Best Practices for Purchasing an Automated Conformal Coating Machine

Increasing productivity while maintaining product quality is a top priority for businesses that specialize in spray-coating PCBs or panels. However, this is challenging when utilizing a manual process because it’s difficult to improve efficiency and deliver consistent results. Because of this, many companies are turning to automated conformal coating machines for their needs. But how do you know which one is right for you? In this blog, we’ll review some best practices to help you make the best decision.

Automated Conformal Coating - Raphael 4040 Thumb 2

When to Consider an Automated Conformal Coating Machine

As your PCB assembly business grows and productivity needs increase, you may notice signs that manual coating methods don’t meet your needs. Here are some indications that you need to consider utilizing an automated conformal coating machine:

You Want to Reduce Masking & Material Waste

While the initial investment in an automated conformal coating machine may seem significant, it often leads to substantial cost savings in the long run. Manual processes, especially manual conformal spray coating, require significant masking of keep-away areas and waste coating material. Automated conformal coating machines reduce labor costs associated with manual operations, minimize material wastage, and lower reject rates. Additionally, the increased efficiency and productivity gained from automated coating machines can help meet production targets and improve overall profitability.

You Need a Consistent Coating Thickness

In manual coating processes, achieving consistent coating thickness across all components can be challenging. Variations in operator technique, environmental factors, and human error can lead to inconsistent results. An automated conformal coating machine ensures precise and uniform application, reducing rejects and improving product quality. This consistency is particularly critical for industries with stringent quality standards, such as aerospace and medical device manufacturing.

The Boards You’re Coating Are Increasing in Complexity

As electronic devices become more compact and complex, manual coating processes struggle to adequately cover intricate assembly structures, recessed areas, and tight spaces. An automated conformal coating machine with advanced dispensing technologies, such as selective coating or robotic arms, can precisely target specific areas while avoiding keep-away areas.

You Want to Improve Safety

Conformal coating materials can be hazardous to human health if not handled properly. Automated conformal coating machines provide a controlled environment, minimizing operator exposure to harmful chemicals. This promotes a safer working environment and ensures compliance with health and safety regulations.

How to Find the Right Conformal Coating Machine

Finding the right conformal coating machine for your PCB assembly business is the best approach for getting equipment that suits your needs. Here are some factors to consider when searching for a partner:

Your Coating Requirements
Evaluate your specific coating requirements, such as the type of coating material, viscosity, and desired thickness. Ensure that the machine you choose is compatible with the coatings you commonly use in your manufacturing processes. Note that changing from manual to automated coating, may trigger a change in the coating type, viscosity, and other factors.
Your Throughput and Capacity Needs
Choose a machine that can handle your current needs and has the potential to accommodate future growth. Consider cleaning, maintenance, and change over requirements to allow ease of switchover between PCB board runs.
The Features You Need
Look for features such as programmable coating parameters, adjustable coating thickness, and the ability to handle different component sizes and shapes. Consider the ease of operation, maintenance requirements, and the availability of technical support and training.
The Supplier’s Knowledge and Experience
Research conformal coating machine suppliers thoroughly. Look for reputable suppliers with a proven track record in delivering reliable and durable machines. Check customer reviews and testimonials to assess their customer service and after-sales support.
Your Cost Analysis
Consider the initial cost, as well as the long-term return on investment. Assess the potential savings in labor costs, material wastage, and rejected components when compared to manual coating processes.
Your Staff Capabilities
Finally, verify that the machine you choose can be run and managed by your available engineering and production staff. Upgrading your staff may negate any anticipated savings.

See How the Raphael 4040 Improved Coating for a Client

Want to see an example of the Raphael 4040 in action? Check out our latest case study about how Agility Engineering enhanced their processes with Invention House.

Learn More

Maximize Productivity With Our Automated Conformal Coating Robot

Traditional coating methods are tedious, time-consuming, and difficult to perform if the boards have areas that can’t be coated. Invention House designed and built the Raphael 4040 to take advantage of recent innovations in low-cost manufacturing techniques. Our robot is ideal for contract manufacturers with narrow margins.

The Raphael 4040 uses a brush tip to coat boards accurately and quickly, and offers the following advantages:

Increased Quality

The Raphael 4040 requires fewer passes and touches than traditional manual coating methods and leads to a better quality product.

Improved Productivity

Traditional techniques require extra board touches to verify all components are covered. The Raphael 4040 minimizes additional tasks, which leads to a cleaner board and eliminates damage.

Reduced Costs

Spray-on and brush-coating methods lead to overspray waste and require masking. The Raphael 4040 reduces costs by eliminating these elements, creating a more economically friendly product.

Improved Operator Conditions

Many coating methods expose workers to chemicals that can impact their long-term health. With the Raphael 4040, your operator can work from a safe distance and eliminate interactions with dangerous materials.

The Raphael 4040 Conformal Coating Process

The Raphael 4040 creates conformal coating paths using a combination of two inputs, a joystick, and Raphael Suite, our proprietary software program. The operator then coats the boards using the following process:

Step One: Import Board Image
The automated conformal coating process starts with importing a Gerber file or board image, then indicating its X, Y, and Z dimensions. This process is completed for the board’s front and back.
Step Two: Create a Path
The operator uses the joystick, keyboard, and click-and-drag actions to create a series of coating segments. This step is performed in a dry run, allowing the user to make the necessary adjustments.
Step Three: Wet Run
After finalizing the dry-run path, the operator selects a single board and performs a wet run to verify the preferred path.
Step Four: Production Run
Once the path is complete, the operator can begin the production of conformal coating. We recommend analyzing early samples to ensure proper results.

Contact Invention House today to learn more about our conformal coating robot.

Best Practices for Purchasing an Automated Conformal Coating Machine

When to Consider an Automated Conformal Coating Machine

You Want to Reduce Masking & Material Waste

You Need a Consistent Coating Thickness

The Boards You’re Coating Are Increasing in Complexity

You Want to Improve Safety

How to Find the Right Conformal Coating Machine

Your Coating Requirements

Your Throughput and Capacity Needs

The Features You Need

The Supplier’s Knowledge and Experience

Your Cost Analysis

Your Staff Capabilities

See How the Raphael 4040 Improved Coating for a Client

Maximize Productivity With Our Automated Conformal Coating Robot

Increased Quality

Improved Productivity

Reduced Costs

Improved Operator Conditions

The Raphael 4040 Conformal Coating Process

Step One: Import Board Image

Step Two: Create a Path

Step Three: Wet Run

Step Four: Production Run

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