Aspect Automation Coating Method Comparison

Comparison of Coating Methods

The chart below offers some basic information to help guide you through the maze of coating options. Every project is different, however, and Aspect Automation can help you find the perfect solution to your unique coating requirements.

Coating Method	Speed (fpm)	Viscosity Range (centipoise)	Coating Thickness	Width	Advantages	Disadvantages
PRECISION SLOT DIE COATING
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
PRECISION PATTERN COATING
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
PRECISION ROLL COATING
Gravure	5 - 500	100 - 10,000	1.0 - 5.0 mils	To 2M	Uniformity of coating Streak-free	Restricted viscosity range Open system
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
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
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
INTEGRATED COATING SOLUTIONS
Bead	0 - 1,000	500 - 100,000	0.15 - 0.062 dia	-	Non-contact Single line(s) of bond Simple and inexpensive Low adhesive consumption	May thermally distort substrate Subject to air flow disturbances
Atomized Spray	0 - 1,000	5,000 - 10,000	5 - 15 gsm	-	Non-contact Little thermal conduction to substrate	Subject to air flow disturbances Poor edge definition Fluid must form droplets
Spiral Spray	0 - 1,000	5,000 - 50,000	15 - 50 gsm	-	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
Fiberized Spray	0 - 1,000	5,000 - 50,000	5 - 50 gsm	-	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
OTHER COATING METHOD
Knife over Roll	0 - 400	1,000 - 30,000	2.0 - 20.0 mils	To 2M	Simplicity	Coating accuracy Open system