Many contract manufacturers are seeking ways to reduce conformal overspray and masking. Conformal overspray is wasteful and results in the need to mask keep away areas to prevent accidental conformal contamination. Eliminating masking and overspray speeds up production, reduces costs, and leads to a safer work environment. Keep reading to learn about automated brush-on conformal coating from Invention House, is a solution to eliminating conformal masking and overspray.
What Is Automated Brush-On Conformal Coating
Automated bush-on conformal coating is a new system and technique for safeguarding PCB components from unwanted debris that causes corrosion and mechanical failure. This process uses a robot-controlled conformal coating brush to apply a thin layer of material on a PCB and must be done carefully to ensure proper coverage. Precision pumps deliver coating and thinner to a special mixing tube and flow-through brush for depositing onto the PCB surface. The coating rate can be adjusted from front to back and from point to point on the board. A computer controller guides the brush over an X, Y, Z access around the board, while avoiding keep away areas. The result: smooth coating, with no overspray, no masking and no mixing.
Enhance Brush-on Conformal Coating Tasks With the Raphael 4040
Brush-on coating has historically been done manually on boards with significant keep away areas or in low volume situations. Manual brush coating creates an environment where success is heavily dependent on the operator’s skill set. Also, it increases the likelihood of inconsistent results if you have multiple employees working at the same time. Invention House’s Raphael 4040 helps operators deliver consistent results in low-volume production processes by combining 3D automation and a robotic brush to coat PCBs efficiently. Our innovative robotic brush provides operators with the following advantages:
- Enhanced productivity: The Raphael 4040 allows users to operate at a faster pace because it minimizes board touches and can reduce coating time by as much as four minutes.
- Reduced costs: Manual processes can create material waste that increases overall costs on a project. The Raphael 4040 precisely covers PCBs and eliminates material waste, allowing operators to reduce spending.
Raphael 4040’s End-to-End Brush-On Conformal Coating Process
The Invention House team understands that other conformal coating techniques are labor-intensive, time-consuming, and increase costs by creating waste. Our goal is to help operators enhance their products without sacrificing quality. Our innovative robotic-brush conformal coating system was discovered by studying various coating methods and pinpointing an undiscovered niche. The Raphasel 4040 is a tabletop-sized robot designed for coating PCBs that contain components that can’t be coated. Users follow this process to complete their tasks:
Step One: Create Board Layout
The first step in our process is programming the customized path by installing a Gerber file or board image into Raphael Suite, our proprietary software program. The user then sets the PCB’s X, Y, and Z dimensions.
Step Two: Create the Coating Path
The operator uses the joystick, keyboard, and easy-to-use click-and-drag actions to create a series of coating segments. This path is created as a dry-run, allowing the user to make an optimal path.
Step Three: Wet Run
After finalizing the preferred path, the operator then selects a single PCB, activates the pumps, and practices a wet run. We recommend paying close attention to flow and brush movement during this step to ensure coating accuracy.
Step Four: Production
Full production can begin after successfully completing a series of wet runs. Be sure to inspect early samples to make sure it’s meeting your specifications and make the necessary small tweaks.
Streamline Processes With Invention House
The Invention House team 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 built to withstand extreme environments. Contact our team today to learn more about our modern equipment.
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Engineering reliable, efficient, and economical motor control products for our customers. Our machines are American-made, operating in challenging environments, and meet strict military-grade compliance.