Understanding which conformal coating process is right for your PCB is essential to properly shielding components from unwanted debris and heat. Learn more about the different types of coating processes and the innovative technique offered by Invention House’s Raphael 4040.
Brush-on conformal coating is one of the most common methods for safeguarding surfaces and components from corrosion, extreme temperatures, and other environmental factors. It involves an operator applying a thin layer of coating onto a circuit board using a small brush.
Pre-treatment is the first step in the brush conformal coating process. This involves the operator ensuring the surface is clean and debris-free. Once completed, the correct brush applicator is selected; a soft-bristled brush is ideal for thin-film coatings, while a stiff-bristled brush is recommended for thicker coats. Testing the brush for compatibility is essential for getting the best results.
After finding the right brush, the operator applies the conformal coating layer. This step includes dipping the brush in the material and carefully applying it to the substrate, ensuring the correct areas are covered. Sometimes multiple coats are required to achieve even coverage and maximize protection. After application, the user uses a clean cloth to remove any excess material from the PCB.
Finally, the operator cures the PCB to meet their exact specifications. This process is done by baking or air drying the components at high temperatures to verify the coating material is dry and adequately protects the board.
This manual brush method is an effective technique for coating PCBs and other equipment. However, it requires high levels of skill and careful application to ensure the right components are covered.
Another common method of applying coating materials is the dip coating technique. This is an ideal practice for protecting PCBs and other equipment from corrosion, abrasive material, electrical elements, water, and other unwanted debris. It also allows the operator to apply a thin layer across a large surface.
The dip coating process involves submerging the board into a tank filled with the preferred coating material. Once withdrawn from the coating tank, excess material is removed, and the PCB is hung to dry. The dip coating process allows operators to apply a uniform coating layer, eliminating many of the problems of over-spray, including pollution.
The dip coating technique is effective when coating various materials; it safeguards against corrosion and water and allows operators to increase efficiency. However, it’s not recommended for jobs that require selective coating applications.
The spray coating method is a good choice for operators that want to increase production while reducing waste. It involves applying a thin layer of coating on a PCB using a specialized spray gun or nozzle.
The first step in the spray coating process is verifying the PCB’s surface is clean and debris-free to ensure that an even layer of material is applied. After determining the right coating type, the operator adjusts the spray gun settings, including pressure, nozzle, size, and flow rate to optimize performance. The user then applies multiple layers to maximize coverage, removes excess material, and allows the PCBs to dry.
Overall, the spray coating method is an effective technique that allows operators to reduce costs and minimize waste. However, like dip coating, this is not recommended for tasks that require careful applications in tight spaces.
Want to see our conformal coating equipment in action? Check out our case studies and see the benefits of working with the Invention House team.
While traditional coating methods are effective, they require manual labor, and the overall effectiveness is heavily reliant on the user’s experience and knowledge. Streamlining operations by using an automated conformal coating robot is the best approach to getting a consistent product while minimizing costs.
Invention House’s Raphael 4040 is an automated conformal coating machine that allows operators to reduce costs while increasing efficiency and productivity. Our innovative equipment combines 3D automation and a robotic brush to precisely coat boards to your specifications. Utilizing Raphael 4040 in your operations provides the following benefits:
Our process starts by programming the path by importing a Gerber file or board image into Raphael Suite, our proprietary software program. Once uploaded, the user sets the PCB’s X, Y, and Z dimensions.
The operator uses the joystick, keyboard, and click-and-drag actions to implement a series of coating segments. This path is created as a dry run, which allows the user to make adjustments until the optimal path is finalized.
After finalizing the optimal path, the operator then selects a single PCB, activates the pumps, and performs a wet run. We recommend paying close attention to flow and brush movement to ensure coating accuracy.
Once everything is set, full production can begin. Be sure to inspect early samples to make sure it’s meeting your specifications and make small tweaks when necessary.
Invention House takes pride in helping our clients enhance productivity with innovative equipment. Along with our Raphael 4040 conformal coating robot, we also offer single-phase, 3-phase, and 400 Hz motor drives that are military-grade and can withstand extreme conditions. Contact our team today to learn more about our modern equipment.
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Invention House introduces Robotic Brush Conformal Coater