Defence with qualified bonding
Preparing composites and metals before structural bonding, coating adhesion and contamination control.
The surface challenge
Defence systems rely on demanding composite and metal assemblies. Bonding reliability and coating durability depend on a perfectly prepared surface and on a repeatable, documented process.
Atmospheric plasma delivers clean, traceable activation, with no aggressive abrasion and no solvent, for critical assembly and finishing steps.
What plasma changes
| Indicator | Before | After plasma | Method |
|---|---|---|---|
| Surface energy — composite | ≈ 44 mN/m (epoxy matrix) | 45 to 70 mN/m | Test inks |
| Bond strength | [x] | [x] | Single-lap shear |
| 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
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01
Structural bonding
Prepare composites and metals for high-requirement joints.
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02
Surface decontamination
Remove residues before assembly.
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03
Coating adhesion
Fix technical finishes durably in place.
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04
Repeatable process
Documented parameters for qualification.
From your sample to your line
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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.
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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.
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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.
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04
Integration
At the station or robot-mounted, depending on the part. Parameters and their traceability are documented to the level your prime contractor expects.
What plasma does, and what it does not. The detailed comparison.
What plasma does, in detail
The right equipment for this sector
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Turnkey treatment cell
Repeatable, traceable treatment, part by part.
View the family -
Thin-film deposition station
Functional layer: barrier, hydrophobic, tie coat.
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Compact plasma torch
Localised activation on critical zones.
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 — Defence
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.
Can process parameters be frozen and audited?
Yes — that is what the validation stage exists for. The deliverable covers the parameters chosen, the characterisation method and the results obtained, in a form that can be re-read and re-run. The level of detail matches what your prime contractor requires: tell us up front, because it determines what we record during trials.
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
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Automotive
The adhesive bead on filled polymer, in high volume.
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Aerospace
Structural bonding on composite, with the traceability that comes with it.
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Construction
Profiles and panels running continuously, before bonding or painting.
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
Reliability starts at the surface.
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.