Surface Adhesion in the Automotive Industry

Plastic Remains the Material of Choice

The automotive industry has embraced plastics as the material of choice from bumper to bumper beginning in the 1950s. The reasons are obvious- plastic is light, cheap, moldable and can be decorated. What’s more, plastic doesn’t corrode, it can handle impact, it contributes to safety (less metal and glass), fuel efficiency, and elevates possibilities in design. In fact, in today’s internal combustion vehicles plastic makes up nearly half of the volume but only ten percent of the weight.

Surface Treatment’s Essential Role: The plastic materials and parts incorporated into vehicles very often require surface treatment because of plastics’ chemical resistance to bonding with any type of media. Corona and plasma treatment in the automotive industry are an effective way to raise the surface tension on polymers causing them to readily accept media. Consequently, surface treatment is invaluable in functionalizing polymers and other substrates for numerous automotive applications. Examples of this are wetting out surfaces prior to applying adhesives, improving the bonding of paint for metalizing parts, decorating and labeling components,  applying flocking and coatings on profiles for better part performance, and improving the bonds between similar and dissimilar materials. Additionally, metal, glass, and composites often require surface treatment to improve their wettability for downstream processes.

Transitioning to Battery Power: With the evolution and push towards electric vehicles, manufacturers in the automotive industry are experiencing many changes and opportunities.

Due to the weight of EV batteries, auto manufacturers are working to reduce the weight of other vehicle components. This is important because the lighter the vehicle the further the range with the same battery power. “Lightweighting” is causing major shifts in materials, the reconfiguration of structure, even in paint finishing.

As EV auto manufacturing develops, opportunities for plastics do as well. This includes the manufacture of the battery itself utilizing films, foils and separators in next gen battery technology. Battery enclosures represent an opportunity for plastics in this complex and critical part. Other important changes include lightening the structure of  vehicles with the use of polymer composites and other types of reinforcements for added strength. 3DT’s surface treatment technology is applicable to each of these developments by functionalizing film, composites, metal and more.

Another challenge of EVs lies in the increased voltage, which generates higher temperatures requiring high-performance, heat tolerant plastics that meet the same demands of durability and sealing for internal combustion engines. Surface treatment may be needed for these heat durable parts to perform up to standards.

Full Speed Ahead with More Changes in the Industry: Many automotive manufacturers are switching to bioplastics, recycled plastics, and polymer composites to improve their carbon footprint and promote sustainability. These materials typically benefit from surface treatment to improve their adhesive qualities.

Manufacturers are turning their focus to entertainment options, sensing features and driverless capabilities. Plasma and corona surface treatment in the automotive industry are ideal for improving the bonding on glass and metal as well. These applications are important as cars become higher tech with digitized screens, embedded wiring, exterior sensors, cameras and more.

Film is now replacing traditional auto painting especially in new EV facilities. Benefits include film lines are less expensive, and the film itself is more economical, faster to apply, more durable and lighter weight than paint. What’s more, film doesn’t contribute to air pollution. However, plastic film is highly hydrophobic and requires corona treatment to become receptive to ink and laminating processes.

Let 3DT Be Your Partner: It’s an exciting time in the automotive industry and surface treatment has an important role in improving the adhesion on polymers and numerous other materials. 3DT provides 30+ years of experience and expertise in developing corona and plasma treatment solutions in the automotive industry. We manufacture a full line of surface treatment systems; each is customizable for your unique application. We also provide product handling and automation options as needed.

Let’s collaborate on your automotive application. 3DT’s team will problem solve with you utilizing our lab and surface treatment equipment. We will discuss your application and requirements, test your materials, provide a detailed report, and develop recommendations.

For improved adhesion, wettability, better product quality and performance, 3DT is your provider of plasma and corona solutions. Contact us or request a quote today to discuss your application.