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Coating Method Comparison |
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This chart offers some basic information to help guide you through the maze of coating options. Every project presents unique challenges, however, and Aspect Automation can help you find the perfect solution for your specific coating requirements. |
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| Precision Slot Die Coating | ||||||||
| Method | Speed (fpm) |
Viscosity Range (centipoise) | Thickness | Width | Advantages | Disadvantages | ||
| Slot Die | 0 - 1,200 | To 1,000,000 | 0.5 - 80.0 mils |
To 2M | - Enclosed system - Higher viscosities - Can be applied as in-line stripes - Can be applied intermittently - Can be direct or transfer coated |
- Requires die contact to product - Streaks |
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| Precision Pattern Coating | ||||||||
| Method | Speed |
Viscosity Range | Thickness | Width | Advantages | Disadvantages | ||
| Rotary Screen |
0 -1,000 | 1,000 - 25,000 | 15 - 50 gsm |
To 40" | - Almost any pattern - Quick pattern changes - Closed system - Dot pattern breathable, flexible |
- Pattern consists of dots - Patterns with 100% coverage limited in - size and shape |
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| Precision Roll Coating | ||||||||
| Method | Speed |
Viscosity Range | Thickness | Width | Advantages | Disadvantages | ||
| Gravure | 5 - 500 | 100 - 10,000 | 1.0 - 5.0 mils |
To 2M | - Uniformity of coating - Streak-free |
- Restricted viscosity range - Open system |
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| Offset Gravure |
100 - 1,000 | 100 - 10,000 | 1.0 - 5.0 mils |
To 2M | - Uniformity of coating - Streak-free - Low coat weights |
- Restricted viscosity range - Open system |
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| Multi-Roll | 0 - 1,200 | 100 - 25,000 | 0.2 - 2.0 mils |
To 2M | - Streak-free - Optically clear coating - Uniform coating - Low coat weights |
- Open system - Complex setup |
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| Reverse Roll |
10 - 1,200 | 100 - 19,000 | 1.0 - 5.0 mils |
To 2M | - Streak-free - Optically clear coating - Uniform coating - Low coat weights |
- Open system - Complex setup |
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| Integrated Coating Solutions | ||||||||
| Method | Speed |
Viscosity Range | Thickness | Width | Advantages | Disadvantages | ||
| Bead | 0 - 1,000 | 500 - 100,000 | 0.15 - 0.062 dia |
na | - Non-contact - Single line(s) of bond - Simple and inexpensive - Low adhesive consumption |
- May thermally distort substrate - Subject to air-flow disturbances |
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| Atomized Spray | 0 - 1,000 | 5,000 - 10,000 | 5 - 15 gsm |
na | - Non-contact - Little thermal conduction to substrate |
- Subject to air-flow disturbances - Poor edge definition - Fluid must form droplets |
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| Spiral Spray |
0 - 1,000 | 5,000 - 50,000 | 15 - 50 gsm |
na | - Non-contact - Little thermal conduction to substrate - Breathable bond |
- Subject to air-flow disturbances - Fluid must be extensible - Edges overlap - Spiral changes with web speed |
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| Fiberized Spray | 0 - 1,000 | 5,000 - 50,000 | 5 - 50 gsm |
na | - Non-contact - Little thermal conduction to substrate - Flexible bond retains product "feel" - Breathable bond |
- Subject to air-flow disturbances - Fluid must be very extensible - Only fair edge definition |
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| Other Coating Method | ||||||||
| Method | Speed |
Viscosity Range | Thickness | Width | Advantages | Disadvantages | ||
| Knife over Roll |
0 - 400 | 1,000 - 30,000 | 2.0 - 20.0 mils |
To 2M | - Simplicity | - Coating accuracy - Open systems |
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