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Transitioning from Manual to Automated Conformal Coating
By Michael Szuch, Senior Applications Engineer, Nordson ASYMTEK
vents, and other harsh environ- ments. In the past, conformal coat- ings were reserved solely for expen- sive military or aerospace applica- tions. Today, they are commonly used to protect a variety of automo- tive, commercial, industrial, medical, and consumer electronic devices. For many manufacturers, con-
C
formal coating starts as a manual process where coatings are applied by brushing, dipping, or hand spray- ing. Manual processes are initially attractive since they require a mini- mal up-front investment and are rel- atively easy to implement. However, manual coating
processes come with risks and chal- lenges. Operators are at risk of over- exposure to harmful solvents and va-
onformal coatings protect sen- sitive electronic circuitry from moisture, dust, chemicals, sol-
pors, masking and de-masking steps can become overly labor-intensive, and the quality of the coating process
Manual coating processes come with
the risk of exposure to harmful solvents and vapors, and can become overly labor-intensive.
is completely dependent on the skill level of the operator. Throughput al- so depends on the skill level and number of available operators. In ad- dition, constant manual handling of PCBs increases their risk of physical damage. As production volumes ramp
up, throughput, quality, and safe op- erating conditions become more and
High Performance Chemistry for Advanced Technologies
more challenging to maintain. If manufacturers are grappling with any of these manual coating chal- lenges, they might want to consider automating the process by investing in an automated selective conformal coating system.
The Decision to Automate
Making the decision to
transition from a manual coating process to an auto- mated one can be challeng- ing. For most managers, the five primary areas of consid- eration are cost, safety, quality, repeatability, and throughput.
Quality. A highly skilled operator can deliver excellent quality. Howev- er, consider the amount of time it takes to reach that skill level and the variable quality that naturally oc-
June, 2017
Cost. Cost is usually the most influential factor. The initial cost of a new robotic coating system may seem high, but a simple cost comparison against a manual process can yield surprising results.
The cost of the spray booth,
coating material and associated sol- vents is fairly straightforward. The total labor cost should include not on- ly the actual spray time, but also any masking and de-masking steps, re- work or touch-up time, and any cleanup that might be required. With proper configuration and
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programming, an automated coating process generally eliminates the la- bor costs associated with manual masking, de-masking, rework, and touch-up. Since selective coating sys- tems only apply coating where it is required, overspray and material waste is greatly reduced or eliminat- ed, leading to an overall reduction in material cost.
Safety. To maintain a safe and healthy work environment, it is im- portant to understand how frequently and how long operators are exposed to harmful solvents and vapors. Is ade- quate ventilation provided? Are prop- er safety procedures being used dur- ing production? Do operators use per- sonal protective equipment such as masks, gloves, and suits, and are they using them properly? Automated selective coating
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systems address these concerns by providing a “hands-off” coating pro - cess. In an automated process, coat- ing is done inside a ventilated enclo- sure. This significantly reduces or eliminates any exposure to harmful solvents and vapors. Automatic door and hood safety locks and automated SMEMA-compliant conveyors pre- vent operator injuries while running production.
Replacing manual coating with an automated process can improve throughput, safety and reliability.
curs as skills improve. It can be chal- lenging to find, train, and keep skilled operators. With the right hardware config-
uration and optimized programming, an automated selective coating sys- tem can maintain production quality regardless of operator skill level or personnel changes.
Repeatability. Repeatability is the essence of automation. When an au- tomated selective coating system has been optimized to produce the best possible quality, the result is repeat- able and consistent output, cycle af- ter cycle. As long as the system is properly used and maintained, it can reproduce the same level of quality every day, every week and every month.
Throughput. To increase through- put in a manual process, it is gener- ally necessary to hire and train new employees or to add a shift. Addi- tional spray booths and floor space might also be necessary. If there are constraints in any of these areas, coating automation could offer a vi- able solution. The decision to convert from a
manual coating process to an auto- mated one may seem daunting, but with careful planning and considera- tion, manufacturers can increase throughput and improve quality. Im- portant considerations include initial investment and long-term labor costs, operator safety requirements, quality standards, repeatability, and
throughput goals. Contact: Nordson ASYMTEK,
2747 Loker Avenue West, Carlsbad, CA 92010 % 760-431-1919 fax: 760-431-2678 E-mail:
info@nordsonasymtek.com Web:
www.nordson.com r
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