White Paper: Manufacturing & Prototyping
Advanced Surface Treatment in a Shifting Trade Environment
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Shifting trade policies, rising import costs, and VOC regulations are forcing automotive manufacturers to rethink bonding processes. This quick guide explores how plasma surface treatment enables reliable adhesion without primers or solvent-based chemicals. Learn how OEMs and Tier 1 suppliers are improving performance on EV assemblies, localizing production, and reducing material dependency — all while meeting strict compliance standards. A timely resource for engineering and operations teams facing global supply chain disruption.
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Overview
The document serves as a technical guide on advanced surface treatment technologies, particularly focusing on the automotive industry’s challenges and the benefits of atmospheric plasma treatment. It highlights the evolving trade conditions, tight margins, and the need for reliable bonding in lightweight, multi-material assemblies, especially in the context of electric vehicles (EVs).
Key engineering benefits of plasma treatment include reduced dependency on imported primers and adhesion promoters, minimized inventory of solvent-based chemicals, and simplified quality control processes. The technology enhances bond reliability by ensuring consistent wettability across complex surfaces, improving bond strength and fatigue resistance, and being suitable for a variety of materials, including polyolefins, elastomers, composites, and metals.
The document outlines the critical role of surface energy in ensuring proper adhesion of paints, sealants, and adhesives. Many automotive materials naturally resist bonding, necessitating effective surface engineering solutions. Atmospheric plasma treatment emerges as a scalable alternative to traditional chemical surface preparation and flame treatment. It operates by cleaning surfaces, activating them to increase surface energy, and functionalizing them to enhance bonding through the introduction of reactive groups or the application of ultra-thin coatings.
The Openair-Plasma® system is highlighted for its inline processing capabilities, operating at atmospheric pressure without the need for vacuum chambers. It can achieve processing speeds of up to 800 mm/s and utilizes compressed air or inert gases for optimal results. The treatment process includes cleaning contaminants, activating surfaces to elevate energy levels, and applying customized chemical layers for specific adhesion needs.
The document also emphasizes the importance of validation and testing protocols, including contact angle measurement, dyne ink testing, and adhesion testing standards. These protocols ensure that surface treatments meet the required performance metrics and environmental durability standards.
In conclusion, the guide positions Plasmatreat as a partner for automotive manufacturers looking to enhance their bonding processes, reduce reliance on imported materials, and comply with stringent environmental regulations. It offers support through onsite trials, technical consulting, and custom system design, aiming to create a cleaner, faster, and more resilient production process.