Aerospace demands bonding without surprises
Preparing composites and metals ahead of structural bonding and painting, with a clean, repeatable process.
The surface challenge
Bonded composite structures require a perfectly prepared surface. A trace of residual mould release agent or a surface energy that is too low, and the joint loses performance. In this sector, process repeatability matters as much as the result.
Atmospheric plasma delivers controlled, documentable surface activation, with no aggressive abrasion and no solvent. It fits naturally into a process qualification approach.
What plasma changes
| Indicator | Before | After plasma | Method |
|---|---|---|---|
| Surface energy — composite | ≈ 44 mN/m (epoxy matrix) | 45 to 70 mN/m | Test inks |
| Peel strength | [x] | [x] | T-peel (ASTM D1876) |
| Contact angle (water) | 90 to 105° (polyolefins) | 35 to 70° depending on exposure | Goniometer, sessile drop |
| Effect retention | — | near-logarithmic decay; still hydrophilic at 7 days | Controlled ageing |
| Pass speed | — | 6 to 120 m/min per source | Configuration to be validated |
Documented order-of-magnitude figures, not our own measurements: pre-treatment values come from the Accu Dyne Test reference tables, post-treatment values from the atmospheric plasma literature. They place the process — they still depend on the substrate, its geometry and the line speed. A trial on your own part gives you your own numbers. Have my material measured.
What plasma changes
-
01
Structural bonding preparation
Activate composites and metals for high-performance joints.
-
02
Surface decontamination
Remove organic residues ahead of a critical step.
-
03
Paint and coating adhesion
Prepare surfaces for durable finishes.
-
04
Documented process
Traceable parameters for your qualification files.
From your sample to your line
-
01
Characterisation
You send us a sample. We measure its starting surface energy and identify what is blocking adhesion: contamination, release agent, non-polar polymer.
-
02
Parameter trial
We vary power, pass speed, nozzle-to-substrate distance and gas until the target effect is reached, and record the parameters that got us there.
-
03
Validation
We check the result with the test that matters to you — adhesion, sealing, wetting — and document how long the effect holds on your material.
-
04
Integration
At the station, before structural bonding, or robot-mounted for large parts. Parameter traceability is part of the deliverable.
Preparing a composite for bonding without abrading it. The detailed comparison.
What plasma does, in detail
The right equipment for this sector
-
Turnkey treatment cell
Repeatable robot path on large-format parts.
View the family -
Compact plasma torch
Local activation on bond zones, without treating the whole panel.
View the family -
Thin-film deposition station
Tie or barrier layer when activation alone is not enough.
View the family
The final choice is made on your part and your cadence, not from a catalogue. All equipment, sorted by the problem it solves.
Frequently treated materials
This list is indicative. The vast majority of polymers, metals, glasses and composites can be treated with DBD plasma. The best way to confirm your case is to send us a description of your part and your objective. For the hardware, see the plasma equipment sorted by the problem it solves.
What we get asked — Aerospace
How long does the treatment effect last?
Activation is not permanent: surface energy decays after treatment, faster on mobile polymers and in warm storage. That is why plasma is placed immediately before the step it serves — printing, bonding, sealing. The decay rate is measurable, and we document it on your material during the trial.
Does plasma replace corona treatment?
Both raise surface energy, but not under the same conditions. Corona suits flat film running over a roller. Atmospheric DBD plasma also treats three-dimensional geometries, hollow parts and non-conductive surfaces, with a uniformity that does not depend on holding a constant air gap. On your part, the answer is settled by comparison, not by principle.
Does the treatment change the part's appearance or dimensions?
No. Plasma acts on the first few nanometres of the surface: mass, dimensions and bulk mechanical properties are unchanged. On heat-sensitive substrates, parameters are adjusted to avoid any marking, and that is one of the things checked at the validation stage.
Are chemicals or a drying step required?
No. The treatment runs on electricity and process gas, with no primer, no solvent and no drying time. That is what lets it sit inside a line without lengthening the cycle, and what removes a hazardous-goods handling station.
Can it be retrofitted to an existing line?
That is the most common case. The treatment installs inline, at production speed. Three things need checking: the space available at the useful point, the electrical and gas connections, and extraction. Those three are what the integration stage covers.
Does treatment replace abrading or priming?
It often replaces abrading, whose main job is removing a contaminated layer: plasma does that without removing material or generating dust. Primer does not always play the same role — where it brings chemistry and not just wetting, plasma improves it without eliminating it. That trade-off is settled by trial, on your own stack-up.
The selection guide
Atmospheric or vacuum? The question comes up on every project, and it is settled on three concrete criteria — not on a preference for one process.
- Both architectures, what each one can do and what it costs
- Three deciding criteria: part geometry, robotic integration, cycle time
- A grid to fill in so you can defend the choice to an investment committee
Guide being written — leave your email and you will get it on release.
In the meantime, the article comparing both architectures : The detailed comparison.
Related sectors
-
Automotive
The adhesive bead on filled polymer, in high volume.
-
Construction
Profiles and panels running continuously, before bonding or painting.
-
Defence
Same composites, with qualification demands on top.
What you send, what you get back
- You send
- [x] samples of your part or film, [x] minimum size.
- You receive
- surface energy values before and after, one treated sample, and a written record of the parameters used.
- Turnaround
- first reply within 48 hours, trial report within [x] business days.
- Cost
- [x]
Send a description of your part and your goal. Answer within 48 hours.
Three fields, and we get back to you
The surface, critical link in your assembly.
48 hours to find out what plasma can do for your surfaces. No commitment, just clear answers from an expert.
Response within 48 hours. No commitment. A technical discussion with an expert.