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Tag Archive: plasma surface treatment

  1. Guide to Plasma Surface Treatment and Corona Surface Treatment in Medical Device, Pharma, and Labware Manufacturing

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    Medical practitioners are increasingly utilizing plastics in their devices and instruments due to the material’s versatility, quick processing, light weight, bio-compatibility, sterility and price point. Plasma and corona surface treatment are an ideal fit for medical, pharmaceutical, and labware manufacturing. Once surface treated the value of inexpensive polymer parts greatly increases due to now becoming specialized, functionalized, engineered components. Plasma and corona surface treatment produce reliable, durable, and uniform results through electrical discharge that heighten energy on the surface of polymers and other substrates to increase their capacity for adhesion and bonding.

    What Can Plasma Surface Treatments and Corona Surface Treatments

    Note how the ink adheres in the center of the bottle where it was plasma treated with 3DT’s PlasmaDyne Pro.

     Achieve in Medical Device Manufacturing?

    Medical device manufacturers use plasma and corona surface treatment for various reasons. First, surface modification improves adhesive, coating, and ink bonds with a substrate by chemically changing substrates from being hydrophobic to hydrophilic. Manufacturers utilize corona and plasma treatment to solve complex challenges, especially plastic material applications that present incompatibility issues for bonding. Other specialized applications include applying protective coatings that either draw or fend off fluids and improved cell adhesion in laboratory containers made from polycarbonate and polystyrene.

    What Are Some Useful Applications for Plasma and Corona Treatment in the Medical Industry?

    Within medical manufacturing, the range of uses for plastics is vast. As a result, corona and plasma technology is regularly used for improving the bonding power of ink, adhesives and cell culture growth. Surface treated items include syringes, tubing, pipettes, bottles, flasks, vials, multi-well plates, Eppendorf tubes, culture plates, and other polymer labware items manufactured for research, drug discovery, and diagnostics testing. Surface treatment is employed for all types of parts and components for medical devices and pharma packaging.

    Plasma treatment can assist the bonding of dissimilar materials. This can involve bonding metal to plastic, silicon to glass, polymers to other polymers, biological content to microtiter plates, and even bonding to polytetrafluoroethylene (PTFE). Whether bonding metal to plastic, silicon to glass, polymers to other polymers or biological content to microtiter plates, corona and plasma can be used to promote adhesion. 

    Adhesion promotion is achieved by increasing the substrates surface-free energy creating a dramatic improvement in bonding. In some cases, up to a 50x increase in bond strength can be achieved.

    What Are the Benefits of Using Plasma and Corona Surface Treatments?

    Plasma and corona surface treatment generate numerous benefits for medical, pharmaceutical, and laboratory components. These treatments offer:

    syringe, tubing, corona treated, printed

    Surface treatment creates secure bonding of ink, coating, adhesive and more.

    High-Quality Results

    Businesses in these sectors all require reliable, high-quality products for critical applications, making plasma and corona treatment ideal. As these surface treatments ensure consistent and superior wettability, the resulting products will have greater capabilities for adhesion—even for the most challenging of plastic substrates—as well as overall product performance. The secure bonding with media such as ink, paint, and adhesives is an important benefit for medical devices, changing a two-dollar plastic part into a fifty-dollar component. 3DT specializes in developing these processes and systems for customer’s unique applications. 

    Speed

    Both plasma and corona surface treatment are typically fast, usually taking little time at all, depending on the process and materials. Treating can take just seconds to complete, with the potential for treating up to 1,000 parts per hour. As an added benefit, these surface treatments do not necessitate primers, curing or drying; cutting those stages from the production timeline for greater time savings.

    Uniformity

    These processes are an excellent solution for products that need treating on the whole of their surface, even hard-to-reach nooks, crannies, and drill holes. As such, they are ideal for 3D components with complex configurations, providing consistent, reliable pretreatment. Processes utilize highly repeatable, recipe-based programming.

    3DT’s MultiDyne with 2 treating heads treats a medical device placed on a spinning mandrel prior to printing.

    Cost-Effectiveness

    Plasma and corona surface treatments have opened up additional opportunities for medical manufacturers. To start, the speed of these treatments plays a part in increased savings. They can also reduce operating costs by allowing companies to adopt the use of alternative materials that are less expensive than typical base substrates, as well as chemicals, primers, and adhesives. This also leads to less scrap and waste generated which equates to greater savings as well.

    Environmental Friendliness

    Surface treatment improves the adhesion of environmentally-friendly, solvent-free, water-based primers, adhesives, and inks, eliminating the use of chemical baths and primers.  Plasma surface treatment, unlike chemical processes such as priming or etching, are clean processes that do not produce environmentally harmful waste. Instead, they give off minor amounts of non-hazardous gasses only. Corona processes generate ozone, but using an ozone filter eliminates the issue. Additionally, corona and plasma do not use an open flame, and are much safer for operators. 

    What Medical Devices Are Treated with Plasma Surface Treatment or Corona Surface Treatment?

    3DT’s FlexiDyne Pro quickly corona treats polystyrene labware for improved cell culture growth.

    Plasma and corona surface treatments are applicable for:

    • Ampules, vials
    • Catheter tubing
    • Implants
    • Insulin pens
    • Lenses
    • Medication bottles
    • Needle hubs
    • Ostomy bags
    • Petri dishes
    • Labware: flasks, multi-well plates
    • Surgical instruments
    • Syringes

    3DT is Your Source for Corona & Plasma Technology

    Plasma and corona surface treatment are vital in healthcare manufacturing for providing effective, reliable adhesion and product performance. As a leading manufacturer in surface treatment, 3DT LLC provides clients with innovative, high-performance bonding solutions for a wide variety of substrates from plastics and rubber to glass and metal. We offer both standard and custom-engineered systems for greater application versatility. Learn more about our product line here. Our team can incorporate 3DT’s systems into new or existing production lines. For more information on our capabilities and how our surface treatment technology can support your operations contact us today at sales@3DTLLC.com or call 1-262-253-6700.

     

  2. 8 Facts About Plasma Surface Treatment

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    3DT has manufactured corona and plasma treatment systems for over 30 years. Our solutions enhance the surface characteristics in materials and components, including adhesion, bond strength, cell culture growth, cleanliness, and wettability. We offer a broad range of standard and custom options in our PlasmaDyne Pro series for use in customer facilities that accommodate a wide number of applications and substrates. 3DT’s systems can be used for plasma treatment for plastics, glass, foam, metal, and more.

    What You Should Know About Plasma Treated Surfaces  eight interesting facts about plasma treatment that address why they are used, how they are used, and more.

    #1 Plasma: The 4th state of matter.

    lightning is plasma

    Everyone is familiar with the three states of matter (solid, liquid, gas), but the fourth state is one that is less well known- plasma energy. Yet, everyone is familiar with lightning seen on a summer evening. This powerful energy is plasma! Essentially, plasma is an ionized gas consisting of approximately equal numbers of positively and negatively charged particles. There are two general forms of plasma: high-temperature plasmas that are found in stars and in fusion reactors; and low-temperature versions used in surface treatment, neon and fluorescent lighting, plasma TVs and semiconductor manufacturing.

    #2 Plasma surface treatment is powerful enough to break hydrogen bonds.

    Plasma surface treatment is created by combining reactive gas molecules and an electric field. This method uses one or more high voltage electrodes which charge the surrounding blown gas molecules, resulting in a highly ionized field that is forced onto the targeted surface. This highly ionized air stream creates a thermal property that reacts with the substrate and breaks the existing hydrogen bonds by introducing oxygen which recreates the chemical properties of the surface. The plasma process causes a molecular reaction on the substrate. It also creates finely etched and micro-cleaned surfaces resulting in better wettability, stronger bonding traits. See a video of PlasmaDyne Pro treating bottles in a trial here. 

    #3 Plasma surface treatment improves adhesion.

    Plasma surface treatment modifies the surface of a material on a molecular level, enabling it to bond more readily with adhesives, ink, paint, and other media. It is effective on a variety of materials; even difficult-to-bond materials can achieve better adhesion without experiencing surface damage.

    #4 Plasma treatment improves adhesion on a wide variety of materials.

    Bonding problems are pervasive throughout manufacturing, especially the plastics industry. Manufacturing and decoration often include joining plastic-to-plastic, plastic-to-metal, plastic-to-composite and more. But, plastics and many other materials possess low surface energy or “wettability” and therefore, require plasma pretreatment.

    Plasma treatment is a non-invasive, non-heat-based process that can be used on virtually any material. It encourages molecular bonding on surfaces, micro-cleans contaminants, and causes fine etching. Plasma treatment facilitates the bonding of adhesive,  ink, paint, and other media to a range of substrates. These materials benefit from plasma treatment:

    • Plastics
    • Rubber and Elastomers
    • Engineering Polymers
    • Composites
    • Glass
    • Metals and alloys
    • Ceramics

    #5 Many industries rely on plasma surface treatment for their products.

    Plasma surface treatment is used to enhance the wettability, adhesion, and cleanliness of materials within numerous industries, including:

    • Aerospace: The aerospace industry uses plasma surface treatment on critical surfaces to enhance adhesive bonding.
    • Automotive and Transport: The automotive and transportation industries utilize plasma treatment to improve adhesive bonding between components and enhance paint and coating adhesion to a variety of substrates.
    • Consumer Goods: Plasma treatments enhance the functional and aesthetic quality of various consumer goods.
    • Electronics: Plasma treatments protect sensitive components within potting. Plasma treatment is nearly potential-free allowing plastics with embedded circuitry to be safely surface treated.
    • Medical and Biotech: Plasma treatment is used for raising surface energy and micro-cleaning surfaces to ensure optimal bonding between components and devices.
    • Packaging: Packaging materials, such as plastic films, cardboard, and plastics, are often plasma treated to promote adhesive and ink application during printing and labeling operations.
    • Printing: Printing operations integrate plasma treatments to enhance surface wettability to ensure precise, vivid, and long-lasting ink adhesion.

    #6 Plasma surface treatment is versatile.

    Due to its exceptional versatility, plasma treatment has become critical for a wide range of applications, such as:

    • Painting, coating, and printing for plastic products
    • Enhancing coating adhesion for polymer extrusions
    • Printing, painting, and coating rubber profiles
    • Cleaning the surface of aluminum and other metals
    • Improving adhesion of glue on cardboard products
    • Treating silicone foam to enhance adhesive application
    • Improving adhesion of paint and ink to composite materials

    #7 The advantages of plasma treatment include speed, cost-efficiency, eco-friendliness, and more.

    Plasma treatment offers a number of advantages over other treatment options. For example:

    • It is potential-free: Atmospheric plasma is potential-free, so the treatment process can be used in conductive, semi-conductive, and non-conductive applications.
    • It is effective for surface cleaning: Plasma can be used for micro-cleaning operations, which removes surface impurities and contaminants.
    • It is environmentally friendly: Plasma cleans and enhances material surfaces without the use of harmful chemicals or ozone emission.
    • It is cost-efficient: Plasma treatment reduces process time by improving bonding, increasing surface cleanliness and wettability. You spend less time processing the substrate and use less ink, paint, glue, or coating due to optimal adhesion. Less waste and scrap are created, plus our plasma systems have low energy costs.

    #8 3DT is your go-to source for all plasma surface treatment products!Plasma Dyne Pro Cut Out 4 MB 4455AP

    3DT is a leading provider of plasma surface treatment solutions. Equipped with more than three decades of experience, our experts will thoroughly discuss your application with you and help to select one of our standard PlasmaDye Pro systems or a custom-engineered PlasmaDyne Pro based on the requirements of your application. PlasmaDyne Pro can be customized for nearly any 3D or flat surface. We also offer product handling and automation.

    Learn More About Plasma Surface Treatment From 3DT

    Plasma surface treatment improves the surface properties of materials, which is why they are used in many industries and applications. To learn more ask the experts at 3DT. As an experienced manufacturer of plasma surface treatment systems, we can address any questions you may have about the process and our systems. If you need a plasma system for your facility, we’ve got you covered.

    To learn more about our products and how they can benefit your components and materials, check out our PlasmaDyne Pro or contact us today.