Dymax Corporation Application Case Histories
Our Technology. Your Advantage®
Our ability to provide oligomers, formulated products, dispensing and curing equipment, and unmatched technical expertise in light-cure technology allows us to truly collaborate with customers and bring our total process knowledge to their specific application challenge. By providing system solutions where chemistry, material, and equipment work seamlessly together with maximum efficiency, we give your customers a competitive edge they can't get anywhere else.
Improving Efficiency of Aerospace Printed Circuit Board Assembly
CUSTOMER’S OLD PROCESS- Total Process Time: 210 min
- Total Heat-Cure Time: 360 min
- Throughput: 16 boards per day with 2 workers
DYMAX SOLUTION- Process Time Reduction: 201 minutes per day or 52,260 minutes per year
- Throughput Improvement: 37 PCBs per day, from 16 to 53, with 1 worker
- Manual Masking Step Eliminated
- Replaced 3-Part Solvated Conformal Coating with 1-Part, Low-VOC Product
Customer’s Challenge: The ProblemA manufacturer specializing in aerospace PCB assembly wanted to improve their efficiency and throughput by reducing overall processing time while lowering labor costs. The customer’s original method involved a 10-step procedure including premixing materials, applying ruggedizing materials, manual masking, application of conformal coatings, and lengthy heat-cure times for each side of the PCB. The customer’s total process time was 210 minutes and the heat-cure time was 360 minutes for each board, and with two people, the throughput was only 16 PCBs per day.
Our SolutionThe Dymax team, including the territory manager, sales partner and application engineer, met with the customer to review their assembly process and understand their manufacturing needs. After listening to their challenges, the Dymax team recommended a UV light-cure solution with automated dispense and cure options to meet their efficiency goals and expectations. The proposed products included Dymax dual-cure 9481-E conformal coating and 9309-SC ruggedization / reinforcement adhesive. To eliminate the manual masking step, a PVA Delta 8 dispensing robot for precise application of the materials was incorporated into the process along with a Dymax UVCS 12" conveyor with Fusion F300 lamps for fast UV curing of the printed circuit boards.
The ResultsBy switching to light-curable materials, removing the masking step, and implementing an automated process, the customer drastically reduced the total processing time by 95.7%, from 210 minutes to only 9 minutes. Altogether, Dymax helped the customer increase production by 231.3% and save 871 hours per year. In addition, a light-cure solution eliminated the lengthy heat-cure process, mixing time, and provided an environmentally friendly green process.
Improving PCBs Masking Process in Aerospace and Defense Applications
CUSTOMER’S OLD PROCESS- Application Time - 19 minutes/board followed by air dry
- Throughput per day – 22 boards/person across 5 workers
- Total production – 110 boards
DYMAX SOLUTION- Process Time Reduction: 32 hours
- Throughput increase: 22 boards/person: > 96 boards/person
- Labor reduction: 80%
Customer’s Challenge: The ProblemA manufacturer specializing in PCBs for aerospace and defense applications wanted to improve its process efficiencies by increasing throughput and with automation of the masking process. The customer’s original process involved masking military-grade PCBs in preparation for coating with a solvated conformal coating. Each board contained 28 plated mounting holes, 33 flush test points, and 8 through-hole connectors prior to coating. The customer’s application time was 19 minutes per board followed by racking the boards for air drying of the maskant. With five people, they were only able to process 22 PCBs per person, per day for a total of 110 PCBs.
Our SolutionThe Dymax Team Territory Manager and Sales Partner met with the customer to review their process and understand their needs. The Dymax team looked at a UV solution, automated dispense and cure options as an alternative. They proposed Dymax SpeedMask 9-20479-B-Rev-A and PVA Delta 8 Dispense Robot with FC100 dispense valve supported with Dymax UVCS12 Conveyor with Fusion F300 UC curing lamps.
The ResultsBy switching to SpeedMask 9-20479-B-REV-A and the implementation of an automated process, the customer was able to cut the process time from 19 minutes to apply only the maskant to 5 minutes to dispense and cure. Altogether, Dymax helped the customer increase production output from 22 boards/person to 96 boards/operator, a 14-minute reduction in the process. The customer achieved daily process savings of 32 hours while freeing four operators for other processes.
Improving Masking Process for Electroless Nickel Plating in Aerospace and Defense Applications
CUSTOMER’S OLD PROCESS- Each part requires 2 to 3 coats of lacquer maskant to get necessary thickness
- Brushed on by hand which takes 30-45 min per each coat
- Long cycle time to apply/cure maskant up to 72 hours
- High scrap rate of 10% with current masking process
DYMAX SOLUTION- Process Time Reduction: under 45 minutes
- Validation of cure with color change upon proper cure with SpeedMask 7601
Customer’s Challenge: The ProblemAn international company specializing in manufacturing and repairing landing gear and actuation systems for the aerospace market was looking for process efficiencies in their Electroless Nickel Plating process. Their target was to automate the masking process and increase throughput. The customer’s original process involved applying 2-3 coats of long drying lacquer based maskant prior to the electroless nickel plating of landing gear components. The customer’s manual brush application time of the lacquer maskant was 45 minutes per coating. Air-drying the parts also added a minimum of 8 hours to their production time. The customer ran production one shift per day, the masking (application and drying) process took up to 3 days (72 hours). The inconsistencies of the manual hand-brush masking application caused rework and a scrap rate of 10%.
Our SolutionDymax Territory Manager and sales partner met with the customer to review their process and understand their needs. The Dymax team selected an UV solution, and light-cure system that addressed the customer issues. They proposed Dymax SpeedMask 7601 maskant and the SG-150 Spray Valve System supported with Dymax BlueWave® 200 curing-system.
The ResultsBy adapting the proposed Dymax UV-solution, the customer was able to drastically reduce cycle times to less than 45 minutes. In addition, the spray application improved part quality, consistency and reliability of the maskant helped reduce scrap and rework.
GenZe Electric Transportation Application Case History
GenZe is a leading US-based pioneer in two-wheel electric transportation, with headquarters in Silicon Valley and manufacturing in Ann Arbor, Michigan. As part of the $19 billion Mahindra global network, GenZe has developed leading edge engineering, R&D, and design innovations.
THE CHALLENGEProducing an aesthetically-pleasing removable Li-Ion battery pack without compromising safety and reliability.
THE SOLUTIONGA-201 is formulated for sealing plastic, glass, metal enclosures, and plated surfaces that require a soft, tack-free, flexible gasket. It acts as a moisture barrier and prevents absorption or penetration of air, dust, noise, liquids, gaseous substances, or dirt.
THE RESULTSThe Dymax system solution enabled consistent production of GenZe battery assemblies that meet strict design standards of weight, performance, and safety. GenZe 2.0 Scooter Battery for GenZe 2.0 Scooter GenZe Battery Lid - Gasket on Outer Edge Dispense/Cure Cell - Robot Outfitted with BlueWave® 200 and Dymax Dispensing Valve
Customer’s Challenge: The ProblemPackaging state-of-the-art electronics with energy-dense Li-Ion battery cells presented some unique challenges and opportunities. Because the battery pack is removable, many design challenges had to be addressed. Weight, performance, and safety were top priorities. GenZe engineers pored over the designs for thousands of hours and those efforts resulted in a safe, aesthetically pleasing, yet extremely complex battery system. The question was, could it be mass-produced, and at the same time be serviceable? The manufacturing engineering team had to develop a process to assemble the system, while ensuring it could be disassembled and resealed reliably, time and time again. Countless trials of different options ranging from solid die cut gaskets to individual O-rings and liquid materials were run. None of the trials proved to be a solution that could provide the necessary sealing performance while being easy to apply.
Our SolutionAfter visiting the GenZe production floor to assess the process, a Dymax team of marketing, application engineering, and sales personnel suggested a solution - GA-201 – a form-in-place gasket that would satisfy the needs of the application, not only in terms of sealing protection, but also in terms of manufacturability. In addition, this “dispensable” gasketing material demonstrated previously unseen flexibility to the product engineers. This was a breakthrough because the product’s styling and packaging would no longer be limited by its sealing requirements.
The ResultsAfter running months of performance and validation testing, GA-201 proved to be the solution GenZe was searching for. The Dymax team not only brought their materials expertise to the table, they offered process application recommendations and assisted GenZe process engineers with the selection of the proper dispensing and UV curing systems. This shortened the equipment selection process significantly and added much needed confidence in attempting to produce a product that had never been offered before. A complex manufacturing cell, which includes a 6-axis robot complete with precision dispensing equipment and a BlueWave® 200 curing unit, was installed. And in a very short time, battery assemblies that power the GenZe 2.0 scooter were in production and passing the rigorous in-process tests with flying colors.
Cinch Gaming Case History
Cinch Gaming, a national leader in custom professional video game controllers, was looking for a durable solution to provide a rubber grip coating to their ABS plastic controller shells. Cinch controllers are used at all major gaming tournaments and LANs around the world. The controllers are fully customizable and unlike competitive products, feature ergonomically placed rapid-response back buttons, fully adjustable trigger stops, and Cinch Tech® game skill recognition technology. Cinch was looking for a way to incorporate a textured surface on the grips of their controllers to provide gamers with better feel and increased performance.
THE CHALLENGEFind a material that provided a less sticky, more textured, grabby surface for gaming controllers.
THE SOLUTIONThe SpeedMask® resin had excellent adhesion to the controllers and provided the non-sticky, textured feel the customer needed. An SG-100-RH spray gun and a BlueWave LED Flood completed the system.
THE RESULTSThe Dymax system solution enabled the customer to get a durable and tactile grip that is now being offered as an option on all Cinch controllers. Cinch Grip Applied to Controller - Style 1 Cinch Grip Applied to Controller - Style 2
Customer’s Challenge: The ProblemOver-the-counter rubber and adhesive products didn’t sufficiently bond to ABS materials enough to provide both a durable and tactile solution. Because gamers can use game controllers for extended periods of time, Cinch needed a product that could not only withstand extended use, but provide a comfortable and tactile grip experience as well. Our Dymax Application Engineers recommended using light-curing adhesives to replace the current laser weld process.
Our SolutionThe Dymax Application Engineering team recommended several light-curable coatings that would provide a strong bond with ABS plastic materials. Ultimately, a SpeedMask® resin was selected as the coating of choice because it was able to provide good “grip” without being sticky. A Dymax SG-100-RH spray gun was selected to apply the coating. This resulted in additional benefits as it allowed for the coating to be dispensed in a type of splatter pattern that created a more secure grip-like texture that gamers prefer. A Dymax BlueWave® LED Flood System was selected to cure the coating because it could cure it in a matter of seconds without risking damage to the surface of the controller.
The ResultsThe Dymax system solution enabled the creation of a durable and tactile grip that is used across a wide range of professional video game controllers. “Cinch Grip” is currently being offered as a new or retrofit option on all Cinch controllers.
Dymax SpeedMask resins are not intended for applications involving direct or prolonged contact between the skin and the resin, and Dymax has not tested or evaluated its SpeedMask resins for such applications. Dymax does not warrant that its SpeedMask resins are suitable for such applications, and it is the purchaser’s responsibility to test the suitability of any Dymax resin for the purchaser’s specific application. Should a purchaser choose to use a Dymax resin in an application similar to the one described above, purchaser does so at its own risk, and Dymax will not be held liable for any claim, damage or injury that allegedly arose, whether directly or indirectly, from contact between a complainant’s skin and a Dymax SpeedMask resin. Please refer to Dymax’s General Terms & Conditions of Sale.
A leading industrial electronics company, was looking to enhance quality, and increase production of their inverter PCBs. In their search for an environmentally friendly solvent free conformal coating they turned to the Dymax Application Engineering (AE) team for help.
THE CHALLENGEFinding a solvent-free coating with a high dry thickness that will protect against corrosion caused by gas and salt.
THE SOLUTIONSolvent–free Dymax 9482 conformal coating is engineered for coating thicknesses up to 25 um (0.010 in) and offers superior protection to alternative products. The Dymax Edge Carry Conveyor was customized to boost productivity.
THE RESULTSOur Dymax solutions system helped the customer increase output by 30%.
Customer’s Challenge: The ProblemOur customer was developing a new industrial inverter model that required a high dry thickness of conformal coating to meet electric performance. The product they were using at the time was a solvent based coating with a low dry (25um/0.010 in) thickness. Air pollution and odor from solvent based coatings were also a huge concern as the employees’ health was at risk.
Our SolutionCommitted to nurturing collaborative partnerships with our customers, our AE team worked closely with the customer to come up with an innovative solution to protect the PCBs from harsh environments. Our customer needed an environment-friendly conformal coating that does not crack, delaminate, or show signs of corrosion, while maintaining mechanical and electrical properties after testing. After researching and testing our customer’s parts, dual-cure 9482, a light-curable secondary moisture-cure coating, was recommended to ensure complete coating that flows underneath components on printed circuit boards. This conformal coating achieved a UL 94-V0 flammability rating up to 10 mils thick, which makes it ideal for environmental protection of PWBs, wire harnesses, electronic components, and other surfaces needing a protective coating. It passes thermal shock requirements from -55°C and up to 135°C at 10 mils, while protecting against moisture, condensation, dust, dirt, salts, chemicals, abrasion, thermal shock, mechanical shock, and other factors that can all affect circuit performance. Dymax 9482 was ideal for the customer’s application as it is engineered for coating thicknesses up to 25 um (0.010 in) and becomes tack free immediately after UV curing, helping to avoid handling defects and reduce processing time and costs. In addition, it contains no nonreactive solvents and fluoresces vivid blue when exposed to UV light (365 nm) for easy post-cure inspection. To speed curing time our application engineers suggested using a Dymax Edge Carry Conveyor system. The conveyor was customized to a 6 lamp system to optimize their production process. Rapid curing allowed the coated boards to swiftly move onto the next step in the manufacturing process with virtually no down/wait time.
The ResultsOur customer was very satisfied with how our complete Dymax system solutions improved their process. 9482 provided the ideal coating with no cracking or delamination, while the customized conveyor cured the boards in seconds, allowing the customer to increase output by 30%.
A leading manufacturer of premium portable lighting, was looking to ruggedize its safety flashlights, which are used by fire fighters, police officers, and military troops in the field. In their search for a fast curing sealant with excellent adhesion properties, they turned to the Dymax Application Engineering team for help.
THE CHALLENGEFinding a strong fast curing adhesive to ruggedize the lens and reflector housing.
THE SOLUTIONMulti-Cure® 621-T has excellent adhesion properties, while curing in seconds. Dymax 2000-EC flood lamp provided the best curing solution for the 8" x 8" curing area.
THE RESULTSA very happy customer that reduced its costs and increased its output because of the Dymax systems solutions.
Customer’s Challenge: The ProblemWhen the customer developed some new flashlights, they were looking for a way to ruggedize the lens and reflector housings by applying a sealant to bond the subassembly together. Their engineers needed the flashlights to withstand rough handling and extreme conditions in the field, and to work in a wide range of environments, such as search-and-rescue or life-threatening situations.
Our SolutionDymax application engineers, always looking for the next challenge, worked closely with the customer’s team to come up with an innovative solution. After researching and testing our customer’s parts, Multi-Cure® 621-T was recommended to bond the glass lens to the reflector housing. The decision was made based on 621-T’s ability to adhere dissimilar materials, its fast cure, and excellent adhesion properties. To bond the subassembly, the lens and reflector housing were placed into a small rotary system underneath a dispensing valve and 621-T was applied in a uniform bead into the bond line. Our application engineers suggested using a Dymax 2000-EC flood lamp to cure parts post-assembly, because it offered a large 8” x 8” curing area, as well as high-intensity curing in 5-30 seconds. The parts were assembled and then exposed to UV/visible light under the Dymax flood lamp. Rapid curing allowed the bonded parts to swiftly move onto the next step in the manufacturing process with virtually no down/wait time.
The ResultsOur customer was impressed with the technical expertise of our AE team. They were also very satisfied with Multi-Cure ® 621-T and with how our 2000-EC Flood Lamp enhanced their process by curing a large area in just a few seconds. Our solution enabled faster processing, greater output, and lower processing costs.
A world leader in electrical explosion protection and sensor technology, was looking to turn away from laser welding for an application that requires sealing two polycarbonates of their photoelectric sensors.
THE CHALLENGEFinding an alternative solution to laser welding for bonding a PC –PCBA holder to a PC clear cover in a photoelectric sensor.
THE SOLUTIONDymax 3094-GEL-REV-A provides the best bonding results by providing IP67 ingress protection and meeting reliability requirements.
THE RESULTSThe customer improved their process by achieving better bonding and higher UPH.