Invention House is happy to announce the Raphael 4040, our automated conformal coating robot that eliminates overspray and masking.
Introducing the Raphael 4040: Our Brush-On Conformal Coating Robot
Coating printed circuit boards (PCB) using traditional methods is a tedious process. Brushes require a user with a high level of expertise and can create inconsistent results if they aren’t operating carefully. Also, manually conformal spraying PCBs leads to excessive material waste and isn’t an effective method if they contain switches, connectors, and other components that shouldn’t be coated.
Invention House believes that necessity is the mother of invention. We sought to build a solution that increases coating time without sacrificing precision at a low cost. The Raphael 4040 was introduced and demonstrated at the SMTA Dallas Expo & Tech Forum in March 2023. Our innovative conformal coater applies the coating material using a robotic flow-through brush and is controlled over an X, Y, and Z-optimized path.
Are You Ready to Increase Conformal Coating Production With the Raphael 4040?
The Invention House team is available to help train your team on the Raphael 4040. Contact us today to schedule your free consultation and start enhancing your operations.
Advantages of Our Circuit Board Conformal Coating Robot
The Invention House team designed and manufactured the Raphael 4040 for contract manufacturers that operate with razor-thin margins. Our robot leverages innovative low-cost manufacturing techniques and is both accurate and fast. The brush tip can be controlled to within 7000th of an inch and coats boards quickly and efficiently.
We understand that the pre- and post-production coating tasks, including masking, capping, and demasking, are demanding. Our goal was to create a solution that eliminated these issues while allowing operators to maintain quality. Some of the advantages of utilizing this equipment include:
Increased Product Quality
Using the Raphael 4040, your operators can coat PCBs using fewer passes and touches, and it eliminates overspray. These elements enable your staff to increase their coating quality and enhance customer satisfaction.
Traditional brush-on coating and manual conformal spray methods require extra board touches and careful inspection to verify all components are protected. The Raphael 4040 minimizes board touches, which allows your operators to significantly reduce coating time and increase productivity.
Reduced Coating Costs
Companies that utilize the manual spray-on coating method must tediuously mask critical components and have extensive fume mitigation systems due to overspray waste. One of the biggest advantages of using the Raphael 4040 is that it’s a safe coating technique that doesn’t require masking and eliminates wasted materials. Our product also delivers a more cost-effective coating process.
Improved Working Environment
Operators wear masks during spray-on and brush-on coating tasks because the materials can be dangerous when it’s breathed in. The Raphael 4040 allows your workers to eliminate their interactions with chemicals and cans and overspray, dramatically enhancing their working environment.
How The Raphael 4040 Brush-On Conformal Coating Robot Works
The Raphael 4040 works by creating conformal coating paths using two inputs, a joystick, and Raphael Suite, our proprietary software program. The process then follows these steps:
Step One: Import Board and Create Layout
The path programming is created by importing a Gerber file or board image into the Raphael 4040. Then, the operator establishes the layout by setting its X, Y, and Z dimensions. This step is complete for the board’s front and back, and multiple PCBs can be placed on its 15.5” x 15.5” work area.
Step 2: Determining the Optimal Path
The operator uses a joystick, keyboard, and user-friendly click-and-drag actions to create a series of coating sections around the PCB. Our tools allow them to control the X, Y, and Z axis movement to move around or over components that shouldn’t be coated. We recommend creating the initial path as a dry run and making the necessary tweaks until you’re satisfied with the programmed path.
Step 3: Perform a Wet Run
After finalizing the optimal path, the operator performs a wet run using a single board. Carefully analyzing the coating flow and brush movement during this step helps determine if they’re properly protecting the board. Also, this is the step where adjustments to brush height, flow rate, and speed are recommended.
Step 4: Production Run
Once the operator determines that the Raphael 4040 is following the proper path, they can begin full production on their coating run. We suggest carefully inspecting early samples and making small alterations when necessary.
What Clients Have to Say About Our Conformal Coating Robot
“The Raphael 4040 is ideal for coating PCB with a high number of keep-away areas and components. Due to overspray from traditional costing methods, such boards require extensive masking prior to coating, and the Raphael 4040 eliminates overspray and masking entirely.”
“We started using the Raphael 4040 on one board that we were manually spray coating. For that project, the Raphael 4040 saves 4 minutes per board, and we use 3x less conformal coating. The ROI was six months!”
Invention House: Offering Our Innovative Conformal Coating Robot and More
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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.