operators invest in automation, remote monitoring, intelligent sensing and broader digital transformation, the electronics behind these systems need to perform reliably in some of the harshest working environments in Australia.

For mining companies with a strong digital roadmap, technology is no longer just about innovation. It is about operational resilience. Every connected device, controller, sensor and embedded system must support safer decision-making, reduce avoidable downtime and withstand demanding field conditions.

These requirements are familiar to Hetech.

Through decades of electronics design and manufacturing for the defence sector, Hetech has developed the capabilities needed to support complex, rugged and safety-focused technologies. The same strengths that make Hetech a trusted manufacturing partner in defence also make us well suited to support mining companies, OEMs and technology innovators developing the next generation of mining solutions.

1. Rugged reliability in demanding environments

Defence technology is often deployed in conditions where reliability is critical and failure simply isn’t an option. Equipment must withstand vibration, shock, changing environmental conditions and sustained operational demands while continuing to perform exactly as intended.

A strong example is Hetech’s involvement in Project Currawong, Boeing’s LAND2072/2B Battlespace Communications System for the Australian Army. Hetech manufactured two sub-systems for the Network Access Module as a turnkey box-build solution, delivering hundreds of complex ruggedised hardware modules used in a mission-critical communications network. Boeing recognised Hetech’s manufacturing and project management capabilities as integral to the project’s success, highlighting the consistent delivery of ruggedised systems that met demanding performance requirements while maintaining delivery schedules and quality standards.

The same engineering principles that underpin successful defence systems are equally relevant in mining.

Mining equipment regularly operates in harsh environments characterised by dust, moisture, heat, vibration and continuous duty cycles. Electronics failures can result in costly downtime, interrupted production and increased maintenance requirements. As mines become increasingly automated and digitally connected, reliable electronics become even more important.

This is demonstrated through Hetech’s work with WEIR Minerals on the MULTIFLO Dewatering Pump Controller. The controller was designed to operate heavy-duty dewatering pumps in mining environments while delivering the durability, security and ease of use required by operators in the field.

The system was engineered to provide reliable performance while managing complex control functions and withstanding the harsh conditions commonly found on mine sites.

Whether supporting military communications networks or critical mining infrastructure, the challenge remains the same: creating rugged, dependable electronics that continue working when reliability matters most. This ability to deliver rugged reliability across demanding industries is one of the key reasons why defence manufacturing expertise transfers so effectively into mining applications.

2. Uptime economics: reducing the cost of failure

In defence, equipment availability and system reliability are critical. Every component must perform as expected because failures can affect operational capability, mission readiness and the ability to make informed decisions in complex environments.

A strong example is Hetech’s involvement in the Collins Class Submarine Integrated Ships Control Management and Monitoring System (ISCMMS). The ISCMMS is responsible for monitoring and controlling critical submarine systems, providing operators with the information needed to safely manage vessel performance and maintain operational effectiveness. In environments where maintenance opportunities can be limited and system failures carry significant consequences, reliability and long-term performance are essential requirements rather than desirable features.

Mining operators face a remarkably similar challenge.

While the consequences may not be military in nature, the financial impact of equipment failure can be substantial. Unplanned downtime affects production schedules, reduces equipment utilisation, increases maintenance costs and impacts profitability. This is why many mining companies now focus heavily on uptime economics; understanding that improving equipment availability often provides greater value than simply reducing upfront equipment costs.

This thinking is reflected in Hetech’s work with Decoda and the RockAware™ Safety System. Developed to monitor tyre wear and haul road conditions in real time, RockAware™ helps identify hazardous conditions before they result in tyre failures, equipment damage or unplanned outages. By providing early warning of emerging issues, the system allows operators to take proactive action before a costly incident occurs. The value extends beyond safety. Every avoided tyre failure, every reduced maintenance event and every prevented interruption contributes to improved operational efficiency and lower total operating costs. In other words, RockAware™ helps improve uptime economics by enabling mines to move from reactive maintenance towards proactive asset management.

Whether supporting the monitoring systems of a Collins Class submarine or helping detect issues on a remote mine site’s haul roads, the underlying objective is the same: provide reliable information that enables better decisions, prevents failures and keeps critical operations running. This ability to design and manufacture dependable electronics for monitoring, control and decision-making systems is a capability Hetech has developed in defence and is now applying to the future of mining technology.

3. Safety-focused technology for high-risk environments

Safety is a core requirement in both defence and mining. In defence, systems are often designed to reduce risk to personnel and improve operational effectiveness in challenging conditions.

The BIA5 Tactical Initiated Lighting System is an example. It was developed as a safer and more versatile alternative to traditional flares, providing reusable and remotely activated lighting while reducing risks to personnel and environmental fire hazards. Hetech’s role was to help transform the concept into a field-ready product capable of being manufactured at scale.

Mining operations share the same need to reduce exposure to hazardous environments.

Hetech’s work with CSIRO and Quantum supported technologies designed to improve underground mining safety and efficiency, including the Longwall Automation System and ExScan 3D laser scanner.

The Longwall Automation System helps longwall mining equipment operate with precision and minimal manual intervention, while ExScan provides real-time visibility of underground environments to help detect movement, fractures and other potential hazards. These mining technologies reflect the future of site safety: fewer people exposed to hazardous areas, more real-time insight, and electronics that support better operational decisions.

4. Precision, accuracy and quality standards

Defence projects demand accuracy, documentation and consistency. Hetech’s work with EOS Defence Systems involved the manufacture of approximately 7,000 PCBs for a Remote Weapons Station, with EOS describing Hetech as an invaluable and critical supply chain partner that delivered on time, on budget and to exceptional Class 3 quality standards.

That level of quality control is equally important in mining, particularly as automated systems, sensing technologies and process control equipment become more deeply embedded in day-to-day operations.

Hetech’s mining capability is supported by ISO 9001 certification and J-STD-001/IPC-A-610 Class 3 manufacturing standards. Hetech’s mining page also notes experience supplying high-quality Australian electronics manufacturing and design solutions to mining industry clients including CSIRO, FLSmidth and WEIR Minerals.

For operators and OEMs, these credentials matter. A strong digital roadmap depends on reliable hardware, repeatable manufacturing processes and the confidence that every board, assembly and system has been built to an appropriate quality standard.

5. Design for Manufacture and ease of serviceability

One of the most valuable lessons from defence manufacturing is the importance of considering production, assembly and serviceability early in the product lifecycle.

In the BIA5 project, Hetech provided detailed Design for Manufacture input across manufacturing tolerances, plastic component design, assembly sequencing, product assembly layouts, production workflows, component selection and sourcing considerations. The team also identified opportunities to simplify aspects of the design and reduce unnecessary complexity, supporting more efficient production and servicing outcomes.

In mining, ease of serviceability is a major operational advantage. Equipment may be located remotely, access to specialist support may be limited, and delays in diagnosis or repair can quickly become expensive.

The Vanadium Spiral Automation project demonstrates this principle in practice. Hetech designed and manufactured an automation system that integrates into existing mining spiral circuits, using linear actuators and motor controllers to adjust feed splitters based on live data. The system provides live data feedback through the mine’s Citec system, supporting online control in step with other circuits.

Hetech’s capabilities included automation system integration and design, embedded Linux platform development, circuit design, prototyping, field testing, assembly, Python software design and motor controller design.

The project also shows the value of ongoing field support. Vanadium Group noted that Hetech delivered within timeframes and sent engineers to assist with diagnosing and maintaining products in the field, helping ensure the system operated as expected.

For mining operators, this combination of smart design, manufacturability and practical field support directly supports ease of serviceability and long-term operational performance.

6. Supporting mining operators with a digital roadmap

Mining companies are increasingly using automation, IoT, data and remote technologies to improve safety, reduce overheads and increase efficiency. Hetech’s mining capability page highlights the role of Industry 4.0, IoT and big data in helping operators make better decisions, reduce manual labour and improve safety by sending automated systems into dangerous areas instead of people.

This shift creates a growing need for electronics partners who understand more than just PCB assembly. Mining technology projects often require a combination of electronics design, embedded systems, prototyping, testing, box build, compliance support, supply chain management and ongoing manufacturing.

Hetech provides services across turnkey product development, electronic manufacturing, contract manufacturing, electronic assembly, electronic design, prototyping, compliance testing, microprocessor programming, technical documentation and project management.

That full lifecycle capability is particularly valuable for mining technology innovators and operators working through a digital transformation roadmap. Whether the goal is to automate a process, monitor critical assets, improve safety visibility or bring a new product to market, Hetech can support the journey from concept through to production.

7. Proven mining experience, backed by defence-grade capability

While Hetech’s defence experience provides a strong foundation, the company also has proven mining projects that demonstrate direct sector relevance.

These include:

• WEIR MULTIFLO Controller: a rugged and secure controller for WEIR Minerals’ dewatering pumps, designed for durability, ease of use and reliable operation in harsh mining environments.
• Vanadium Spiral Automation: an automation system for existing mining spiral circuits, improving feed quality and efficiency through reduced human intervention, risk reduction and improved plant recovery.
• Decoda RockAware™ Safety System: smart electronics supporting real-time tyre wear and haul road condition monitoring to improve safety and reduce downtime.
• CSIRO and Quantum mining safety technologies: electronics manufacturing support for the Longwall Automation System and ExScan 3D laser scanner, supporting safer and more efficient underground mining.
• Bureau Veritas Ultrasonic ShafTest Controller: redesign, update and manufacture of a portable ultrasonic flaw detection system used to monitor shafts and pins in the mining industry.

Together, these projects show that Hetech’s mining capability is not theoretical. It is already being applied across safety systems, automation, monitoring, control systems and rugged mining electronics.

A trusted electronics partner for the future of mining

The mining industry’s future will be shaped by technology. Automation, sensing, data, remote operation and intelligent control systems will continue to drive improvements in safety, uptime and profitability.

However, these outcomes depend on electronics that can survive the real-world conditions of mining operations.

Hetech’s defence experience has built a strong foundation in rugged reliability, disciplined manufacturing, quality assurance, traceability and field-ready production. Combined with direct mining project experience and credentials including ISO 9001 and Class 3 manufacturing standards, Hetech is well positioned to support mining operators, OEMs and technology innovators developing the next generation of mining solutions.

For organisations with a strong digital roadmap, Hetech provides more than electronics manufacturing. We provide the design, production and support capability needed to help transform ideas into reliable, serviceable and commercially viable mining technology.

Looking to develop or manufacture electronics for mining automation, safety, monitoring or control applications? Contact Hetech to discuss how our defence-proven manufacturing capability can support your next mining innovation.