Surface coating epilamization

Epilamization is a surface modification at molecular level that specifically changes the wetting properties. In contrast to conventional coatings, the epilam layer is only a few nanometers thick - practically invisible and dimensionally stable. The technology is based on the self-organization of special molecules that bind firmly to the substrate surface with one end and create the desired surface properties with the other end. Depending on the molecular structure, hydrophobic, oleophobic or selectively wetting surfaces are created. There are many possible applications: in precision mechanics, epilamization prevents the uncontrolled creeping of lubricants. In electronics, it protects contacts from moisture. In medical technology, it facilitates cleaning. It is applied from the solution by dipping, spraying or selective application. The layer formation is self-limiting - a monomolecular layer of defined thickness is always formed. After coating, thermal or UV cross-linking takes place for maximum resistance.

Our epilamization process follows a precisely defined sequence that guarantees reproducible results. Pre-treatment is crucial: components are cleaned in several stages to remove all impurities. Ultrasonic cleaning in special solvents removes oil and grease. Plasma cleaning activates the surface and improves adhesion. Cleanliness is monitored inline. The actual epilamization takes place under controlled conditions: Temperature, humidity and solvent concentration are kept constant. The components are dipped into the epilam solution at a defined speed or the solution is sprayed on precisely. The dwell time determines the coating quality. Cross-linking follows after application: depending on the type of epilame, either thermally in the oven or by UV irradiation. The process parameters are defined for each product in detailed work instructions. Quality controls check the wetting angle, layer thickness and functionality. The process data is fully documented. Our systems are semi-automated for series production and we offer flexible manual workstations for prototypes.

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Epilamization works on almost all technical surfaces - the challenge lies in the material-specific adaptation. Metals such as steel, stainless steel, aluminum, copper or titanium require different pre-treatments and epilam types. With precious metals, adhesion is often critical and requires special adhesion promoters. Plastics have special requirements. Elastomers require flexible epilams that can withstand stretching. Glass and ceramics have ideal conditions due to their OH groups on the surface. Coated surfaces - such as DLC, hard chrome plating or anodizing - require adapted processes. The areas of application range from watch technology to electronics and medical technology. In the automotive industry, we epilaminate injection systems and sensors. The aerospace industry uses Epilame for instruments and actuators. The optical industry protects lens edges from oil contamination. Every application has specific requirements that we meet with customized solutions.

Dip epilamization is our standard process for the full-surface coating of complex components. The process begins with the incoming goods inspection: cleanliness and surface condition are checked. Cleaning takes place in our multi-stage system with ultrasound, rinsing and drying. Sensitive parts are fixed in special holders that ensure minimal contact. Immersion is carried out with low vibration at a defined speed. The immersion time is set to the nearest second. Batch traceability is guaranteed throughout. Each part is clearly marked. Random samples pass through our quality control. For critical applications, we check 100%. The packaged parts are delivered with detailed test reports.

We epilamize components of all types and sizes - from microscopically small watch parts to large machine elements. Typical precision engineering components are gear wheels, bearings, springs and guides. Here, epilamization prevents the spread of lubricants and ensures long-term function. Electronic components such as connectors, switches and relays benefit from improved corrosion protection and reduced contamination. In medical technology, we coat instruments, implants and diagnostic devices. Epilamization facilitates cleaning and prevents protein build-up. Optical components such as lens mounts, aperture blades and focusing mechanisms remain free from oil contamination. Automotive components - injection nozzles, sensors, micromotors - are given improved resistance to fuels and oils. The spectrum ranges from individual pieces for research to series of millions for industry. Each component is considered individually: Material, geometry, function and operating conditions determine the optimum epilamization process. Our experience with numerous different components enables fast and reliable process development.

An often underestimated property of epilamization is its noise-damping effect. The monomolecular layer changes the tribological properties of the surface and reduces stick-slip effects, which are mainly responsible for squeaking and creaking noises. In combination with optimized lubricants, this results in particularly quiet-running systems. The mechanism is based on the altered interfacial energy: the epilame layer reduces adhesion between contact surfaces. Micro-jerk sliding is transformed into continuous sliding. Vibration excitation is reduced. The combination of epilamization and acoustically optimized lubricants is particularly effective. Epilamization keeps the lubricant in the right place and prevents dry running. Applications can be found wherever quiet running is important: luxury watches whose mechanics should work inaudibly. Automotive interior components without disturbing noises. Medical devices for noise-sensitive environments. Premium class household appliances. Our acoustic measurements prove noise reductions of up to 15 dB. Optimization takes place on an application-specific basis by matching the type of epilame, lubricant and surface topography.