A side-by-side comparison of three thin film coating technologies for electronic applications.
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R&D product leaders like you and me drive innovation. We turn ideas and problems into safe and manufacturable products by exploring new technologies, materials, and processes to meet technical needs and customer expectations. One such need and expectation is the development of smaller, "smarter," more reliable components and products.
Protective coatings, particularly thin films (materials with thicknesses ranging from a few nanometers to a few micrometers), are one way to enable this development. Three of these coating techniques are thermal Chemical Vapor Deposition (CVD), Atomic Layer Deposition (ALD), and Plasma-enhanced Chemical Vapor Deposition (PECVD). Each of these techniques can deposit a wide range of materials. However, here we are going to refer to them as the techniques used to deposit HZO Guardian (Parylene), HZO Defender (thin ceramic), and HZO Sentinel Zero (layered hydrophobic) coatings using the respective methods.
Read more about HZO Guardian Plus Parylene Coatings
Understand Sentinel Zero PECVD Coatings
Let's examine the basic science behind each coating and the pros and cons of each. By the end of this overview, you should have a good idea of which option might be best for you, but I'll sum things up with some generalizations and questions you and your team can ask as you continue your research. This won’t be as much of a scientific paper, but rather a plain-language or conversational explanation of the concepts. If you’d like a deeper dive into the science, feel free to contact me personally and set up a meeting.
But before I dive in, let's align on what aspects of the coating you will likely be interested in. I realize everyone's knowledge of thin film coatings may vary. My company has a resource page, and I also recommend this paper by Vasilyev here to explore the science of thin film coatings further. However, in general, depending on your product, you might prioritize understanding the following:
Conformality: Can the coating reach deep crevices and cover 3D geometries evenly?
Barrier Properties: How well does it block moisture, oxygen, or gases?
Mechanical Properties: Will it withstand abrasion or flexing?
Dielectric Performance: Is it insulating enough for sensitive or higher-power electronics?
UV Resistance: Will it hold up in direct sunlight or sterilization conditions?
Process Constraints: These include throughput, masking needs, temperature, etc.
With those criteria in mind, let's look at Parylene, ALD, and PECVD coatings. For transparency, these are the coatings we offer or have offered at my company, HZO, which is also why I can speak to the science. I optimize and solve problems with these materials and processes every day.
Parylene is a vapor-deposited polymer known for uniformly coating complex shapes and internal crevices. This is thanks to its long-lived reactive species, which can travel deep into structures before reacting.
Parylene is deposited using a thermal chemical vapor deposition (CVD) process, which means it has a better “throw,” allowing you to get really conformal around components. The thermal activation of the precursor molecules typically allows the activation to last longer than an electrical activation. Parylene would be able to get inside smaller or deeper crevices, and you'd be able to coat hidden and difficult to reach areas that you normally can't conformally coat in a dip coating process.
The coating is also flexible, but thick. And by thick - I mean relatively thick. Compared to an acrylic conformal coating, Parylene coatings are typically half as thick. But we're comparing it to the coatings yielded by the other two techniques in this overview - PECVD and ALD.
A common Parylene coating project is 7-25 microns thick, PECVD coatings could be 6 microns thick, but they are routinely 0.8-2.7 microns thick, and ALD coatings get even thinner. This is typical, but at HZO, we do a lot of customization, so if you have a question about a different thickness, please reach out.
A low magnification SEM image (left) and a corresponding Cl (chlorine) map (right) of a cross-section of a board-to-board connector. Note that the 10-micron thick coating covers the surfaces of the thin gap under the connector, reaching as far as the edge of the opening allowed it to.
If you need to coat underneath pins or if you need to coat in some crevices, then Parylene's a good balance between having something that's really conformal and not too thin versus something that's not conformal enough. I'll sum up Parylene's strengths and limitations below.Snapshot of the ALD Process.
Snapshot of the PECVD Process.
Plasma Enhanced Chemical Vapor Deposition (PECVD) is a plasma-assisted deposition technique that offers flexibility and speed. At HZO, our PECVD applied coatings excel in applications requiring thinner coatings (<6 microns) and at these thinner coating levels they give better protection than the equivalent thickness of a parylene coating. They can be hydrophobic, more oleophobic, transparent to high frequencies, and UV resistant.
Get Technical Datasheet for Sentinel Zero – UV resistant, PFOS & PFAS-free PECVD Coatings
Get Technical Datasheet for EX – Transparent to High Frequencies (Low Loss Tangent), Omniphobic
Have more questions about the different properties of our PECVD coatings? Contact me.
PECVD-applied coatings can be deposited quickly and made in layers. For example, you can have a hard layer that is less conformal and more of a line-of-sight coating, and you could include that with a more conformal layer that is softer, but penetrates deeper into crevices. Then, the last or top layer could be a highly hydrophobic layer to prevent liquid water from ingressing into the stack or it could be harder layer to prevent the stack from being scratched.
PECVD coatings are a lot more conformal than many other coating techniques, but out of the three coatings we are discussing here, the PECVD coatings are less conformal because you have to activate your species electrically in a plasma, and that activated chemical has a limited lifetime.
In other words, if the travel time required before your activated gas reacts with a surface is too great because the area to coat is too far away or around too many corners, then that area will get less to no coating. The activated species has a limited time remaining active once it leaves the plasma zone.
Our PECVD coatings are often chosen for their hydrophobic properties and UV resistance, which are crucial in specific applications. Take hydrophobicity. Water carries ions, and those ions help transport electricity and water itself. All devices run on some kind of electricity. So we want to prevent the water from staying on the board and causing damage from the ions. The hydrophobicity prevents the water from staying on the board if the board isn’t immersed in water.
Think about the typical use case for electronic devices—most entail only temporary exposure to water. Even though our PECVD coatings can be tailored for longer exposure to water, sweat, or other harmful solutions in tests such as the IPX7 or IPX8 tests, all of our PECVD coatings are significantly hydrophobic regardless of thickness. For example, we will probably spill water on our laptop; we won't use it underneath a pool. Hydrophobicity helps a lot with that. If the water gets into a little crack, capillary forces keep it in. If everything is hydrophilic, the water will want to stay in these cracks.
Of course, this causes problems you may not see with your computer right after the spill, but later on, corrosion develops because the water is still stuck in there.
Hydrophobicity helps the water not want to be there anymore. It pushes it out and helps it evaporate quickly, preventing the water from sitting on your device for too long. Meanwhile, UV resistance is critical for any application outside and not already in some kind of housing. Other coatings will degrade and break down in UV exposure, and so will their protection. This isn't the case with PECVD coatings.
A huge benefit of going with a thinner PECVD coating is the potential for cost savings. Six microns or less is generally the cut-off for costs. If you can keep close to this thickness layer, you can have punch-through capabilities. This means that when you have a connection that's often removed and put back on, you're punching through the coating once you plug in that connection.
It is true that if you remove that connection from where it was plugged in, it isn't protected anymore. But other products like greases can help protect that area from water ingress, so if you want to plug in and unplug something while it's underwater, then greasing up that connection will help a lot, but as mentioned above a product with a thin plasma coating wouldn’t be constantly used in an underwater environment.
This will drastically reduce or eliminate the need for masking parts, reducing the price of the coating process and the cost of repairing it. If you need some areas without coating, you can use shadow masking, which is much cheaper than actual masking with glues.
Another benefit of the thin PECVD coatings is their ability to be transparent for high-frequency signals like radio waves, Wi-Fi, Bluetooth, or other signals that your device will be sending or receiving. One reason for this is the thin nature of the PECVD coatings, and the other is the low loss tangent of the chemistry used in our Sentinel EX coatings.
Moderate
Dielectric Properties Excellent ModerateGood
Mechanical Properties Flexible, relatively thick Fragile (ceramic) Softer than Parylene WVTR/Barrier Performance Good, relatively thick Excellent, thin Moderate UV Resistance Low Moderate High Hydrophobicity Moderate Low High Process Speed Moderate Slow Fast Masking Complexity High High Moderate-Low Coating Cost (Speed+Masking) Moderate High Low-Moderate Best Use Case Flexible, dielectric Ultra-thin, barrier UV, incidentalWhat are the common factors influencing the choice of one coating technology over another?
Factors to think about are what environment your end product is going to be in and what the coating will cost. Do you have something that's going to be underwater all the time and can cost more? Parylene is your best bet. Do you need to ensure that there's no particular ingress of a certain gas species in your environment? You might need an ALD coating to help with the protection you need. And if you need this to be out in a UV environment where we don't want any of it to degrade, then a plasma coating is a better choice. Do you just need to extend the life of your product by keeping water and sweat away? Then, a hydrophobic PECVD coating would work great.
Another factor is longevity. Do you want your product to last for years? Tens of years? Hundreds? We know that the longer you want a coating and its protection and enhancement to last, usually, the bigger, the thicker, and the more durable the coating needs to be. Most of our plasma coatings are thinner and help you protect a product from incidentals, but not for continuous immersion uses, although mass production coatings with a harder outer layer are being developed.
Ultimately, though, I'm afraid there's no "winning" coating here. Only the right tool for the job. Some good questions to ask as you continue your research might be:
And some general advice?
Biocompatibility is vital to medical device safety. It ensures implants and other devices can be used in and on the body with minimal adverse reactions. Medical devices must be highly biocompatible, as they often contact the body's internal tissues and fluids.
Parylene's biocompatibility is crucial for its use in medical devices. Additionally, Parylene is physiologically non-reactive and isn't toxic.
Medical professionals and device makers rely on strict biocompatibility testing for safety. They follow established standards, especially ISO and the USP VI Standard.
A complete analysis of Parylene shows it is biocompatible. It meets the strict standards for medical device use. Third-party sources have tested the material, and it causes no harm to tissues or body fluids. Parylene's chemical inertness makes it compatible. It provides a safe interface between the device and human tissue.
Parylene's chemistry and structure make it biocompatible. It meets the USP's highest, Class VI, biocompatibility standards. Parylene has passed the USP's strict tests, described here. Also, it has a proven track record of reliable performance in the medical device industry.
Decades of use show Parylene coatings maintain their performance and integrity. Bodily fluids, varying pH levels, and enzymes do not reduce their effectiveness. Parylene-coated medical devices are vital. They provide reliable, long-lasting protection and function.
Parylene's uniform, pinhole-free coating does more than protect. It provides a reliable interface between the device and the body. So, encapsulated medical components can serve patients for as long as they are used. The difference is not just in Parylene's inertness. Parylene can also resist the harsh conditions of the human body.
Below, you can see a Parylene-coated Raspberry Pi computer running underwater in HZO’s lobby. As of the date of publication, this computer has been running fully submerged in tap water for over two years now:
Parylene often stands out for its unique properties. So, it is a good biocompatible material for medical uses. But, a range of alternatives exists. They include silicone, Teflon, and various medical-grade metals and polymers. Each material has a unique set of traits best in certain conditions.
Parylene is known for its great chemical resistance. It can also form pinhole-free coatings at a micron-level thickness. This lets devices work reliably in the harsh human body. Parylene coatings are ultrathin. They keep the feel and function of the underlying material. This is a big advantage over bulkier options like silicone rubber or polyurethane.
Consider Parylene versus stainless steel, which is a common choice for implants. Stainless steel is strong and fatigue-resistant. But it can't match Parylene's ability to conform to complex shapes. The difference shows in applications needing a seamless coat over complex parts. Here, Parylene's conformal nature gives a uniform layer. It fully isolates the parts from the body's fluids and tissues.
Unlike Teflon, a popular biocompatible material, Parylene is PFAS-free. It is REACH and RoHS compliant, and its ability to maintain physical integrity under sterilization methods boosts its comparability.
However, Parylene is not without its limitations. Parylene has great barrier properties and electrical insulation. But, its mechanical strength is not as good as that of metals or ceramics. This property requires careful thought in load-bearing implant uses where strength is vital. Also, the Parylene application process uses chemical vapor deposition. It's very effective but may complicate the manufacturing workflow. Simpler methods, like dip or spray coating, are used for silicone and latex.
Read about how to incorporate Parylene into your process
Other materials may have specific advantages, like higher tensile strength or elasticity. But, Parylene's combination of properties often justifies its selection. It depends on the intended use, performance, and regulatory standards. Manufacturers must balance performance and material costs. They also consider the complexity of application methods for producing and using medical devices.
Learn more in our webinar, Parylene: Pros, Cons, and Practicalities
Parylene is a very popular protective coating in the medical industry. In , the parylene market was valued at $98.38 million; by , it is expected to grow to $118.52 million. Why is Parylene so widely used? The answer lies in its powerful protective properties.
Parylene is highly resistant to moisture, chemicals, and other environmental factors. The coatings protect medical devices in and on the body at 50% of the thickness of conventional conformal coatings, reducing product bulk and weight. Also, Parylene has very high dielectric strength, up to 7,000 V/mil. This ensures that electrical components can function uninterrupted by external stimuli.
Parylene's conformal coating attributes ensure a uniform, pinhole-free application. It adheres to every contour of the complex geometries in medical devices. This ensures complete encapsulation with no areas left vulnerable. Parylene's coating uniformity greatly improves device protection.
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Parylene coatings have established their utility in a wide range of medical devices. They improve protection and longevity. Here are some use cases for Parylene:
Diverse biomedical applications capitalize on Parylene's biocompatibility. It is present in both in vivo and in vitro environments. These include surgical instruments, cochlear implants, and diagnostic equipment sensors.
Do you have any questions about Parylene or what it can do for your next project? Please reach out to our team. We’re standing by to answer your questions and help you determine your next step.
Temperature affects the behavior of materials, causing them to expand or contract. However, not all materials respond to temperature variations in the same way. Some materials, like metals, tend to expand when heated, while others, like water, show a more complex behavior, with expansion occurring at specific temperatures.
Learn about other thermal coating properties, like thermal conductivity and glass transition temperature.
This property is crucial in predicting how a material will respond to temperature changes. This coefficient, represented by the Greek letter alpha (α), describes how much a material expands per unit length for each degree of temperature rise. Understanding this concept helps engineers make accurate predictions and design structures that can withstand temperature fluctuations.
The coefficient of linear expansion (α) can be calculated using the following formula:
α = ΔL / (L₀ × ΔT)
Where:
α is the coefficient of linear expansion
ΔL is the change in length
L₀ is the original length
ΔT is the change in temperature
Units used for expressing the coefficient
The coefficient of linear expansion is typically expressed in units of length per unit temperature, such as millimeters per degree Celsius (mm/°C) or inches per Fahrenheit (in/°F). These units emphasize the linear dimensions and temperature change required to induce a specific change in length. By using consistent units, scientists and engineers can easily compare and analyze the behavior of different materials.
Accurately measuring values is essential in understanding how materials respond to changes in temperature. Several experimental techniques are commonly employed to measure the coefficient of linear expansion. The most widely used method is known as the thermal expansion apparatus. This apparatus consists of a rod or sample material, which is heated or cooled while its length changes are recorded. By carefully analyzing the recorded data, researchers can calculate the coefficient of linear expansion for the material.
The interferometric method utilizes interference patterns created by light passing through a material. This technique accurately measures the changes in length resulting from thermal expansion.
Additionally, some advanced techniques like dilatometry, which involves measuring volume changes, and strain gauges, which record dimensional changes, are used for highly precise measurements of the coefficient of linear expansion.
Thermal expansion refers to the increase in size or volume of a material as its temperature rises. This expansion occurs because heat causes the atoms and molecules within the material to move more rapidly, increasing their average spacing. As a result, the material takes up more space and expands.
Meanwhile, the coefficient of linear expansion represents the change in length per unit length per unit change in temperature.
The relationship between the coefficient of linear expansion (α) and thermal expansion can be expressed using the following formula:
Thermal expansion = coefficient of linear expansion × Original length × Change in temperature
This formula allows engineers to calculate a material's dimensions change when its temperature changes.
Several factors can influence the coefficient of linear expansion in materials. These factors can affect how much a material expands or contracts when subjected to changes in temperature.
Crystal Structure, Bonding Types, and Impurities
The crystal structure of a material heavily influences the coefficient of linear expansion. Different crystal structures can lead to variations in the coefficient. The type of bonding between atoms in a material can also affect its coefficient. For example, materials with stronger intermolecular forces tend to have lower coefficients, while those with weaker ones tend to have higher ones.
Impurities in a material can also impact its coefficient of linear expansion. Their presence can disrupt the regular arrangement of atoms, causing changes in the expansion behavior.
External Factors
External factors such as pressure, magnetic fields, and electric fields can also influence this value. Pressure can alter the arrangement of atoms in a material, affecting its expansion behavior. Similarly, magnetic fields and electric fields can cause changes in the alignment and movement of atoms, leading to variations in the coefficient.
This property is highly dependent on the material properties of a substance. Different materials exhibit different coefficients due to their unique structures and bonding arrangements. For example, materials with stronger intermolecular forces tend to have lower values because their particles are held tightly together, making them less likely to expand significantly with temperature changes.
Material properties such as elasticity, rigidity, and thermal conductivity also play a significant role in determining this value. Elastic materials can return to their original shape after being subjected to deformation caused by thermal expansion. On the other hand, rigid materials are less prone to significant expansion due to their stiffness and resistance to deformation.
Additionally, materials with high thermal conductivity tend to have higher values. High thermal conductivity allows for faster heat transfer, leading to greater expansion or contraction in response to temperature changes.
When dimensional stability is critical, materials with low coefficients are preferred to minimize undesired expansions or contractions. On the other hand, materials with higher coefficients may be utilized in applications where controlled expansion is desired.
Engineers can make informed decisions regarding material selection, product design, and manufacturing processes by understanding how different materials expand or contract with temperature changes. This knowledge helps create efficient and durable structures, products, and systems. If you are looking for a coating material to suit your application needs, please contact our engineers to discuss DFM. Or, learn more about thin film protection capabilities, such as optical properties like transparency and index of refraction.
The ability to accurately predict the behavior of coating materials under tension is crucial in ensuring the integrity and reliability of electronic components. This includes studying different materials' deformation and failure mechanisms when subjected to a tensile load. One key parameter that is used to quantify the ability of a material to withstand such loads is its tensile strength at yield.
Tensile Strength at Yield indicates a material's ability to withstand loads and forces during its lifetime, making it crucial for designing structures and components that can endure various stresses. It is a vital measurement in numerous disciplines, such as engineering, manufacturing, aerospace, and automotive.
When a material is subjected to a tensile load, it experiences stress and undergoes deformation. The stress-strain curve, representing the relationship between the applied stress and resulting strain, provides valuable insights into the material's behavior. This curve can determine the ultimate tensile strength, the maximum stress the material can withstand before failure occurs.
The yield point is a critical parameter in studying tensile strength at yield. It refers to the point on the stress-strain curve where a significant increase in strain occurs with minimal or no increase in stress. The tensile strength at yield is the stress level at this point and represents the maximum stress a material can withstand without undergoing permanent deformation.
During the deformation process, materials can exhibit different types of behavior. Elastic deformation occurs when a material returns to its original shape upon removal of the load, while plastic deformation occurs when the material undergoes permanent changes in shape. Understanding the concepts of elastic and plastic deformation is essential in analyzing a material's behavior under tension.
Due to the importance of this mechanical material property, obtaining accurate Tensile Strength at Yield data is critical. Accurately measuring it requires appropriate testing methods, equipment, and adherence to specific standards. The most commonly used technique is the tensile test, where a sample material is subjected to an increasing axial load until it reaches its yield point. Sophisticated equipment, such as universal testing machines, performs these tests and obtains reliable measurements. Standard organizations, such as ASTM International, provide guidelines and standards for conducting these tests, ensuring consistency and comparability of results.
Standards and specifications are crucial in ensuring the accuracy, reliability, and consistency of measurements. National and international organizations have established various standards to regulate this critical characteristic of materials.
Similarly, numerous national and international standards have been developed to guide the measurement and characterization of tensile strength at yield. These standards outline the specific testing methods, equipment, and conditions to ensure accurate and comparable results across different laboratories and industries.
The American Society for Testing and Materials (ASTM), International Organization for Standardization (ISO), and Deutsches Institut für Normung (DIN) are among the leading organizations that have established widely recognized standards for tensile strength at yield. Compliance with these standards is essential in ensuring test data's uniformity, reliability, and compatibility.
Material composition plays a crucial role in determining values. Different elements and their proportions can significantly affect the mechanical properties of a material, including its yield strength. For example, increasing the amount of carbon in certain materials can enhance tensile strength at yield.
The microstructure of a material also plays a vital role in determining this value. Factors such as grain size, phase distribution, and dislocation density can impact the material's ability to withstand deformation before yielding.
Because this mechanical property is crucial in determining various structures and products' overall reliability and safety, it should be closely considered during material selection. Every industry and application has unique requirements for choosing a coating material. Engineers must account for environmental conditions, load-bearing capacity, and durability requirements. They can select appropriate materials to meet the desired performance and safety standards by evaluating the tensile strength at yield requirements specific to each industry. A summary of requirements for particular applications is below.
Tensile strength at yield is a critical mechanical property used in coating material selection. It provides valuable information about the protective coating material's ability to withstand applied forces without permanent deformation. If a protective coating were to break, it could allow corrosives and contaminants to destroy electronic components, causing failure.
Design engineers rely on this property to evaluate and compare different coating materials, ensuring their suitability for specific applications. If you are designing an electronic component and need help determining which coating material is best for your product, please contact our engineers, or read additional information on thin film coating properties.
Biocompatible coatings seamlessly integrate with the human body, offering benefits through their ability to promote healing and prevent adverse reactions. They can improve patient outcomes, reduce complications, and enhance device functionality. As such, biocompatible coatings have become an indispensable tool in various medical applications.
Biocompatibility refers to the ability of a material to function without causing any harmful effects to the living tissues or organs it comes into contact with.
Several factors influence the biocompatibility of coatings. One such factor is the material composition. The choice of materials used in a coating can significantly impact its compatibility with the human body. Additionally, the surface properties of the coating play a vital role in determining its biocompatibility. Roughness, porosity, and surface energy can affect how the coating interacts with biological tissues and fluids.
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When it comes to achieving biocompatibility in coatings, there are key considerations. First and foremost, the material should be non-toxic and non-allergenic. It should not trigger any adverse immune responses or elicit any toxic effects. Furthermore, the coating should withstand the physiological environment it will be exposed to, such as changes in pH, temperature, and mechanical stress.
Coating application processes also play a significant role in achieving biocompatibility. The application technique must ensure uniform coverage and adherence. Proper surface preparation and application techniques are essential to avoid issues arising from poor coating adhesion or inconsistencies.
Biocompatible coatings can significantly influence the body's response to medical devices and implants. A well-designed biocompatible coating can minimize inflammatory responses, prevent bacterial adhesion, and promote tissue integration. Furthermore, by providing a protective and biologically compatible barrier, these coatings enhance the safety and effectiveness of medical devices, improving patient outcomes.
There have been several successful applications of biocompatible coatings in medicine and biomedical engineering. Here are a few examples:
Various coating technologies are employed to achieve biocompatibility in different medical devices. These technologies involve using specific materials and techniques to create coatings that meet the required standards:
Chemical Composition
Different biocompatible coating materials, including polymers, such as Parylene, ceramics, and metals, are used. Each type has its unique characteristics and advantages for medical applications. Polymers, for example, are known for their flexibility and ability to mimic natural tissues. Ceramics offer excellent wear resistance and can provide a stable surface for cell growth, while metals are valued for their durability and strength.
Coating Techniques
Each coating technique has its advantages and limitations. The selection of a particular method depends on factors such as the desired coating properties, the substrate material, and the intended application. The deposition of biocompatible coatings requires specific techniques to ensure uniformity and adherence to the substrate. Several coating techniques are commonly employed in the medical industry, including:
Biocompatible coatings can be employed in manufacturing electronic devices, food processing equipment, and cosmetic products, among others. With their ability to provide a safe and reliable surface, biocompatible coatings offer advantages beyond the medical field.
However, within various areas of medicine, biocompatible coatings play a crucial role in enhancing the compatibility of medical devices, improving tissue engineering techniques, and revolutionizing drug delivery systems. These coatings have transformed the field of medicine by reducing rejection and adverse reactions and improving the overall efficiency of medical interventions. Three use cases are described below.
Medical Implants
One of the critical applications of biocompatible coatings is in the field of medical implants. For instance, in orthopedic implants, biocompatible coatings create an optimal environment for the implant to integrate seamlessly with the surrounding tissues and bones. Similarly, dental and cardiovascular implants benefit from biocompatible coatings, promoting long-term stability and functionality.
Drug Delivery Systems
Biocompatible coatings have revolutionized the field of drug delivery systems by improving stability, enhancing bioavailability, and enabling targeted drug delivery. The efficacy and safety of drug delivery are significantly improved by coating drug carriers such as nanoparticles, microparticles, and implants with biocompatible materials. These coatings protect the drugs from degradation, facilitate controlled release, and ensure targeted delivery to specific tissues or cells.
Biomedical Devices
Biocompatible coatings find extensive applications in various biomedical devices, including biosensors, microfluidic devices, and prosthetics. These coatings enable seamless integration and interaction with biological systems, enhancing the device's functionality and reducing the risk of adverse reactions. For example, biocompatible coatings on biosensors allow accurate and reliable detection of biomarkers, while coatings on prosthetic limbs improve their integration with the human body and enhance user comfort and mobility.
Selecting the most suitable material for a specific application is essential to ensure optimal biocompatibility and overall performance of the coating. There are various factors to consider when selecting materials for specific medical applications. These factors include:
Please contact our engineers if you require a biocompatible coating material for your application or have questions about protective thin film coating properties. Meanwhile, please browse our resource section to learn about other relevant properties, such as tensile strength, yield elongation, and corrosion resistance.
Whether designing circuit boards or protecting electrical components, knowledge of the volume resistivity of coating materials plays a pivotal role in creating efficient and reliable electronic products. This critical measurement refers to the ability of a material to resist the flow of electric current within its volume. In other words, it measures how well a substance conducts or insulates electricity.
Volume resistivity refers to a material's resistance per unit volume when an electric field is applied. It is measured in ohm-meters (Ω·m) and depends on the material's nature and composition.
One way to understand this property is by comparing it to electrical conductivity. While volume resistivity measures the resistance to the flow of current, electrical conductivity measures how easily current flows through a material. In other words, it is the inverse of electrical conductivity. Volume resistivity is especially important in coating materials used for electrical insulation. Insulating materials like polymers or ceramics need high values to prevent electrical current leakage and ensure the circuit's integrity.
Due to its importance, the accurate measurement of volume resistivity is essential to understanding the electrical conductivity of materials. By determining how well a coating material can resist the flow of electric current, engineers can assess its suitability for a wide range of applications.
Several techniques are common. One such method is the four-point probe technique, which involves passing a known current through a material and measuring the voltage drop across four evenly spaced points. This method enables precise calculations of the material's resistivity. Another popular technique is the two-point method. This approach passes a current through the material using two electrodes, and the voltage drop is measured. By applying Ohm's Law, the resistivity can be easily determined.
Specialized equipment is necessary to measure this value. This equipment includes multimeters, which can accurately measure voltage and current. Custom-built setups are often employed for specific applications to ensure precise measurement results.
Various factors can influence the volume resistivity of a coating material. These factors can alter the resistance properties of a material and potentially affect its performance in electrical applications. They include the following:
Polymer materials have different volume resistivity values, determining their ability to conduct or resist electrical current. The volume resistivity of a polymer is directly influenced by its molecular structure and composition. Some examples of polymer materials with high values include polyethylene and polypropylene. These materials are commonly used in cable insulation and high voltage applications, where electrical current needs to be contained. On the other hand, polymer materials with low values, such as conductive polymers and carbon-filled composites, are often used as electrical conductors. They are suitable for applications requiring efficient electrical current flow.
Volume resistivity is a critical value that helps determine the suitability of coating material for specific applications. Engineers can select the most appropriate materials to ensure optimal performance and safety by knowing how conductive or insulating a substance is. Additionally, understanding this property helps diagnose and prevent electrical failures in electronic products. Analyzing the volume resistivity of protective coating material within an electrical system allows potential issues, such as short circuits or unexpected voltage drops, to be identified and rectified before they cause significant damage or failures. This proactive approach saves time and money while enhancing the system's reliability. Last, volume resistivity is essential in complying with industry standards and regulations. Many sectors, including electronics, automotive, and aerospace, have stringent requirements for electrical systems. By ensuring that materials used in these systems possess the appropriate volume resistivity values, businesses can meet these standards and ensure the longevity of their products.
In circuit design, selecting coating materials with appropriate volume resistivity is paramount. This property plays a significant role in ensuring electronic devices' proper functioning and performance. By selecting materials with appropriate volume resistivity, circuit designers can ensure the proper operation of different components, minimize the risk of electrical failures, and enhance the overall functionality of the circuit.
Overall, this is a critical factor to consider during circuit design. It not only influences the performance and efficiency of electronic devices but also allows for the optimization of circuit design by selecting materials based on their electrical properties. If you are searching for a protective coating with volume resistivity that meets the criteria for your application, please contact us; we may be able to help. For more information about the critical electrical properties of coating materials, please visit our coating properties page.
Elongation yield refers to the maximum amount of deformation a material can undergo before it experiences a permanent change in shape or size. This property is fundamental in determining various coating materials' mechanical strength and behavior, making it an essential factor in design engineering and product design.
Understanding how this property affects material performance is crucial in determining the suitability of coating material for a particular application. It directly affects the material's ability to deform without breaking and sustain loads without failure. This high-level overview will discuss elongation yield and its implications for product design.
Elongation yield can be measured in various coating materials, including metals, polymers, and composites. Coating materials such as metals with higher values typically exhibit greater ductility, the measure of a material's ability to deform before fracture.
On the other hand, coating materials with a lower elongation yield tend to be less ductile and more prone to brittle behavior. They have limited ability to deform before reaching their breaking point. Such materials are usually more suitable for applications that require high strength and rigidity but not necessarily significant deformation.
Polymers, including plastics and rubber, display higher values than metals, enabling them to withstand extensive stretching or bending before breaking.
Composites, which consist of two or more different material components, can possess varying characteristics depending on their composition. The individual materials within a composite can have different abilities to undergo elongation yield, making the overall behavior complex.
Unit of Measure
Two standard units of measure are used to quantify elongation yield: percentage and millimeters.
The percentage unit of measure represents the elongation yield as a percentage of the original length of the material. For example, if a metal specimen stretches 10% before breaking, it has elongated by 10% of its original length.
On the other hand, millimeters are used to measure the actual physical elongation of a material. This unit of measure provides a more tangible representation of the deformation a material undergoes before reaching its breaking point.
Both units of measure have their advantages and are suitable for different applications. The choice between percentage and millimeters depends on the material type, testing specifications, and industry standards.
When determining a material's elongation yield, reliable data and thorough testing methods are essential to ensure accurate measurements and a deeper understanding of how a material will perform under various conditions. The data obtained during material testing provides valuable insights into the behavior of a material and its elongation yield. It includes measurements such as strain and stress, which calculate values.
By analyzing the relationship between stress and strain, engineers can identify the point at which the material starts deforming permanently, known as the elongation yield point.
Overview of the Different Testing Methods Used
Various testing methods are employed to measure this property, each offering advantages and limitations. Tensile testing, for example, is commonly used to evaluate a material's mechanical properties, including elongation yield.
In tensile testing, a material sample is subjected to controlled tension until it reaches its elongation yield point. The resulting data helps determine the material's ability to withstand loads and deformations.
On the other hand, impact testing measures the energy absorbed by a material when it fractures under sudden stresses. This method provides valuable insights into the material's toughness and resistance to sudden impacts.
Other testing techniques, such as bend and hardness tests, can also provide insights. The bend test involves subjecting a material to bending forces to determine its flexibility and resistance to deformation. On the other hand, the hardness test measures the material's resistance to indentation, indirectly indicating its elastic deformation capabilities.
Specific standards established by regulatory bodies and industry organizations govern the testing procedures. These standards ensure consistency and comparability of test results across different laboratories and manufacturers.
Engineers and designers can make informed decisions regarding coating material by considering the elongation yield. They can determine the material's capacity to stretch and deform before reaching its breaking point, safeguarding the reliability of the end product.
Moreover, understanding the elongation yield can also help optimize designs, reduce material waste, and enhance overall efficiency. Engineers can create designs that balance strength, flexibility, and cost-effectiveness by accurately predicting the coating material's behavior based on elongation yield values.
Electronic product reliability hinges on protective coating durability. If a coating breaks in any way, it could open the door to corrosives, chemicals, and other contaminants that could cause electronics to stop working. Therefore, understanding the elongation yield value is vital in ensuring electronic products' safety, durability, and performance in real-world applications. If you need help identifying the best coating material for your application, please contact our Applications engineers for a DFM consult. Alternatively, you can learn more about our coating protection capabilities, including Young's modulus, elongation at break, and tensile strength at yield.
Dayton's leading-edge coatings and other unique surface treatments have been developed to improve inplant performance by increasing tool hardness and wear resistance.
A cryogenic steel conditioning process used in addition to heat treating. An effective way to achieve optimum toughness, improved strength, and dimensional stability. Used primarily with hard, thick materials.
A low temperature, cost-effective surface application that treats all exposed surfaces. Provides increased dimensional stability. Ideal for punches and die buttons.
A thin film coating provides superior hardness (harder than carbide). Super-smooth finish on the point helps reduce galling and maintenance. Ideal for higher-than-normal punching frequency.
Super-smooth polish on the point to reduce galling and improve punch life. Use with the appropriate coating for your application to maximize punch life and reduce maintenance costs. Excellent for extruding applications.
Excellent wear resistance and lubricity. Not recommended for stainless steel, copper, or nickel. A good general-purpose coating. Approx. hardness: *Vickers .
Ultra-hard (harder than carbide), thin coating. Provides superior abrasive wear resistance and lubricity. A very good general-purpose coating for all materials. Upgrade over XNT. Approx. hardness: *Vickers .
Ultra-hard (harder than carbide), high-aluminum coating. Provides high temperature resistance. Well-suited for applications where surface heat is generated. Ideal for HSLA, dual phase, and TRIP steels. Upgrade over XCN. Approx. hardness: *Vickers .
Superior hardness (harder than carbide); provides superior abrasive wear resistance and excellent lubricity. Provides highest temperature resistance, thermal shock stability, & hot hardness. Approx. hardness: *Vickers .
A solid lubricant coating. Provides both lubricity and wear resistance not available from other PVD or CVD processes. Ideal for aluminum, copper, pre-painted, and galvanized steels. Approx. hardness: *Vickers .
Diamond-like carbon coating. Combines high hardness with an extremely low coefficient of friction. Good protection against abrasive and adhesive wear. Ideal for aluminum. Approx. hardness: *Vickers .
Super-smooth finnish combined with advanced DLC coating for a very low coeficient of friction with extremely high wear resistance. Approx. hardness: *Vickers .
Super-smooth finish combined with a DLC coating for a very low coefficient of friction with high wear resistance. Excellent for stamping aluminum. Approx. Hardness: Vickers .
The ultimate coating for improved resistance to galling; excellent wear resistance, superior surface finish, and high lubricity. Ideal for extruding and forming applications. Tolerance is ±.". Approx. hardness: *Vickers .
Ultra-hard coating that absorbs shear stress; provides excellent high-temperature resistance. Ideal for stamping where tools are exposed to extreme stress profiles. A good alternative to TD coating without the dimensional changes associated with that process. Approx hardness: *Vickers .
Excellent adhesion, high toughness, and good corrosion resistance. Primary applications are metal forming (copper, brass, & bronze), metal die casting, and plastic injection molding. Approx. hardness: *Vickers -.
All coatings are PVD.
XAN, XNA, & XNAP are not recommended for Aluminum.
M2, PS, and PS4 tool steels can be coated without lowering the hardness (Rockwell). Coatings are not applied to A2 & D2 tool steels as these materials are subject to a softer hardness (Rockwell), hardness variations, size control problems, and bad adhesion.
* Vickers used when RC exceeds 80.
® DayTride and DayTiN are registered trademarks of Dayton Lamina.
™ DayTAN, DayKool, and ZertonPlus are trademarks of Dayton Lamina.
Regardless of the end product(s) your company manufactures, you can improve the length of run time, reduce changeover time, improve uptime, and get more for your stamping dollar by selecting the type of coating that matches your individual operational capabilities.
The chart describes the causes, effects, and solutions for abrasive wear and adhesive wear. The slider graph following shows the relative suitability for each type of treatment/coating in both of those categories. The bubble chart shows the relationship between service temperature, coefficient of friction, and hardness of the coating.
Dayton coated punches are heat treated, precision ground, and made with high performance steel, including, but not limited to, the following:
Dayton is the industry's leader with the largest selection of state-of-the-art coatings–many of them tested in our lab.
In general, surface treatments enhance wear resistance and reduce surface friction above and beyond the capabilities of the substrate material (tool steel). However, surface treatments can be applied to a wide variety of tools steels with varying results.
Dayton's expertise in developing coatings to meet a specific requirement is second to none. We are constantly updating and improving these coatings to meet the ever-changing needs of our customers.
Punch performance depends on the design of the punch, the tool steel used, the finishing process, and other factors. Equally as important, the total performance is directly related to the quality of the heat treatment, i.e., hardening, cryogenics, or tempering.
In order to acquire optimum results for a given application, specific heat treatment guidelines must be followed. Careful monitoring of this process is essential to ensure the toughness of the tool steel-a prerequisite for high-quality stamping tools.
No company pays more attention to heat treating than Dayton Progress. Our in-plant facilities are constantly updated; product performance is regularly monitored; and our Chief Metallurgist oversees all heat treating processes.
Dayton's in-house metallurgy lab is designed to develop new products and to test and analyze the quality and viability of materials used in the manufacture of Dayton products. Our metallurgy lab comes fully equipped with top-quality testing and analytical equipment, and boasts best-in-class metallurgy and quality assurance.
Laboratory services include: hardness testing; metallography (e.g., coating thickness); and failure analysis. Routine testing (metallurgical, mechanical, and chemical) is performed on raw materials, semi-processed, and finished parts to determine compliance with quality requirements and design/manufacturing specifications.
Dayton technical experts deliver a wide range of technical assistance and support-on the web, over the , or in person.
Services include component design assistance; manufacturing advice (e.g., precision finishing, such as polishing and lapping); heat treatment protocols (e.g., high-volume coating production); product applications and usage; and metallurgical expertise.
Dayton's leading-edge coatings and other unique surface treatments have been developed to improve in-plant performance by increasing tool hardness and wear resistance, thus reducing punching friction and torque, inhibiting galling and chip welding, and/or improving lubrication.
The standard surface treatments and coatings shown in this brochure were developed with a specific hardness rating based on the optimum usage of the punch. The hardness and type of coating you need depends on the steel selection, the application, the duration of the die run, and other factors.
In addition to our standard treatments and coatings, Dayton provides custom coatings/treatments based on your special needs and applications. For example, some steels can be coated to increase wear. Others can be coated for toughness, plus a single-layer coating can be applied that provides greater wear than a multi-layer coating.
For help in selecting the right surface treatment or coating for your operation, contact your nearest Dayton representative today.
Dayton VersaPlus® punches feature a thin film coating for superior, harder-than-carbide hardness; a super-smooth finish on the point, resulting in less galling and reduced maintenance; and more. Select Dayton VersaPlus® for optimum punch performance.
Are you interested in learning more about Optical dome? Contact us today to secure an expert consultation!