A thermoplastic elastomer bond fails at the interface far more often than in the adhesive itself. The reason is almost always a mismatch between what the joint demands and what the adhesive chemistry can deliver. Getting the match right starts with defining the joint, not the product. Define the Joint First Before comparing adhesives, characterize four things about the assembly: Substrate pair. TPE to TPE behaves differently than TPE bonded to a rigid polymer, metal, or glass. Service movement. Estimate the strain the bondline sees during handling, assembly, and use. Environment. Operating temperature range, humidity, and any solvent or oil exposure. Optical and inspection needs. Whether the bond must stay clear and whether an automated system needs to verify it. Each of these narrows the field. A joint that flexes rules out rigid chemistries; a joint exposed to fuel or cleaning solvents rules out others. Light-Curable Acrylics UV and visible-light-curable acrylic adhesives dominate TPE assembly for one reason: cure on demand. The adhesive stays liquid until a lamp triggers it, which removes the pot-life and clamping constraints that slow two-part systems. Incure light-cure grades reach handling strength in seconds and full cure within a minute under adequate irradiance. For elastomer work, the key property is elongation. A grade with 250 to 350 percent elongation at break stretches with the substrate instead of splitting at the bond edge. Look also for low linear shrinkage, since shrinkage during cure pre-loads the interface before the part ever sees service. Many grades carry a fluorescing additive so a machine-vision station can confirm coverage and position before the part advances. For guidance on curing equipment for these adhesives, see how to match a UV LED flood lamp to your curing area. Bonding TPE to Rigid Plastics Wearable consumer electronics, automotive interior trim, and appliance controls all bond a soft TPE overmold or gasket to a rigid polycarbonate or ABS body. The modulus difference between the two materials can exceed two orders of magnitude, so the adhesive must absorb that gradient. Two strategies help. First, use a toughened, flexible adhesive rather than a high-modulus one, so the bondline yields slightly under strain. Second, design a transition zone rather than a hard edge. The physics here mirror how CTE mismatch causes adhesive bond failure: a stiff bond between materials that move at different rates concentrates stress until the interface separates. The rigid side of the joint has its own requirements. The Uni-Weld plastic bonder range is formulated for PC, ABS, and PMMA, and pairs well with a flexible grade on the elastomer face. For help selecting a chemistry for a dissimilar-substrate joint, Email Us. Environmental and Optical Considerations TPE assemblies often live in humid or thermally cycled environments. Choose an adhesive with documented resistance to damp heat and repeated thermal cycling, and verify it on aged samples rather than trusting a datasheet figure. Low water absorption matters because absorbed moisture plasticizes the bondline and drops shear strength. When the bond sits behind a clear lens or window,…

Thermoplastic elastomers combine the feel of rubber with the processing ease of plastic, which is exactly why they resist most adhesives. Their low surface energy, flexible backbone, and plasticizer content defeat bonds that hold on rigid plastics. Choosing the right TPE glue means understanding why the failure happens first. Why TPE Is Difficult to Bond Most thermoplastic elastomers have a surface energy between 28 and 34 mN/m. Adhesives wet a surface reliably only when their own surface tension sits below that of the substrate, so a standard acrylic or epoxy beads up instead of spreading. The result is a weak interfacial bond that peels cleanly under load. Two other factors work against adhesion. TPE grades often contain processing oils or plasticizers that migrate to the surface over weeks, forming a slip layer under any adhesive already in place. And because the elastomer stretches while a rigid bondline does not, every flex cycle concentrates stress at the bond edge. Surface Preparation Options Preparation does more for TPE bonding than adhesive selection. Effective methods include: Atmospheric plasma or corona treatment, which raises surface energy above 40 mN/m for a working window of several hours. Abrasion with a fine non-woven pad to create mechanical tooth, followed by a solvent wipe to remove loose particles. Adhesion promoters formulated for polyolefin and elastomer surfaces, applied as a thin primer coat and flashed off before bonding. Always bond within the treated window. Surface energy decays as polymer chains reorient, and a treated part left overnight often bonds no better than an untreated one. For help matching a surface treatment and adhesive to your TPE grade, Email Us. Adhesive Families That Work on TPE UV and visible-light-curable acrylics cure in seconds under a lamp, which suits high-volume assembly. Incure formulates light-cure adhesives with elongation in the 200 to 350 percent range so the cured bond flexes with the substrate rather than cracking at the interface. A fluorescing tracer lets an automated vision system confirm adhesive presence before cure. Cyanoacrylates with rubber toughening bond many TPE grades quickly but stay brittle relative to the substrate, so they fit small static joints rather than parts under repeated flex. Silicone adhesives tolerate the movement well and resist heat, but cure slowly and bond with modest strength, making them a sealing choice more than a structural one. For bonding TPE to a rigid housing of polycarbonate or ABS, the Uni-Weld plastic bonder line covers the rigid side of the joint, while a flexible light-cure grade handles the elastomer interface. Joint Design for Flexible Substrates A butt joint on TPE almost always fails. Design the joint so the adhesive works in shear, not peel or cleavage. Practical measures: Increase overlap length to spread load across more bond area. Add a lead-in radius or flexible transition zone so stress does not step sharply from bonded to unbonded material. Keep the bondline thin and uniform, typically 0.05 to 0.15 mm, to limit internal stress. Because a modulus mismatch drives many of these failures, the…

Form-in-place gasketing dispenses a liquid sealant bead onto a flange and cures it into an elastomer gasket bonded to the part. With a UV-curable material the cure takes seconds, which is what makes the method viable for a production line. This guide walks through the process from surface prep to inspection. When to Use Form-in-Place Form-in-place gasketing pays off when you have medium-to-high volume, complex or non-planar flange paths, tight control requirements on gasket position, or a history of seam leaks with cut gaskets. It removes cut-gasket inventory and scrap, gives an exact fit to any 2D path, and delivers consistent bead volume from an automated dispenser. For very large flanges or very low volume, a cut gasket may still be simpler. Step 1: Surface Preparation The gasket has to adhere to the flange to stay positioned and to seal at the bead-to-flange interface. Clean the flange with isopropyl alcohol to remove machining oil, mold release, and handling residue. On low-energy plastic flanges, add plasma or corona treatment, or a compatible primer, and verify surface energy with a dyne pen. On metal flanges, a light abrasion improves durability for demanding service. Bond within the material's stated open time after preparation. Step 2: Bead Design Compression target: Size the dispensed bead so that at assembly it compresses 20 to 40 percent. Under-compression risks leaks; over-compression fatigues the gasket. Groove or hard stop: A retaining groove positions the bead and caps how far it compresses. On a flat flange, design a metal-to-metal hard stop so fastener torque cannot crush the gasket. Flange stiffness: Space fasteners closely enough that compression stays even. A flexible flange bows between bolts and opens the seal mid-span. Cross-section: A rounded bead compresses predictably. Avoid a tall, narrow bead that can roll or shadow its own base during cure. Step 3: Dispensing Use a programmable dispenser with volumetric or progressive-cavity metering for a repeatable bead. Program the path to follow the flange centerline with a controlled tie-in where the path closes on itself, so there is no thin spot or overlap lump. Keep the needle standoff and travel speed constant; changes in either alter bead width. Dispense at a stable material temperature, since viscosity drifts with temperature and changes the deposited volume. Incure's Uni-Seal form-in-place gasket line is 100 percent solids with no solvent, cures rapidly under low-energy LED lamps, and cures to a soft, resilient elastomer with good elastic memory, moisture and temperature resistance, and chemical resistance to oils and process fluids. For help matching a grade to your flange material and service conditions, Email Us with the enclosure drawing. Step 4: Curing Cure the dispensed bead under a UV source sized to the flange. A UV LED flood lamp covers a bench-scale part in one exposure; higher volume runs on a conveyor curing system. Verify the delivered dose at the bead with a radiometer against the data sheet. Expose a deep bead from more than one angle so the base cures. If the exposed bead surface…

Encapsulating components on a circuit board is a balance. The coating has to seal against moisture and mechanical stress, but it cannot distort fine-pitch parts as it cures, and inspectors still need to confirm it went where it should. Incure Uni-Seal 3718F is formulated around those three constraints. What a Precision Encapsulant Has to Do Seal without stress. A board-level encapsulant sits directly on solder joints, wire bonds, and small passive components. If the material shrinks hard as it cures, it drags on those features. Over thermal cycling that residual stress becomes cracked joints and lifted pads. A low-stress, low-shrinkage formulation keeps the mechanical load on delicate features small. Cure fast, in line. Board assembly runs at a cadence. An encapsulant that needs an hour to gel forces work-in-process to pile up. UV cure in seconds keeps the encapsulation step in step with the rest of the line. Be inspectable. After application, quality control has to verify coverage: did the material reach every component that needed it, and did it stay off the ones that had to remain clear? A fluorescing additive makes that a fast visual check under blacklight instead of a slow manual trace. Incure Uni-Seal 3718F Properties Fast cure in seconds under UV or visible light, with an optional secondary heat cure for regions the light cannot fully reach, such as under a tall component or in a deep pocket. Low stress and low shrinkage, minimizing distortion of fine-pitch parts and the substrate during cure. Superior moisture barrier, protecting sensitive components from humidity-driven corrosion and dendrite growth. Fluorescing feature for rapid coverage inspection and quality control under blacklight. Good moisture and temperature resistance for the board's service life. 100 percent solids, no VOCs, so there is no solvent-loss shrinkage and no solvent handling requirement. Thermal cycling ready, suited to products that see repeated temperature swings. For a recommendation on application method and cure setup for a specific board, Email Us with the board layout and the components to be encapsulated. Applying It Board cleanliness. Remove flux residue and handling oils first. Contamination reduces adhesion and can let moisture track under the cured film. Dispense control. Use a programmable dispenser for repeatable bead volume and position. Selective application keeps the material on target components and off connectors and test points. Bond-line and fillet. A controlled film thickness cures more predictably than a thick, uneven pool. Where a fillet is needed around a component base, size it so light can still reach the fillet toe. Curing Cure under a UV LED flood lamp for bench and low-volume work, or run boards through a conveyor curing system at production rate. Verify the delivered dose at the board with a radiometer against the data sheet. Where a tall component shadows encapsulant at its base, follow the UV exposure with the optional heat cure to complete the shadowed region. Confirm full cure by hardness or solvent-rub check on a trial board. Inspection Under blacklight, the fluorescing encapsulant shows a clear outline of…

Potting protects electronics from moisture, vibration, and aggressive fluids by embedding them in a cured resin. The property that most often separates a reliable potting compound from a problem one is cure shrinkage. A resin that pulls in as it cures puts every embedded component under stress and can open a leak path at the pot wall. Why Shrinkage Matters All curing resins shrink to some degree as liquid monomer converts to a solid network. In a potted module that shrinkage acts in three damaging ways: Component stress. The resin grips leads, solder joints, and component bodies and pulls on them as it contracts. Fine wires, ceramic capacitors, and glass diode bodies are sensitive to this. Interface separation. Shrinkage away from the potting-shell wall or a connector face creates a gap that moisture and gas can enter, defeating the seal. Warpage. Uneven shrinkage through a thick pot bends the substrate or the housing. A low-shrinkage resin minimizes all three. UV-curable acrylic potting compounds formulated at 100 percent solids avoid the additional shrinkage that solvent-borne systems suffer as solvent leaves, and they cure fast enough for inline production. Incure Uni-Seal Potting and Sealing Line Incure's Uni-Seal potting grades are designed for encapsulation where dimensional stability and fast cure both matter: Rapid cure, with some grades reaching full cure in about 60 seconds under a UV source, versus hours for a two-part thermoset. Very low shrinkage and very low water absorption, so the cured resin stays dimensionally stable and does not swell in humid service. Protection against mineral oils, gases, and common process chemicals, which suits utility metering, fluid-system electronics, and industrial sensor potting. Good adhesion to many metals and to glass, keeping the resin sealed to the housing and to feed-through pins. Color options, including opaque grades where the potted circuit must be hidden. Where an application references specific standards such as EN 16314 or EN 1359 for gas-metering equipment, confirm the exact grade's documented compliance against the current standard text. For a grade recommendation against your module and its environment, Email Us with the potting geometry and fluid exposure. Design and Process Pot depth and light path. UV cure needs light to reach the resin. A shallow pot cures top-down in one exposure. A deep pot, or one with components that shadow the resin below them, needs either a translucent resin that lets light propagate, a dual-cure grade with a secondary heat step, or staged filling with a cure between lifts. Fill technique. Dispense slowly along the pot wall to avoid entraining air. Vacuum degassing before cure removes trapped bubbles that would otherwise become moisture traps. Bond-line and wall adhesion. Clean the housing interior. Residual mold release or flux lets the resin debond from the wall as it shrinks, however slightly. Curing Cure under a UV LED flood lamp for bench work, or a conveyor system for volume, with a batch cure chamber an option for even exposure of many parts at once. Verify the delivered dose at the resin…

On a populated circuit board, some areas must stay sealed and some must stay coating-free. Connectors, test points, switches, and displays cannot be conformal coated, but they still need protection from the coating process and from moisture in service. A UV-curable gasket dispensed onto the board solves both problems in one fast step. The PCBA Sealing Problem Conformal coating protects a board from humidity, dust, and corrosion, but it must be kept off certain components. The traditional approach is hand-applied masking dots, tape, and boots, which are labor-intensive, inconsistent, and generate waste. They also do nothing for in-service sealing around a connector or a board-to-enclosure interface. A dispensed UV gasket replaces masking with a precise, automated bead. It defines a keep-out boundary the coating cannot cross, seals the perimeter of components that need it, and stays on the board as a permanent gasket where a board-to-housing or connector seal is required. Incure Uni-Seal 3393 Incure's Uni-Seal 3393 is a UV-curable form-in-place gasket and sealant developed with PCBA work in mind. Its characteristics: Fast LED cure for high-volume board assembly, cured before the board moves to the next station. Soft yet tough, balancing enough compliance to seal against uneven surfaces with enough toughness to resist tearing during handling. Ease of peel for rework, so a sealed area can be reopened to replace a component and re-gasketed, without damaging the board or pads. Air-tight sealing around connectors and enclosure interfaces. Moisture and temperature resistance for the board's service environment. Chemical resistance, consistent with the electronics and automotive use where the chemistry is common. Applied along a keep-out boundary before conformal coating, the cured gasket gives the coating a clean edge to stop against. Applied around a connector footprint, it provides the in-service seal. For guidance on bead placement and cure setup for a specific board, Email Us with the board layout and coating process details. Dispensing and Bead Design Bead width and height: Match the bead to the gap it has to seal and the compression the mating part applies. For a masking boundary with no compression, a low, wide bead that adheres firmly to the laminate is enough. Standoff from components: Program the path with enough clearance that the bead does not creep onto a pad or lead, while staying close enough to keep the coating out. Adhesion to the laminate: Boards should be clean and dry. Residual flux or handling oils reduce gasket adhesion and can let coating wick underneath. Automated dispense: A programmable dispenser gives repeatable bead volume and position, which manual masking cannot match. Curing Cure the dispensed bead under a UV LED flood lamp sized to the board, or run boards through a conveyor curing system for volume. Verify delivered dose at the board with a radiometer. Tall components can shadow a nearby bead, so check that beads next to connectors and headers get full exposure, or expose from a second angle. Cure the gasket fully before applying conformal coating so the coating solvent does not attack…

Form-in-place and cure-in-place gasketing replace a cut rubber part with a liquid bead dispensed and cured directly on the component. Done with a UV-curable material, the cure takes seconds instead of hours, which is what makes the method practical for volume production. FIPG and CIPG: The Difference Form-in-place gasket (FIPG): The seal bead is dispensed onto one flange and cured before the mating part is assembled. The result is a fully cured elastomer gasket attached to one half of the joint. The parts then bolt together, compressing the cured gasket like a conventional seal. Cure-in-place gasket (CIPG): Similar dispensing, but the emphasis is on the gasket being a permanent, adhered feature of the part, cured in place as a functional component rather than a consumable. In practice UV FIPG materials serve both roles, since they cure fully and quickly on the flange without needing the second part present. Both approaches share the same advantages over die-cut gaskets: no pre-cut inventory, no scrap skeleton, no seam leak paths, an exact fit to any flange path, and consistent bead volume from an automated dispenser. Why UV Cure Room-temperature-vulcanizing silicone FIPG needs minutes to hours of skin and cure time, tying up the part and limiting line speed. A UV-curable FIPG cures on demand: dispense the bead, pass it under a lamp, and it is a handleable gasket in seconds. That collapses work-in-process and lets the gasket station keep pace with the rest of the line. Incure Uni-Seal 6322 Incure's Uni-Seal 6322 is a UV-curable form-in-place gasket and sealant. It serves as both a gasket and a sealant in one material, and cures very fast under low-energy LED lamps, which suits high-volume production. Its properties for enclosure sealing: Air-tight seal with excellent conformance to the flange surface. High resilience and flexibility, with good elastic memory so the gasket recovers after repeated compression cycles, outperforming many conventional cut gaskets on recovery. Moisture and temperature resistance for demanding service environments. Chemical resistance, which is why the material is widely used in electronics and automotive enclosures exposed to oils and process fluids. 100 percent solids with no solvent, so there is no shrinkage from solvent loss and no VOC handling. For a recommendation on bead size and cure setup for your flange, Email Us with the enclosure drawing and production rate. Designing the Bead Compression target. Size the dispensed bead so it reaches 20 to 40 percent compression at assembly. Too little and the seal is marginal; too much and the gasket fatigues early. Groove or hard stop. A retaining groove positions the bead and limits compression. On a flat flange, design a metal-to-metal hard stop so bolt torque cannot crush the gasket. Flange rigidity. Keep bolt spacing close enough that compression stays even between fasteners. A flexible flange bows outward mid-span and opens the seal. Path tie-in. Program the dispense path to overlap cleanly at the start and end with no thin section. Curing Dispense, then cure under a UV source matched to the flange…

A gasket that seals perfectly on the assembly line and then chalks, cracks, and leaks after a year outdoors has failed at its actual job. For enclosures that live in sunlight, the seal material's resistance to ultraviolet degradation matters as much as its initial compression set. UV-curable formed-in-place gaskets can be formulated to hold up. How UV Degrades a Gasket Ultraviolet energy in sunlight breaks polymer chains at the surface of most elastomers. The visible signs are chalking, surface crazing, loss of elasticity, and eventually through-cracks that open a leak path. Rubber gaskets based on unsaturated backbones, such as many EPDM and nitrile compounds, are vulnerable unless heavily stabilized. Once a gasket loses its elastic recovery, it no longer follows the flange as temperature and pressure cycle it, and the seal is lost. Why a Formed-in-Place UV Gasket Helps A UV-curable formed-in-place gasket is dispensed as a liquid bead directly onto the flange, then cured in seconds under a UV lamp to a resilient elastomer. Compared with a die-cut rubber gasket it removes the inventory of pre-cut parts, eliminates seam and joint leak paths, and lets the seal follow any 2D flange path exactly. Formulated with a saturated acrylic or urethane-acrylate backbone and appropriate stabilizers, the cured gasket resists the chain scission that attacks conventional rubbers, so it keeps its elasticity through prolonged outdoor exposure. Incure Uni-Seal UV Gasket Line Incure's Uni-Seal UV gasket grades are 100 percent solids, cure rapidly under low-energy LED lamps, and cure to a soft, resilient, memory-retaining elastomer. Key properties for outdoor and demanding service: Fast LED cure suited to high-volume production, with no solvent flash-off and no shrinkage from solvent loss. High resilience and elastic memory, so the gasket recovers after each compression cycle and keeps following the flange. Low water absorption and low shrinkage, which supports dimensional stability through thermal cycling. Chemical resistance to oils, fuels, and common process fluids, which is why the chemistry is widely used in electronics and automotive enclosures. Adhesion to metals, glass, plastics, and FR4, so the gasket stays put on the flange rather than migrating. For a grade recommendation against your enclosure material, flange geometry, and exposure conditions, Email Us with the assembly details. Designing the Seal Bead cross-section: Size the dispensed bead so that at the design compression, typically 20 to 40 percent, the gasket fills the groove or contact area without over-compressing. Over-compression accelerates fatigue. Flange stiffness and bolt spacing: The flange has to hold even compression between fasteners. Wide bolt spacing on a thin flange lets the seal gap open mid-span. Groove versus surface bead: A retaining groove controls the gasket position and limits how far it can be compressed. A surface bead is simpler but needs a hard stop designed in. Path continuity: Program the dispense path to close on itself cleanly, with a controlled tie-in at the start and end so there is no thin spot. Curing Dispense, then cure with a UV source sized to the flange. A UV LED flood…

Adhesive bonding has largely replaced screws, rivets, and welds for joining plastic to metal in consumer electronics, automotive trim, appliances, and instrument housings. It spreads load, seals the joint, and avoids the stress concentrations that fasteners create in plastic. The catch is that plastic-to-metal is a dissimilar-material joint, and it has to be engineered as one. The Two Surfaces Metal is high-energy and easy to wet, but its real surface is an oxide layer plus whatever oil, scale, or coating arrived with it. Bond strength tracks how well that layer is cleaned and stabilized. Plastic ranges from easy (polycarbonate, ABS, acrylic) to difficult (acetal, nylon) to very difficult (polyethylene, polypropylene). Surface energy is the tell: above roughly 38 mN/m an adhesive wets well; below it, the adhesive needs help from plasma, corona, or a primer. The Movement Problem The defining feature of a plastic-to-metal joint is thermal expansion mismatch. Metals sit at 12 to 23 ppm per degree C. Plastics commonly run 50 to 100 ppm per C. Every heating and cooling cycle shears the bond line as the plastic grows and shrinks more than the metal. A joint designed only for its static load, with a rigid adhesive, will fatigue at the edges. Designing for the movement, with a compliant adhesive and adequate bond area, is what makes the joint last. See how CTE mismatch causes adhesive bond failure. Adhesive Families UV and visible-light-curable acrylates. Cure in seconds when light reaches the joint, ideal for high-volume lines and for bonding through a UV-transmitting plastic. Grades span rigid to highly elastic, so a compliant grade can be chosen for the thermal mismatch. Clear cure suits visible joints. Two-part epoxies. High rigidity, high chemical resistance, cure in shadow, fill gaps. Long fixture times and limited movement tolerance make them better for hidden, static structural joints. Toughened cyanoacrylates. Fast fixture on small parts, useful for tacking and jigless assembly, but limited durability under thermal cycling, moisture, and peel. Silane-modified polymers and polyurethanes. Stay flexible, tolerate wide temperature ranges, and bridge dissimilar materials well. Slower cure, lower ultimate strength. Incure Uni-Weld Line Incure's Uni-Weld UV-curable adhesives cover the acrylate options for plastic-to-metal work. They cure in seconds under UV or LED light, maintain clarity and non-yellowing character in the appropriate grades, and are 100 percent solids with low shrinkage. High-elongation grades give the flexibility a thermal-mismatch joint needs; rigid grades give maximum shear on a well-fitted static joint. The Uni-Weld plastic bonder guide and the glass and metal bonder guide cover grade selection for each substrate. For a recommendation against a specific plastic-and-metal pair, Email Us with both material names and the joint drawing. Surface Preparation Metal: degrease, abrade to a uniform profile, remove loose oxide, bond promptly. Conversion-coated or anodized aluminum is more durable than bare. Plastic: identify the polymer, clean with isopropyl alcohol, plasma or corona treat low-energy grades, verify with a dyne pen. Joint Design Checklist Load the adhesive in shear, not peel. Size the bond area for the working…