What is a Coating Automated System?

For any manufacturing company that produces high volumes, consistently achieving high quality products greatly impacts both efficiency and bottom line profitability. Coating products using manual methods creates high reject rates and much waste from poorly executed product finishes. In contrast to these manual methods, automated coating systems allow for the consistent and precise application of coatings with 100% uniformity throughout a production run. Through robotics, precise fluid delivery systems, and control software, these automated coating systems enable manufacturers to scale production while dramatically reducing their materials cost.

The Bottom Line: For manufacturers, manufacturing is moving too quickly to allow your product to be inconsistent due to manual mistakes; by using automated coating systems your product will be the same quality from batch one through batch one million.

Overview of Automated Coating Systems

Automated coating systems replace the random variation produced by human application with the constant precision of a computer. Rather than a technician manually spraying or dipping a part, an automated coating system applies the coating using either a multi-axis robot or a static carriage along a pre-determined path.

Automated coating systems utilize a continuous feedback loop that includes data collection and mechanical motion.

Data is collected to determine the viscosity, pressure, and temperature of the coating material, the motion is controlled by a 3-axis or 6-axis robotic arm which precisely positions the applicator nozzle relative to the substrate, and finally, the thickness of the coating is verified using an integrated camera system. The coating is then cured, either by UV or thermal methods, and fully set instantaneously. This workflow operates seamlessly, providing maximum throughput with minimal environmental contamination through vapor discharge from volatile organic compounds (VOCs).

Coating Automated Systems — Category Breakdowns By Coating Type (Plus A Connection To MLCC's And LTCC's)

There are three major categories of different coating automated systems and their behaviours relative to the type of material processed, along with the requirement for application precision:

• Coating Systems: The most widely utilised type of coating; use of a dry containment process to safeguard printed circuit boards (PCBs) from moisture, dust, and dirt.
• Robotic Spray Coating System: The most common coating application process in the automotive and aerospace industries; large batches of coatings to ensure a uniform coating on an object for aesthetic purposes.
• Slot-die & Doctor Blade Coater: The most accurately applied coating; flat, continuous, ultra-thin layers of liquid film to be applied at a micro or nano level.

The Advanced Electronics Industry Connection — The Manufacturing Process Of MLCC's And LTCC's

In the high-tech electronics components industry, automated coating systems serve as essential components for clean rooms. Multi-Layer Ceramic Capacitors (MLCCs) and Low Temperature Co-Fired Ceramics (LTCCs) including their manufacturing processes require the use of specialized automated coating equipment in the form of slot-die and tape cast systems rather than relying on standard equipment to achieve the required quality levels.

In the manufacture of MLCCs and LTCCs, ceramic slurries are coated to a carrier film substrate in an evenly coated manner averaging at micro or nano thicknesses to create "Green Sheets". Any discrepancy in the coating thickness directly alters the electrical capacitance, structural integrity and overall quality of the final product. Guaranteeing that the coating thicknesses are expressed using automated fluid hydraulic systems, coupled with ultra-high precision casting knives, will permit these microscopic electronic devices to have consistently formed layer coatings in order for the electronic devices to function together correctly.

Industries & Applications That Are Targeted

Implementation of coating automated systems has eliminated excess waste throughout many of the high-technology and heavy industrial sectors. High usage sectors and the most well known businesses utilizing automation are as follows:

Electronics / Semiconductors: Examples of use include protecting delicate microelectronics, preparing green sheets for multi-layer ceramic capacitors (MLCC), and protecting high output automotive sensors by insulating them.
Automobile / Aerospace: Examples include using exterior primer and clear coat, applying thermal barrier coating on turbine blades and on battery packs for electric vehicles.
Medical Devices: Examples of use include coating stents, pacemakers, and orthopedic implants with drug-eluting or biocompatible coatings, where zero defect manufacturing is mandated by law.

What are the costs of an automated coating system?

If you are investing in automation, you will want to know how to estimate the capital expenditures of the purchase. Automated coating systems tend to have a high degree of customizability, therefore the cost can vary widely based on the type of precision needed, how many robotic axes are included, and whether or not the system will be used in a clean room environment.

Major Companies in Industry For Automated Coating

If you are pursuing quality in a system, there are several top-rated, world class manufacturers who are considered authorities of E-E-A-T in the field:

For electronic conformal coating and/or high speed dispensing, Nordson has established itself as an industry standard with the ASYMTEK line and great reliability. If your facility needs specialized precision thin-film polymer coatings, Specialty Coating Systems (SCS) can provide you with the best liquid and parylene coating systems. Precision Valve & Automation (PVA) is a recognized global leader with a reputation amongst top-tier manufacturers for robust, highly customizable fluid dispensing, and selective coating automation.

Frequently Asked Questions (FAQs)

What are the common problems with coating machines?

Common coating machine problems include nozzle clogging due to mid-cycle material curing, uneven film thickness due to variable fluid viscosity, and structural defects like "orange peel" or pinholes. Viewing camera capabilities and closed-loop temperature controls substantially reduce the risk of many of these issues.

What are the different types of coating machines?

The most common coaters used in industrial applications include dip coat machines, spin coaters used for semiconductor wafers, spray coating gantries, slot die / tape casting systems for thin films, and roll coaters used for continuous web materials.

What training is required to operate a coating machine?

Coating machine operators generally require basic familiarity with CAD/CAM software for programming coating paths, basic knowledge of fluid dynamics for managing viscosity changes, and rigorous safety training for chemical handling and ventilation protocols.

What are the 4 types of coatings?

Industrial coatings typically fall into four categories per their composition: liquid systems such as acrylics, polyurethanes, and epoxies; powder coatings; UV-curable systems; and vapor deposited systems such as Parylene and chemical vapor deposition finishes.

What is the 80 20 rule for coating?

The 80/20 rule is a well-known guideline in the coatings industry which states that 80% of coating defects come from just 20% of process vulnerabilities. The most prevalent of these defects to solve are proper surface preparation and accurate calibration of the fluid viscosity used during application. Focus on solving these two issues, along with environment stability, and you will dramatically reduce your overall scrap rate.

How do automated coating lines maximize Return on Investment (ROI)?

Automated coating lines maximize Return on Investment (ROI) due to their ability to vastly reduce raw materials and labor costs. Therefore, while upfront costs may seem large, almost always systems pay for themselves in 12 - 18 months. Automated systems significantly reduce the amount of raw materials wasted, often by 30%, virtually eliminate human assembly error, and enable 24/7 production without compromising quality due to fatigue.

Upgrading to an automated coating process can revolutionize manufacturing by enabling facilities to scale production while achieving the highest levels of quality. Providing manufacturers total control over material thickness, waste reduction, and production predictability will enable you to exceed your competition, whether coating microscopic MLCC layers in cutting-edge consumer electronics or protecting industrial equipment from the environment.