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FEATURE


FASTENINGS & ADHESIVES Structural adheSiveS vS


In thousands of applications, structural adhesives are being used as a viable alternative to mechanical connections such screws, rivets or spot welds. Here, Kevin Brownsill, head of learning & development at


Intertronics, explains the advantages that adhesives can bring to structural bonding, including improved product performance, reliability improvements, greater design freedom, and reductions in manufacturing costs


Applying SCIGRIP SG300


MMA Methyl Methacrylate adhesive


multiple fastenings. While adhesives are not inherently lightweight, their ability to distribute stress can give design engineers freedom to reduce part thickness and therefore weight, while removing the weight of metal fastenings. Furthermore, adhesives can bond in


applications where mechanical fastening would be difficult due to design complexity, such as composite sandwich structures, or when bonding different substrates, such as metal to plastic or glass. Adhesives can successfully bond both similar and dissimilar substrates (differing in composition, moduli, coefficients of expansion, or thickness), mitigating different expansion rates. For metals subjected to thermal cycling or at risk of galvanic corrosion, adhesives can provide a more reliable solution.


“Manufacturers can use adhesives to


S


ometimes known as ‘chemical joining’ – to contrast with mechanical joining – adhesive bonding involves an adhesive ‘hardening’


or curing to provide a joint. This joint must be capable of bearing the forces that it is subjected to over the product’s lifetime, while enduring the associated environmental conditions. An adhesive can be considered to be cured when a chemical reaction has taken place and its constituent parts (monomers or oligomers) join up and cross-link to become larger molecules (polymers).


the advantageS of adheSive bonding Adhesives bring many advantages over mechanical joining methods, with the first being improved stress distribution. Once cured, an adhesive bond is continuous and offers a more uniform stress distribution. The joint’s entire surface carries the load, rather than an individual point, avoiding the local concentration of stress found in mechanically joined parts. Adhesives can also minimise or eliminate


corrosion, boost impact resistance, avoid joint fatigue, provide electrical insulation, and dampen vibration. In many applications, an adhesive can also act as a sealant, protecting the assembly from water, moisture, dirt, and other environmental contaminants. For example, when working with a


manufacturer of safety torches that was looking to 2 DESIGN SOLUTIONS MAY 2026 0


make its products more rugged, Intertronics recommended Dymax Multi-Cure 621-T, which worked as both an adhesive and sealant when bonding the lens to the reflector housing. Another customer, Process Instruments, found success with IRS2125 Flexible Epoxy Adhesive, bonding two stainless steel surfaces, while waterproofing its IP-rated seal. “The reason for the astonishingly wide range


of adhesive and sealant applications is that, in the context of joining technologies, only adhesive bonding technology has the potential to join identical or dissimilar materials with complete retention of their properties as well as with long-term stability and safety,” explain Professors Mayer and Groß in the 2022 paper published by Frauhofer IFAM and FEICA, ‘Adhesive Bonding Technology in the 21st Century’. “This preservation of material properties


during joining makes it possible for the products to meet constantly changing requirements such as weight reduction, miniaturisation, functionalisation expansion and design optimisation,” they continue.


adheSive SolutionS in induStry Many manufacturers, such as those in automotive or aerospace applications, opt to use adhesives to reduce the weight of their assemblies. Mechanical fastenings are often made of metal, and their weight can add up in applications requiring


improve aesthetics. As there is no mechanical fastening or spot weld visible in the final


part, an adhesive can provide an almost invisible bond”


Manufacturers can use adhesives to improve


aesthetics. As there is no mechanical fastening or spot weld visible in the final part, an adhesive can provide an almost invisible bond. SCIGRIP SG300 MMA Methyl Methacrylate Adhesive is known for giving reduced bond line read through, resulting in fewer post-finishing processes. Beyond these technical benefits, adhesive


bonding can bring operational benefits through reduced component costs, lower labour and assembly costs, and reduced finishing costs. Specifying fast-curing adhesives can improve production speed greatly, while simplifying operations.


no perfect Solution While adhesives can bring many benefits, all adhesives carry some disadvantages. Structural


www.designsolutionsmag.co.uk


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