Painting & Coating Industry (PCI) logo Powder coating summit logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • MATERIALS
  • TECHNOLOGIES
  • FINISHING
  • RESOURCES
  • EVENTS
  • DIRECTORIES
  • EMAGAZINE
  • CONTACT
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest News
  • Market Trends & Reports
  • Price Alerts
  • Subscribe to eNewsletters
  • Global Top 10/ PCI 25
  • Weekly Featured Article
  • COATLE Word Game
  • PRODUCTS
  • Product News
  • Must See Products and Services
  • MATERIALS
  • Additives
  • Resins/Polymers
  • Pigments
  • Equipment
  • Distributors
  • TECHNOLOGIES
  • Adhesives
  • Architectural Coatings
  • Industrial Coatings
  • Nanotechnology
  • Powder Coatings
  • Solventborne
  • Special Purpose Coatings
  • Sustainability
  • UV Coatings
  • Waterborne
  • Waterborne
  • FINISHING
  • Finishing News
  • Finishing Technologies
  • Finishing Equipment
  • RESOURCES
  • Columns
  • Blogs
  • Coatings Supplier Handbook
  • Podcasts and Videos
  • PCI Store
  • eBooks
  • Sponsor Insights
  • White Papers
  • COATLE Word Game
  • Columns
  • Ask Joe Powder
  • Did you know?
  • Distribution Dive
  • Focus on Canada
  • Formulating With Mike
  • Innovation Insights
  • Moody's Coatings Conundrums
  • Powder Coating Perspectives
  • Target the Market
  • TiO2 Insider
  • Blogs
  • Editor's Viewpoint
  • Industry Insights
  • Podcasts and Videos
  • COAT-IT! Podcast
  • Videos/PCI TV
  • EVENTS
  • Coatings Trends & Technologies Summit
  • Paint and Coatings Academy
  • Webinars
  • Calendar of Events
  • Lifetime Achievement Award
  • DIRECTORIES
  • Buyer's Guide
  • Equipment Directory
  • Materials Directory
  • EMAGAZINE
  • Current Issue
  • eMagazine Archive
  • China Issue Archive
  • Editorial Advisory Board
  • CONTACT
  • Contact Us
  • Advertise
  • Subscribe to eMagazine
  • Subscribe to eNewsletters
Painting & Coating Industry (PCI) logo Powder coating summit logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Painting & Coating Industry (PCI) logo Powder coating summit logo
  • NEWS
    • Latest News
    • Market Trends & Reports
    • Price Alerts
    • Subscribe to eNewsletters
    • Global Top 10/ PCI 25
    • Weekly Featured Article
    • COATLE Word Game
  • PRODUCTS
    • Product News
    • Must See Products and Services
  • MATERIALS
    • Additives
    • Resins/Polymers
    • Pigments
    • Equipment
    • Distributors
  • TECHNOLOGIES
    • Adhesives
    • Architectural Coatings
    • Industrial Coatings
    • Nanotechnology
    • Powder Coatings
    • Solventborne
    • Special Purpose Coatings
    • Sustainability
    • UV Coatings
    • Waterborne
    • FINISHING
      • Finishing News
      • Finishing Technologies
      • Finishing Equipment
    • RESOURCES
      • Columns
        • Ask Joe Powder
        • Did you know?
        • Distribution Dive
        • Focus on Canada
        • Formulating With Mike
        • Innovation Insights
        • Moody's Coatings Conundrums
        • Powder Coating Perspectives
        • Target the Market
        • TiO2 Insider
      • Blogs
        • Editor's Viewpoint
        • Industry Insights
      • Coatings Supplier Handbook
      • Podcasts and Videos
        • COAT-IT! Podcast
        • Videos/PCI TV
      • PCI Store
      • eBooks
      • Sponsor Insights
      • White Papers
      • COATLE Word Game
    • EVENTS
      • Coatings Trends & Technologies Summit
      • Paint and Coatings Academy
      • Webinars
      • Calendar of Events
      • Lifetime Achievement Award
    • DIRECTORIES
      • Buyer's Guide
      • Equipment Directory
      • Materials Directory
    • EMAGAZINE
      • Current Issue
      • eMagazine Archive
      • China Issue Archive
      • Editorial Advisory Board
    • CONTACT
      • Contact Us
      • Advertise
      • Subscribe to eMagazine
      • Subscribe to eNewsletters
    Adhesives and SealantsIndustrial CoatingsFinishing ArticlesFinishing News

    Reducing Adhesion Failures in the Automotive Industry

    By Henniker Plasma
    Henniker Image 2.png

    Image courtesy of Henniker Plasma.

    September 18, 2023

    Plasma pre-treatment is a crucial step for improving the quality and durability of automotive assemblies and components. It enhances the adhesion and compatibility of different materials that are used for encapsulation, printing, or painting processes. By applying plasma to the surface of low-energy materials, it removes contaminants and creates functional groups that increase the surface energy and reactivity. This results in a stronger and more uniform bond between the materials, reducing the risk of failure and defects.

     

    Henniker Image 1.jpgBatch plasma treatment of automotive parts. Typical Automotive Applications
    Improved Wettability of Exterior Components Prior to Painting

    Plasma treatment can remove contaminants and increase the surface energy of parts such as bumpers, spoilers, and mirrors, resulting in better paint adhesion and appearance. 


    Plasma Activation of Topper Pads Prior To Laminating  

    Topper pads are foam or fabric inserts that provide comfort and noise reduction in car seats. Plasma can activate the surface of the pads, improving the bond strength and durability of the laminating material. 

     

    In-Line Atmospheric Plasma Treatment of Circuits to Improve Wire Bond Adhesion 

    Wire bonding is a method of connecting electrical components on a circuit board using thin wires. Plasma can clean and activate the surface of the circuit board and the wires, enhancing the reliability and performance of the wire bonds. 

     

    Improved Adhesion of Electronic Connectors Prior to Encapsulation

    Electronic connectors are used to join electrical circuits in various devices and systems in a car. Plasma can improve the adhesion between the connector and the encapsulant, which protects it from moisture, dust, and corrosion.

     

    Localized Treatment of Headlight Assemblies to Prevent Moisture Ingress  

    Headlights are exposed to harsh environmental conditions and need to be sealed properly to prevent fogging and water damage. Plasma can treat the edges of the headlight lens and housing, creating a stronger seal and preventing moisture ingress.

     

    Atmospheric In-Line Plasma Pre-Treatment

    The Henniker Cirrus atmospheric plasma system is a powerful and versatile tool for surface treatment of various materials. It uses a jet of energized compressed air to activate, clean, and modify the surface properties of polymers, metals, glass, and ceramics. The Cirrus system can be easily integrated into an assembly line, where it can perform localized plasma treatment on specific areas of the parts.  

    In-line plasma treatment is different from vacuum plasma treatment because it does not require a chamber or enclosure. Instead, the plasma is generated in a nozzle or jet that can be moved along the material surface. This makes it faster and more flexible for continuous or large-scale applications. Some examples of in-line plasma treatment uses are improving adhesion of paints, glues, or inks on plastics, metals, or textiles; depositing thin films of functional materials on glass, ceramics, or semiconductors; and sterilizing medical devices or food packaging. 

    In the automotive industry, the Cirrus system can improve the adhesion of the bond line and the electrical connection posts of a component before gluing it to another part. The picture below shows how the Cirrus system is used with a robot arm to apply plasma treatment on an automotive part.

     

    Henniker Image 2.pngBatch-plasma-treatment PDC car parking sensors prior to encapsulation.

     

    Henniker Image 3.pngAtmospheric in-line plasma treatment for automotive component parts prior to encapsulation.


    Henniker Image 4.pngCirrus atmospheric plasma system.


    Advanced Vacuum Plasma Treatment

    One of Henniker’s recent projects involved enhancing the paint adhesion on PDC sensors for a major car manufacturer. The PDC sensors are exposed to harsh environmental conditions and require a durable and uniform coating. 

    Using their Nebula system, Henniker Plasma developed a surface activation process that effectively increased the wettability and adhesion of the PDC sensors. The process was optimized to deliver consistent and reliable results for batch processing. Henniker Plasma collaborated with the client throughout the project to ensure their satisfaction and quality standards.

     

    Henniker Image 5.pngPDC parking sensor installation.


    Treatment Parameters

    The sensor membranes, made from aluminium alloy with an acryl powder coating, were placed into the manufacturer’s specialized coating tray for the treatment trials. Henniker performed two treatments of varying process times for comparison. They were treated for 180 and 90 seconds, respectively, at 100% power. The pressure was set at 0.3 mbar using air as the process gas. The customer requested a surface energy value above a 41 mN/n threshold.

     

    Henniker Image 6.pngBatch plasma treatment, inside the Henniker Advanced Nebula system, of PDC car parking sensors prior to encapsulation.


    Contact Angle and Surface Energy Results

    Contact angle tests are a method of measuring the wetting properties of a surface. They involve placing a drop of liquid on the surface and observing the angle formed between the edge of the drop and the surface. The smaller the angle, the more wettable the surface is. Tests can be conducted on various materials to compare their hydrophobicity and hydrophilicity.

    Henniker Image 7.png

     

    Contact angle measurements of the sensor membrane protruding above the tray cover were made in order to determine the effectiveness of the plasma treatment. Three measurements were recorded from three separate sensors across the coating trays to determine treatment uniformity.

     Henniker Image 8.png

     

    Plasma treatments of 180 and 90 seconds were analyzed, and each produced a measured reduction in contact angle; the 90-second treatment increased the surface energy to 56 ± 1 mN/m, sufficiently above the required 41 mN/m threshold set by the customer. The low degree of error from each result indicates the plasma treatment was uniform across the whole coating tray. Ageing tests demonstrated that slight hydrophobic recovery occurred, with both treatments surface energy values remaining above the 41 mN/n threshold 24 hours post-treatment.

     

    Crosshatch Test Results

    The crosshatch adhesion test (DIN EN ISO 2409) is a widely used method for determining the coating adhesion and is a simple and effective way to evaluate the quality of the paint. The test involves making a series of cuts on the painted surface and then applying a tape to peel off any loose paint. The process samples were prepared in different ways: without mechanical abrasion, with mechanical abrasion (scotch bright), and after plasma treatment. The client then tested and verified the samples using the crosshatch test method. The samples were rated based on the percentage of paint that remained on the surface after the test.

     Henniker Image 9.png

     

    The crosshatch test-cut method used clearly demonstrated the enhanced bonding to the plasma activated surfaces after treatment. 

    Henniker provided the customer with a Nebula Advanced Plasma System, which included an additional barcode scanner for traceability, able to deliver a uniform increase in surface energy across the whole array of sensors in under five minutes. They were very satisfied with the outcome and reported enhanced performance and reliability of their sensors.

    For more information on Plasma Treatment for the automotive industry visit: Reducing Adhesion Failures in the Automotive Industry - Henniker Plasma (plasmatreatment.co.uk).

    *All images courtesy of Henniker Plasma. 

    KEYWORDS: adhesion adhesion science adhesive technologies adhesives for automotive automotive coating technology Automotive Coatings

    Share This Story

    Looking for a reprint of this article?
    From high-res PDFs to custom plaques, order your copy today!

    Recommended Content

    JOIN TODAY
    to unlock your recommendations.

    Already have an account? Sign In

    • PCI-0724-Global10-Feature-1440.png

      2024 Global Top 10: Top Paint and Coatings Companies

      Who ranks on top? PCI’s annual ranking of the top 10...
      Global Top 10 and PCI 25
      By: Courtney Bassett
    • PCI-0724-PCI25-Feature-1440.png

      2024 PCI 25: Top Paint and Coatings Companies

      PCI's annual ranking of the top 25 North American paint...
      Global Top 10 and PCI 25
      By: Courtney Bassett
    • pci1022-Kinaltek-Lead-1170.jpg

      A Novel Pigment Production Technology

      Following an extensive R&D program that demonstrated...
      Paint and Coating Pigments
      By: Jawad Haidar and Nitin Soni
    You must login or register in order to post a comment.

    Report Abusive Comment

    close

    1 COMPLIMENTARY ARTICLE(S) LEFT

    Loader

    Already a Registered User? Sign in now.

    Manage My Account
    • eMagazine
    • eNewsletter
    • Online Registration
    • Subscription Customer Service

    The Coatings Minute: Your Inside Look at PCInnovations

    The Coatings Minute: Your Inside Look at PCInnovations

    CTT Registration Now Open

    CTT Registration Now Open

    The Coatings Minute: Print Returns with PCI’s New Showcase Issue

    The Coatings Minute: Print Returns with PCI’s New Showcase Issue

    The Coatings Minute: Why Industry News Matters More Than Ever

    The Coatings Minute: Why Industry News Matters More Than Ever

    More Videos

    Sponsored Content

    Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the PCI audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of PCI or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

    close
    • Modern arapartment complex painted in bright colors.
      Sponsored byEPS - Engineered Polymer Solutions

      Architectural Polymers Leading the Way in Coatings Innovation

    • paint sprayer in a workshop
      Sponsored byallnex

      Enabling Performance and Compliance: allnex Introduces a New Line of VOC Exempt Solvent-Borne Resins

    Popular Stories

    No. 3 AkzoNobel

    AkzoNobel to Close Two Manufacturing Sites

    Modern living room interior with green plants, sofa and green wall

    Reimagining Architectural Paints with Plant-Based Acrylic Binders

    Modern arapartment complex painted in bright colors.

    Architectural Polymers Leading the Way in Coatings Innovation



    PCI Buyers Guide

    Submit a Request for Proposal (RFP) to suppliers of your choice with details on what you need with a click of a button

    Start your RFP

    Browse our Buyers Guide for manufacturers and distributors of all types of coatings products and much more!

    Find Suppliers

    Events

    September 3, 2025

    Coatings Trends & Technologies Summit

    The Coatings Trends & Technologies (CTT) Summit is an annual conference for both liquid and powder coatings formulators and manufacturers to discuss innovations in coatings technology. This event combines high-quality technical presentations, a resource-rich exhibit hall, and dedicated networking opportunities to connect scientific minds, foster innovation, and cultivate game-changing new ideas!

    January 1, 2030

    Webinar Sponsorship Information

    For webinar sponsorship information, visit www.bnpevents.com/webinars or email webinars@bnpmedia.com.

    View All Submit An Event

    Poll

    Longest-running laboratory experiment

    What is the longest-running laboratory experiment?
    View Results Poll Archive

    Products

    CTT Summit Short Courses (Live 9/3/25)

    Coatings Trends & Technologies Summit is expanding its offerings with four short courses. These short courses will offer an extensive day of interactive learning.

    See More Products
    pci  webinar april 2025

    PCI CASE EBOOK

    Related Articles

    • GettyImages-1330906911.jpg

      Opportunities in the Automotive Refinish Coatings Market

      See More
    • Nanoclay feat image

      Influence of Nanoclay on Elastic and Adhesion Properties in Polyurethane Coatings

      See More
    • AmCoat Super Adhesion Lead Image.jpg

      Superior Adhesion: A Major Factor in Coating Performance

      See More
    ×

    Keep the info flowing with our eNewsletters!

    Get the latest industry updates tailored your way.

    JOIN TODAY!
    • RESOURCES
      • Advertise
      • Contact Us
      • Directories
      • Store
      • Want More
    • SIGN UP TODAY
      • Create Account
      • eMagazine
      • eNewsletters
      • Customer Service
      • Manage Preferences
    • SERVICES
      • Marketing Services
      • Reprints
      • Market Research
      • List Rental
      • Survey & Sample
    • STAY CONNECTED
      • LinkedIn
      • Facebook
      • Youtube
      • X (Twitter)
    • PRIVACY
      • PRIVACY POLICY
      • TERMS & CONDITIONS
      • DO NOT SELL MY PERSONAL INFORMATION
      • PRIVACY REQUEST
      • ACCESSIBILITY

    Copyright ©2025. All Rights Reserved BNP Media.

    Design, CMS, Hosting & Web Development :: ePublishing

    Painting & Coating Industry (PCI) logo Powder coating summit logo
    search
    cart
    facebook twitter linkedin youtube
    • Sign In
    • Create Account
    • Sign Out
    • My Account
    Painting & Coating Industry (PCI) logo Powder coating summit logo
    • NEWS
      • Latest News
      • Market Trends & Reports
      • Price Alerts
      • Subscribe to eNewsletters
      • Global Top 10/ PCI 25
      • Weekly Featured Article
      • COATLE Word Game
    • PRODUCTS
      • Product News
      • Must See Products and Services
    • MATERIALS
      • Additives
      • Resins/Polymers
      • Pigments
      • Equipment
      • Distributors
    • TECHNOLOGIES
      • Adhesives
      • Architectural Coatings
      • Industrial Coatings
      • Nanotechnology
      • Powder Coatings
      • Solventborne
      • Special Purpose Coatings
      • Sustainability
      • UV Coatings
      • Waterborne
      • FINISHING
        • Finishing News
        • Finishing Technologies
        • Finishing Equipment
      • RESOURCES
        • Columns
          • Ask Joe Powder
          • Did you know?
          • Distribution Dive
          • Focus on Canada
          • Formulating With Mike
          • Innovation Insights
          • Moody's Coatings Conundrums
          • Powder Coating Perspectives
          • Target the Market
          • TiO2 Insider
        • Blogs
          • Editor's Viewpoint
          • Industry Insights
        • Coatings Supplier Handbook
        • Podcasts and Videos
          • COAT-IT! Podcast
          • Videos/PCI TV
        • PCI Store
        • eBooks
        • Sponsor Insights
        • White Papers
        • COATLE Word Game
      • EVENTS
        • Coatings Trends & Technologies Summit
        • Paint and Coatings Academy
        • Webinars
        • Calendar of Events
        • Lifetime Achievement Award
      • DIRECTORIES
        • Buyer's Guide
        • Equipment Directory
        • Materials Directory
      • EMAGAZINE
        • Current Issue
        • eMagazine Archive
        • China Issue Archive
        • Editorial Advisory Board
      • CONTACT
        • Contact Us
        • Advertise
        • Subscribe to eMagazine
        • Subscribe to eNewsletters