Adhesive Replaces 2-Part Epoxy for Faster Optical Sensor Assembly

A case study about how a light-curable adhesive replaced a two-part epoxy for faster sensor assembly and improved the application process.


Replace a Slow Curing 2-Part Epoxy and Manual Dispense Process

A 100-year-old company that specializes in developing innovative automation solutions for the electronics, battery, semiconductor, automotive industries, and more, needed to bond components of a sensor together. The business relies on the implementation of high-quality sensors, identification and image processing, and network technology and software to create high-tech automated systems for their end customers.

A specific application they needed assistance with required bonding a small glass window onto a polyamide injection-molded LED optical housing for a photoelectric barrier. They wanted to replace a two-part epoxy, move from a manual to robotic dispense process, have a higher reproducibility rate, and reduce scrap. Additionally, the finished parts needed to main-tain structural integrity for five years and have flexibility to endure tem-perature-induced stresses. 


Light-Curable Adhesive that Provided Fast Assembly of Two Dissimilar Substrates and Offered Structural Integrity

The customer contacted Dymax to see what product might help the company achieve their objectives. They were only interested in an adhesive recommendation but had an additional request for the company to do their own internal trials and qualification of the material. Dymax Application Engineering and the Inside Sales Team worked together with the customer and proposed using Dymax 431 UV/Visible light-curable adhesive for glass, plastic, and metal bonding, an ideal candidate for dissimilar substrate assembly. 

Designed for high-temperature and high-moisture environments, 431 cures in seconds and maintains superior adhesion and flexibility. The versatile product exhibits low shrinkage, resulting in reduced stress on bond lines and larger cured surfaces. To support the company’s internal testing trials, the team suggested using the Dymax 5000-PC flood-curing system at a cure time of 65s in combination with a robotic bead dispenser that applied material in a 4.5 mm circle diameter.


Reduced Processing Time by Two Hours & Eliminated the Challenges of 2-Part Epoxy Disposal

By choosing Dymax 431 adhesive, the customer was able to reduce their processing time by two hours due to the fast-curing characteristics of the material, unlike epoxies which require a much longer cure time before parts can be moved to the next assembly step. 431 is a one-component adhesive that requires no mixing prior to robotic dispensing, unlike a 2-part epoxy that needs mixing prior to application, resulting in less waste and WIP.

Additionally, the ability of 431 to bond polyamide and glass together provides some flexibility to the assembled components to compensate for induced stresses that can happen between bonded dissimilar materials. The superior strength of the adhesive and resistance to high-temperature and high-moisture environments will add to the longevity and structural integrity of the finished sensor.

Since the material has no solvents added and is environmentally friendly, there are no special requirements for disposal making it a “greener” process. By using Dymax 431 adhesive in their process, the company reduced the overall processing time and scrap rate, and increased throughput. 


Related Products

Check out the other Dymax products that work in conjunction with this one to create a complete solution

Check out the other Dymax products that work in conjunction with this one to create a complete solution

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