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Brighton Science Blog
Topic: Bonding & Sealing Processes
Ensuring Gasket Reliability: The Critical Role of Surface Quality in Formed-in-Place Gasket Applications
Formed-in-place gaskets (FIPG) have revolutionized sealing solutions across industries that require high-reliability seals. While there are many types of gaskets, a FIPG is created from a specific method where a liquid sealant, typically applied by an automated dispensing system, is dispensed...
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What Automotive Manufacturers Need to Know About Surface Analysis for Polymer Bonding and Coating
Polymers have taken center stage in automotive manufacturing. Their light weight, durability, and versatility make them ideal for many applications ranging from dashboards and door panels to bumper facias and fenders. However, as any product development or quality control professional will tell...
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Comprehensive Guide to Understanding X-ray Photoelectron Spectroscopy (XPS) for Surface Analysis
X-ray photoelectron spectroscopy (XPS) is a sensitive surface analysis technique with broad applications across numerous industries. Beyond its fundamental role in materials characterization, XPS can provide critical information to solve real-world material challenges. With the help of Rose...
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Environmental Silicone: Detection, Control, and Impact on Adhesion in Manufacturing
Silicone contamination is a huge problem in many painting and bonding applications. It’s impossible to see, hard to remove, and it creeps in unseen like a ghost. Where the harm it can cause is recognized, businesses go to great lengths to clean surfaces and exclude potential sources of...
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The High Cost of Molding Defects: Protect Your Bottom Line
Imagine crafting a colossal mold, a behemoth capable of shaping fiberglass and composites into the intricate contours of a plane wing, the sleek hull of a boat, or even the entire body of a bus. It's a monumental task, requiring months of meticulous preparation and planning. As you gear up to start...
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Gaining a Competitive Edge: The Power of Surface Analysis with Brighton Science
Every manufacturer that bonds, coats, paints, seals, or cleans needs objective surface measurement technology. It's the key to compressing lead times, reducing waste, and improving product consistency. Brighton Science has a versatile suite of solutions for surface analysis based on water contact...
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5 New Ideas to Address Common Challenges Manufacturing Plant Managers Face
Leadership of a manufacturing plant demands exceptional skill. Plant managers navigate a dynamic landscape of ever-evolving responsibilities. Drawing on a decade of collaboration with hundreds of companies across countless operational challenges, we've identified key insights to help tackle these...
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Surfaces Matter: Why Tracking Material Surface Quality is Critical for Aircraft Safety
The relentless pursuit of safety underpins every aspect of aerospace manufacturing. However, two significant hurdles impede this goal: verification and non-destructive testing. Destructive testing, the traditional method for assessing bond strength, is impractical for composite materials – the...
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What is Surface Treatment? A Comprehensive Guide to Surface Treatment Methods for Manufacturers
In the world of manufacturing, surface treatment plays a crucial role in achieving high-performance adhesion. Whether bonding, coating, sealing, painting, or printing, every manufacturer understands the significance of a well-defined adhesion process. Think of adhesion as the glue that holds a...
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Unlock the Key to Successful Adhesive Bonding: What You Need to Know Beyond Adhesive Technical Data Sheets
Manufacturers are increasingly utilizing a greater number of adhesive materials as a joining technique in the construction of their products, and the importance of these uses is continuously increasing with each passing year. As a result, the consequences of adhesive bond failures are becoming more...
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Contact Angle Goniometer 101: A Guide to Successfully Measuring Contact Angle
Have you wondered why some paints or coatings adhere effortlessly while others leave blisters or bubbles? The answer lies in wettability, the intricate dance between a liquid and a surface governed by a powerful principle known as contact angle. And measuring this microscopic tango? That's where...
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Fundamentals of Adhesion Science & Why 3 Molecular Layers Matter
Adhesion is crucial in microscopic and macroscopic worlds, yet it is an often-overlooked force. Adhesion acts as the invisible glue that unites objects, both massive and minute. Adhesion allows us to construct monumental structures like bridges, buildings, and airplanes. It enables us to glue wood...
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Silicone Contamination: The Invisible Intruder to Quality in Assembly Line Production
Some manufacturers go to extraordinary lengths to eliminate the presence of silicone in their manufacturing facilities. Some manufacturers invest significant resources in cleaning procedures to eradicate any silicone contamination. These approaches can be revolutionized by the development of a...
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The Thought Behind our New Brighton Academy
Over the past decade, we have been told that our science is the cornerstone of our customer relationships. Whether you’ve been with us from the beginning or just recently joined the BConnect community, during your journey with us, we’ve likely shared our scientific insights with you. This may have...
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How to Propel Enterprise Success through Effective Knowledge Sharing of Bonding Processes
Wind turbines have a problem: their giant blades fail more often than anticipated. Research on the issue, reported in the journal Materials, notes an average of 3,800 failures each year. Many of these result from adhesive bonding defects, which should be addressed and prevented through improved...
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Adhesive Bonding vs. Mechanical Fastening in Product Design: The Pros and Cons
When creating their next innovative product, designers, and manufacturers strive to achieve optimal performance while minimizing assembly and materials costs. In this pursuit, they often focus on optimizing material usage. In the quest to achieve optimization, it is uncommon for excess materials to...
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The Water Break Test as a Surface Measurement Gauge
The water break test is a common way for manufacturers to test the surface cleanliness of metal surfaces. Compared to other legacy cleanliness tests, it is relatively simple to perform. However, the results rely almost entirely on the subjective eye of the person performing the test. Hydrophobic...
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Unlock Success in Adhesive Bonding: The Definitive Troubleshooting Guide
Manufacturers have numerous options at their disposal when it comes to preventing product failures resulting from imperfect adhesive bonding. Often, the approach is to simply accept adhesive bonding failures as part of the scrap rate and move on. In other cases, companies may completely revamp...
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Ensuring Top-Quality Solder Joints on ENIG PCBs: Best Practices Unveiled
The field of printed circuit board (PCB) finishing and bonding methods has been growing and diversifying for decades. PCB design depends heavily on the use and environment of the electronic package, and those design decisions include what Surface Mount Technology (SMT) is employed. SMT involves the...
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Surface Inspection 101: A Visual Guide to the Surface Analyst, Water Break Tests, and Dyne Ink
In the manufacturing industry, it is crucial to meet certain surface preparation requirements in order to ensure the safety and reliability of products. Various tests have been developed to determine if these requirements are being met and if the cleaning process has been effective enough to...
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Demystifying Dyne Levels: A Comprehensive Guide
The evaluation of material surfaces in terms of quality has long relied on dyne testing. Despite their drawbacks, such as subjectivity, imprecision, damage to surfaces, and safety risks for users, dyne tests have remained popular among manufacturers due to their wide availability and affordability....
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Discover the Top Alternative to Dyne Testing That Gets Results
Dyne solutions have been the most common method of quality-checking material surface cleanliness for decades. Their ubiquity and low cost have led them to be heavily relied upon by manufacturers even though they are imprecise, destructive to surfaces, and harmful to the user. The science behind...
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![Identifying Adhesive Bond Failure Points in Manufacturing [Key Considerations]](https://www.brighton-science.com/hs-fs/hubfs/images/blog-images/instron-adhesion-test-blog.jpg?width=372&height=180&name=instron-adhesion-test-blog.jpg)
Identifying Adhesive Bond Failure Points in Manufacturing
One particular area that has proven to be a challenge in manufacturing is adhesion and surface quality. Research and development teams, product developers, and manufacturing operations frequently encounter difficulties with adhesion processes, such as coating or adhesion problems throughout the...
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Surface Energy Measurement is the Key to Process Control and High Performance
When manufacturing companies take adhesion seriously, they can significantly improve their ability to achieve their business goals. The key is to take a strategic look at adhesion processes early in product development.
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Why You Should Use Predictive Data in Building Material Manufacturing
The building industry relies heavily on adhesives and coatings to ensure structures are weatherproof, durable, and aesthetically pleasing. From modern flooring to sturdy roofs, these building materials rely on a strong bond – both literally and figuratively. However, unlike many other industries,...
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How to Fix Common Causes of Adhesion Problems
Manufacturers often have a large blind spot regarding the causes of adhesion problems. This blind spot makes it impossible to solve these problems and generates frustration and loss rather than productivity and adhesion success. Taking the blinders off and taking on adhesion failure at its...
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Why a Surface Chemistry Input Should be Included in New Product Specifications
When development teams are looking to build a new product that includes a coating, bonding, painting, or sealing process, it's only natural to consider what kind of adhesive, coating, or paint will perform the best. While these selections are critical to the end product's success, development teams...
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What are the Primary Causes of Chronic Adhesion Failures?
Adhesion problems tend to appear in the manufacturing process and then overstay their welcome. The chronic nature of so many adhesion issues is due to factors that many manufacturing companies are oblivious to. That’s not to fault the manufacturers. Until recently, there hasn’t been a reliable way...
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The Best Way to Qualify a Wash Method for Your Manufacturing Process
Parts washers are heavy-duty, hardworking machines that have become irreplaceable staples in automotive andmachined part manufacturing processes. As manufacturing processes have become more sophisticated, the industries using parts washers have expanded to includenot only industrial metals and...
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Easy Ways to Find Manufacturing Adhesion Failure Sources
When adhesion failure plagues a manufacturing process, it can be particularly disruptive. A production process may be humming along just fine, and then it suddenly becomes clear that a coating is uneven, or paint is chipping (when it wasn’t before), joints are weaker than they had been, or film is...
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How to Measure Contact Angle on Convex and Concave Surfaces
Historically, accurately measuring contact angles on concave and convex surfaces has been a challenge. The typical method used to measure contact angle on these types of surfaces has been with abenchtop goniometer. The challenges arise from how goniometers measurecontact angle—from a horizontal...
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Why Automotive Glass Bonding Recalls Should be a Thing of the Past
Automotive glass is a technological marvel. Despite its clarity, much of how it's manufactured is unseen by the average driver. Silica compounds, tempering, and lamination all combine to create one of the most critical components of today’s motor vehicles. Unfortunately, though, things periodically...
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The Surface Analyst™ Instantly Measures Contact Angle to Determine the Potential Adhesive Strength of Bonds
A Handheld Solution for Verifying Surface Cleanliness The Surface Analyst™ is an innovative handheld solution for use in the lab and on the factory floor. It reduces waste, rework, and recalls when poorly prepared substrate surfaces lead to bonding, coating, sealing, painting, or printing failure.
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Meet Brighton Science's Chief Scientist, Giles Dillingham
A Deep History in Materials Science Founder and Chief Scientist of Brighton Science, Dr. Giles Dillingham's fascination with the connections between the invisible (the molecular structure of the world around us) and the perceivable (the properties and behavior of materials and objects) stems from a...
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Data-informed Use of Contact Angle Measurements Minimize the Risk of Making the Wrong Decision about Product Quality
Deciding whether to reject a part or not based on a quality measurement always carries with it a finite risk: you could unknowingly decide that a perfectly good part is actually bad (a Type 1 error), or you might incorrectly conclude that a bad part is actually good (a Type 2 error). There is a...
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How to Master Industrial Adhesion with Scientific Predictability
Manufacturers who produce products with surfaces that require paints, adhesives, or sealants face a challenge in determining the quality and reliability of the final product. The problem is often caused by the fact that most manufacturers don’t have complete control over three critical elements of...
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Why Knowing Water Contact Angle is Important for Successful Adhesive Performance
Adhesives are an integral part of modern manufacturing, but choosing the right adhesive is only one part of the equation. It’s well known that you won’t get a reliable bond with an adhesive if you just slap the adhesive onto your material without doing anything to prepare that surface. What ISN’T...
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How to Avoid Polymeric Coating Failure Which Leads to Corrosion in Materials
These days, if you see a painted product, it is likely a polymer-based coating providing a striking and powerful barrier between the underlying material and elements in the atmosphere that want to corrode that material. Polymer coating technology has advanced tremendously in the last decade....
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What are Surfactants and How Do They Impact Surface Tension?
In recent articles, we’ve discussed what surface tension and surface energy are. Manufacturers must acquaint themselves with these concepts because controlling surface quality through surface energy measurement of solid materials is the most predictive method of ensuring high-performance bonds and...
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What is the Difference Between Surface Free Energy and Surface Energy?
When it comes down to it, this is another purely semantic question, much like the one we dealt with in another article comparing the terms “surface tension” and “surface energy.” Surface-free energy is free energy in a particular space - the surfaces of materials. Free energy, in its most...
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How to Measure Surface Tension
The attractive force of the molecules present at the surface of a liquid towards each other is called the surface tension of that liquid. It may seem like a little thing (and in terms of mass, it doesn’t really get much smaller than the top few molecular layers that make up the surface of a liquid...
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What is the Difference Between Surface Tension and Surface Energy
Using adhesives in manufacturing is becoming increasingly common for building everything from massive machines to everyday tech devices. But companies' reliance on the science of adhesion to make sure their products work perfectly and look marvelous didn’t start there. In the centuries since the...
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Maintaining Consistent Adhesion Quality for Shoe Manufacturers even with Material Changes
There are many reasons why sneakerheads love the shoes they covet. Athletic shoes have become one of the most sought-after clothing items due to their aesthetic appeal and shoe manufacturers' ever-evolving material innovations.
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Surface Quality in Aircraft Sealing and Bonding for Repairs
When an aircraft is manufactured, every single portion of the plane or jet is designed to be able to be serviced and repaired for the next 20-30 years. Aircraft manufacturing OEMs are building aircraft with the expectation that extensive repairs will have to be done later down the road. This is an...
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How Surface Sensitive Measurements Help Medical Device Manufacturers Avoid Regulatory Bottlenecks
The pathway to zero defect manufacturing through the implementation of quality control procedures is found right there in the name. Quality control requires the control of variables to ensure quality outcomes. But it’s the former that is beguiling to quality engineers.
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Manufacturing Best Practices for Business Continuity Plans
The manufacturing industry has undergone unprecedented challenges in recent years, necessitating a fundamental re-evaluation of business continuity strategies. While economic downturns have historically presented obstacles, the complexities of today’s globalized and interconnected business...
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Better Consumer Electronics Reliability: Coatings and Adhesives
In a recent study conducted by Instrumental, the top ten most common manufacturing defects were examined. The number one defect that manufacturers fight against is a deficiency in glue.
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Reliable Wire Bonding Through Quality Data Collection for Industry 4.0
Wire bonding and sintering are critical processes involved in the manufacture of a majority of electronic devices. These processes are used to connect silicon chips, integrated circuits (ICs), and electrical components to their housings and boards.
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Everything Breaks: What Reliability Means for Adhesively Bonded Products
The seemingly easy and obvious answer to the question implied in the title of this article is: reliability means no failures whatsoever forever and ever, amen. Sadly, it’s not quite so simple.
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Process Control Innovations for Card Manufacturers
We've all been there: the frustrating moment at checkout when your card decides to play dead, leaving you scrambling for another way to pay for that mountain of nachos. For credit and debit card manufacturers, these glitches are the ultimate nightmare.Sure, factors like rewards programs and bank...
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The Best Method of Controlling HMDS Use in Semiconductor Manufacturing
Semiconductors are one of the most fascinating areas of electronics manufacturing. The ability to “grow” almost irreducibly small integrated circuit components on silicon wafers has made an incredible amount of micronization possible. The theory has always been that as the chips got smaller, their...
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Using Data to Improve Ink Adhesion to Polymer Film
One of the most frustrating aspects of experiencing a problem in manufacturing isn't necessarily the issue itself, but rather, it's the difficulty of accurately determining and communicating what the problem actually is.
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How to Get a Stronger Weld Through Cleaning
Even though we look around us and see plastic everywhere, in every shape and imaginable application, metals are still a more commonly used raw material in machined products. Metals are the legacy material of choice due to their strength and relative ease of bonding. However, advances in polymers...
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How to Control Surface Quality for Bonding Dissimilar Materials
We’ve mentioned many times in various articles that bonded material systems are becoming the norm for manufacturers in nearly every industry. In order to make finished products more efficient in terms of weight, cut material costs, accommodate more automated processes, lessen the need for repairs...
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How to Bond Fiber Reinforced Plastics for Harsh Environments
Many manufacturers have a dual performance concern when their products are out there in the world being used in whatever capacity they were designed for. These parallel interests are: how to maintain the appearance and how to guarantee structural integrity through common usage of the products.
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Coatings on Car Sensors and Why We Don’t Have Driverless Cars Yet
Our relationship with our vehicles may have changed in the past few months, with the idea of commuting to work looking more like a shuffle to the desk across the room rather than a drive to the office across town. However, cars have not dropped in prominence in our society. With health risks now...
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Controlling Parts Washing Methods for Medical Components
Cleanliness is next to production standardization requirements for medical device manufacturers (as the old saying goes). Devices built to be inserted within the human body understandably need to meet the highest cleanliness standards. Companies in this industry have already known what many of us...
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How to Control Additive Blooming in Polymer Films
We all take the ease of peeling open and resealing packs of double-stuff Oreos for granted. The plastic packaging that maintains the freshness of our favorite snacks and foods has become so ubiquitous it doesn’t even register as existing until we try to open that hotdog pack with our bare hands or...
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Single vs Multi-fluid Contact Angle Techniques Part 1: Surface energy and the attractions between substances
This is part one of a two-part series explaining the finer points of Brighton Science's approach to helping companies build reliability into their cleaning and adhesion processes through consultation and implementation of novel inspection equipment. These two articles are based on this technical...
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Proposed ASTM Standard Will Ease the Pain of Manufacturers
An exciting development is taking place to make surface quality and cleanliness inspection technology more available to all manufacturers. We have collaborated with ASTM International and other stakeholders to craft a revision to establish a standard use of handheld goniometers in production...
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Demystifying the Greatest Metal Brazing Process Challenges
When thinking about what manufacturing looks like, most people envision sparks flying, metal clanking, and fires blazing. This isn’t too far off the mark since metals were used to bond joints together to build larger, sturdier, and more stable structures before the first Industrial Revolution,...
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How to Protect Overmolded Connectors for Medical Devices
Protective coverings are part and parcel of our lives these days. For industries reliant upon electronic components and connectors, protective coverings in the form of polymeric over-molding encapsulation need to remain sealed and impervious to the environment.
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How to Bond PTFE to Anything
Polytetrafluoroethylene, or PTFE, is a very common material widely used in almost every major industry. This ultra-lubricious and multi-use fluoropolymer touches everyone from the aerospace and automotive industries (as an insulating cover on cabling) to musical instrument maintenance (it’s found...
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Cleaning Strategies for Great Adhesion
Cleanliness in manufacturing gains avid devotees all the time. Once the importance of cleanliness is grasped, it’s nearly impossible to think about manufacturing processes without considering the pervasive impact cleanliness has on every aspect and feature of the process.
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Conformal Coating Failure Caused by Poor Surface Cleanliness
Electronic components consist of many exposed and delicate pieces that leave them vulnerable. A lot is relying on these fragile parts to function without fail. From implantable medical devices to navigational equipment and from sensor packages in cars to cell phones, the manufacturers of electronic...
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Importance of Adhesion & Composites in Lightweighting Cars
One of the most pressing questions on the minds of manufacturing engineers is how to take a load off. Lightweighting, or shedding pounds on assembled vehicles and machinery, is a critical puzzle in aerospace, marine, and, most acutely, automotive industries. In fact, with the pressure to optimize...
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Is Roughness as Important as Surface Cleanliness to Adhesion?
When manufacturing engineers discuss material surfaces, they usually focus on their physical attributes, such as surface topography or morphology or, more simply, surface roughness. Preparing material surfaces for assembly, coating, painting, or adhesive bonding typically includes steps that...
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The Tools & Skills to Address Adhesion Problems in Production
When adhesion issues become apparent in a manufacturing process, they can seem to come out of nowhere. When coatings on circuit boards delaminate and cause shorts, when automotive glass doesn’t properly seal and moisture is let through, or when implantable medical devices aren’t meeting cleanliness...
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The 3 Crucial Elements for High-Performance Adhesion in Manufacturing
Excellent adhesion relies on the manufacturer’s ability to understand and control three distinct yet interrelated elements. In manufacturing, adhesive bonding takes many forms, but the fundamental principles of adhesion are always the same. Even if the application is metal joint welding, Parylene...
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Best-practice Surface Preparation Processes for New Products
New Product Development is an essential component to the successful growth of companies that always challenge themselves to improve and innovate. Getting this design stage right is pivotal in that it sets in motion everything the product will be and how well it will perform.
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How to Minimize Production Scrap from Adhesion Failures
In manufacturing, it is extremely difficult to eliminate all inefficiencies and production deficits. It is not uncommon for setbacks to occur in the form of scrap and rework due to product failure before the product is shipped to the market or recalls and returns after the product has already been...
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How to Ensure a Manufacturing Surface is Clean Enough for Adhesion
Cleanliness and adhesion go hand-in-hand. If you’re looking for an adhesion process to be successful, you are also absolutely interested in cleaning the materials involved in the application. To get the most out of your cleaning operations, it’s imperative to know three things: What does clean...
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How Surface Quality Devices Can Validate Adhesion Specs
Regulatory specifications in manufacturing exist to ensure that the highest quality, safest, and most useful products are created. These are devised internally through research and development testing to meet customer demands and through external regulatory bodies to protect consumers and public...
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Can a Surface Science Lab Ensure Adhesion in Manufacturing?
Manufacturers utilize research and design laboratories all the time. To scale new products up to the production line, years of toiling in testing labs are done to ensure that everything goes off without a hitch once production starts.
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Why a Surface Quality Inspection Process Ensures Adhesion
Manufacturing processes that involve bonding, coating, sealing, printing, painting, laminating, or cleaning need a metric to measure the surface quality of the materials involved. Without such a metric, it is impossible to predict whether the adhesion process will be successful or if it's on the...
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7 Most Valuable Tips to Ensure Proper Adhesion in Production
Adhesion problems are an insidious concern to manufacturers in any industry with printing, painting, bonding, laminating, or coating applications. These problems settle into a production process, and they manifest in many different ways. An adhesion issue could look like a joint failure, uneven...
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Guaranteeing Anti-fog Coating Application on Automotive Headlights
The competitive nature of the automotive industry requires manufacturers to engineer the ideal product; failures, no matter how small, are unacceptable and can bring heavy consequences.
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Tales from Brighton Science's Materials & Processing Lab
In the Brighton Science Materials and Processing Laboratory, magic happens. Or, at least, it seems that way. In the lab, our specialists see the unseen. They use expertise, specialized tools, and data to reveal the invisible.
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Surface Treatment Processes: Flame Treatment
Flame treatment is a surface activation treatment process used to chemically modify a surface for better adhesion. This process is typically used on low-energy surfaces that can be difficult to adhere to, such as plastics and composites. The treatment is also very gentle, posing low risk to the...
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Brighton Science's Exceptional Lab: Experts in Advanced Materials and Processes
Brighton Science Lab Capabilities The history of Brighton Science (formerly BTG Labs) is rooted in adhesion research. Originally a development lab, Brighton Science specialized in plasma polymerized coatings. The engineers worked with coatings containing corrosion-resistant and anti-microbial...
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Automotive Series: Surface Preparation of Composite Surfaces
Building a More Fuel-Efficient Automobile The pursuit of producing a more fuel-efficient automobile does not rely solely on the efficiency of the engine. A great amount of fuel efficiency gains are possible not because of improvements to engine design but because of improvements in materials....
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Contact Angle Analysis: Sealing Surface of Aluminum Castings
Surface Quality Requirements of Aluminum Castings Automotive manufacturers widely utilize aluminum castings as the most successful way to create aluminum parts. However, this process can involve inorganic contaminants on the surface, which interfere with potential bonding, sealing, or coating....
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Automotive Applications Series: Ensuring Success for Formed-In-Place Gasket (FIPG) Applications
Controlling Surface Condition in FIPG Application Increasingly, FIPG processes are replacing traditional gaskets for a variety of automotive applications, such as air filters, oil filters, door panels, and external engine parts. The advantages include cheaper material cost, higher throughput...
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