INDUSTRY FOCUS - AUTOMOTIVE ELECTRONICS
Spray heads provide fast, uniform coverage across PCB assemblies, ideal for large-area protection.
Automation and inspection Automation options range from manual load/unload systems to fully automated lines, depending on budget, floor space and hands-off requirements. Understanding possibilities is key to initial decision-making. Even basic in-line units with manual loading provide future-proofing for increased volumes and automation expansion. A gold-standard automated line features multi-magazine loaders feeding coating systems via conveyor, followed by flush-off conveyors and curing ovens. IR ovens heat
acrylic mediums from inside out, allowing defects to escape during curing, while UV ovens handle UV-curable materials. Automated optical inspection is critical for quality control, detecting missing coverage, thickness variations, and defects before final processing. AOI systems perform 2D presence detection or advanced 3D thickness measurement, with No-Good conveyors diverting defective boards to prevent costly rework. Vertical turn conveyors flip boards for second-side processing before multi-magazine unloaders complete the cycle. Four-magazine capacity enables hours of hands-off production with manageable work-in-progress flow.
Facility planning should consider future line length requirements, ensuring adequate space for automation expansion even if not initially purchased.
Gold standard process
A gold-standard conformal coating process integrates validated medium selection, masking strategy, environmental control, cleaning, automation and inspection. Manufacturing sites approach coating plans quite differently. Effective planning identifies areas requiring protection, areas that must remain uncoated for functionality, and areas
where coating provides no additional benefit—such as bare FR4 substrates. Legacy dip coating specifications typically only defined areas requiring coating versus those prohibited from coating. Modern selective coating recognises that unnecessary coverage can be eliminated, creating process buffers that reduce accuracy and tolerance requirements. For example, grounding areas can remain uncoated unless nearby SMT components require protection, simplifying the coating program while maintaining performance standards.
Implementing gold-standard conformal coating involves numerous variables requiring careful validation and operational planning. While in-house capability delivers cost savings and process control, achieving consistent results in automotive applications demands expert guidance on equipment selection and sample validation. Early engagement with experienced partners ensures conformal coating lines meet performance objectives and support long- term reliability in increasingly complex automotive electronics.
www.altusgroup.co.uk
OCTOBER 2025 | ELECTRONICS FOR ENGINEERS
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