Author: Reese Weber, Senior Application Engineer, 3M Industrial Adhesives and Tapes, Bridget Nyland, 3M Industrial Adhesives and Tapes, Global Marketing Manager
COVID-19, supply chain issues, continued labor shortages and higher sustainability requirements have accelerated the need to reassess all aspects of production, including fastening methods and automated production. Tapes and adhesives provide a good solution for three reasons: First, they provide performance similar to mechanical fasteners or welding, and sometimes even better; second, they can be simplified due to ease of use Training or onboarding; third, they can be easily automated to achieve scale or quality requirements.
Solving these challenges at once can be overwhelming, but these different steps are a good starting point:
Tapes and adhesives provide real-time and measurable advantages
When considering labor shortages, switching from mechanical connections to adhesives may not be the first idea that comes to mind, but they may be an effective solution. First, adhesives and tapes do not require skilled or certified operators. Specialized labor skills are difficult to find, so using suitable adhesives as much as possible allows skilled labor to focus on the most critical joints.
Adhesives and tapes also have several other advantages:
Whether and degree of automation
Once you have determined whether an adhesive joint can be used, the next step is to investigate the use of automation to meet your adhesive needs. The term automation may have many meanings that need to be unraveled-it may remind people of millions of dollars of investment and complex robotics, but some automation options require much less budget commitment and complexity.
Generally speaking, if manufacturers fall into one of the following categories, they are ready to automate:
Almost every manufacturer’s needs fall into one of these categories, but jumping into 3D flexible automation does not make sense for every process. Fortunately, adhesive automation can extend from simple improvements using hand tools to six-axis multifunctional robots.
Figure 1. The four levels of automation represent simple to advanced solutions that simplify the process.
Simple tools such as tape blocks and hand-held adhesive dispensers are simple ways to improve the application process without going into automation. They can help increase the repeatability of the process when applying tape or dispense the appropriate ratio of two parts of liquid adhesive each time.
Process assistance is an important first step towards automation. These are usually semi-automatic tools that can increase the productivity of manual applications; one example is a linear laminator, which unrolls the tape and attaches the tape to a flat substrate. Another example is the adhesive dispenser, which can dispense a specified amount of adhesive and free the operator's hands. These tasks allow more work to be completed with the same labor input.
Stationary automation tools are designed to perform a specific assembly process with the goal of improving accuracy, speed or consistency, and/or reducing labor. For tape, a continuous laminator with a conveyor belt allows one operator to handle the entire assembly step, or it can be a component placement system that allows precise and accurate positioning of parts. For liquid adhesives, examples include roller coaters that dispense a specific coating thickness to a large surface area or XY robots that accurately dispense on multiple axes.
Flexible automation is designed to perform multiple assembly processes, or repurpose it later or as needed. Flexible automation usually incorporates robotics, such as a six-axis robot equipped with tape or dispensing heads, depending on the type of adhesive.
Determining the correct level of automation usually comes down to return on investment and short-term and long-term benefits. Variables include assembly volume, part value, labor cost and availability, quality requirements, and of course capital budget.
Figure 2. There are several factors in deciding which automation scope best meets your current needs and considering the scope of automation you choose in the future.
Although automation can bring many advantages, it is important to consider the entire process when making such investments to understand the cost-benefit ratio. In addition to the direct tasks to be automated, factors such as the quality of raw materials, surface treatments, and even seemingly trivial variables such as the type of tape liner all contribute to the success of the automation implementation.
Maintaining good relationships with material suppliers, equipment manufacturers, and integrators is essential to properly set up machines and keep downtime to a minimum. An in-depth overall review of existing production processes is essential to optimize increased productivity, superior product quality, and other benefits of automation.
When seeking to switch to tapes and adhesives, look for material suppliers, equipment suppliers, and integrators who have thought experience throughout the process and can help you throughout the process. With the right partners, the introduction of tapes and adhesives can be an important step in solving today's manufacturing challenges and sustainable development goals.
Regardless of the manufacturer's desired level of automation, 3M has a Bonding Process Center (BPC) designed to help determine customized process solutions for complex bonding challenges, and to enable customers to participate in virtual consultations and live demonstrations. These centers connect customers with 3M experts and promote partnerships that solve problems and optimize processes.
Learn more about 3M Bonding Process Center and schedule appointments by visiting the web page of 3M.com/bondingprocesscenter.
Reese Weber, Senior Application Engineer, 3M Industrial Adhesives and Tapes
Reese is a chemical engineer who has been working on various adhesives at 3M since 2012. He is currently a senior application engineer for 3M™ VHB™ tape, and works with customers on design, technical testing, and product selection.
Bridget Nyland, Global Marketing Manager, 3M Industrial Adhesives and Tapes
Bridget Nyland is the global marketing manager for Connected Automation in the 3M Industrial Adhesives and Tapes division. Bridget has 10 years of industrial manufacturing experience, from project engineering to business development and strategy. She is currently focused on helping 3M's customers use digital and automation solutions to improve their bonding processes and fulfill the promise of Industry 4.0.
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