Process development

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Our company offers many different plasma processes and parylene coatings. Our process development department is always at your side to determine which system technology and processes best meet your requirements.

We develop all processes in-house, from simple cleaning to complex coatings. We start by discussing your wishes and requirements in detail so that we clearly understand the task. Next, we do a series of tests and evaluations of different process parameters at sample parts. For this, our Technical Centre is equipped with 30 test plants of different designs.

In cooperation with you, we adapt not only the process parameters but, if desired, also the system components to your requirements. As we construct the systems in-house ("Made in Germany"), we can carry out the conversion of electrodes, product carriers or special superstructures on our own within a short period of time.

Other services in process development

On the Diener premises or at your site

✓ Development of plasma processes
✓ Advice before purchase of a system
✓ Regular training courses for your new employees
✓ Support in quality management questions
✓ Presentation of rental equipment
✓ Process training and system training, all over the world

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How can the plasma processes be measured?

A wide range of methods can be used to evaluate the process. Depending on the component type and desired plasma effect (cleaning / activation / etching / coating), our laboratory uses the measuring methods described in the following.

3D laser scanning microscope

We use the 3D laser scanning microscope from Keyence to measure surface roughness. The non-contact roughness measurement system uses two light sources: Laser light and white light. With its great depth of field, this microscope is ideal for precise observations and 3D measurements.

**Carbon plate 50x after plasma treatment**

**Carbon plate 150x comparison treated untreated**

Wetting angle measurement

Measuring the wetting angle with a test fluid is a method for more accurate evaluation of the plasma process.

A microscopically small drop (size range 1 µl) is applied to the component surface via precision dosing. A CCD camera transmits the drop contour and wetting angle to the computer for evaluation.

Our laboratory is equipped with a Dataphysics wetting angle measuring device. In addition to the common static measurement on level or curved surfaces, the time-dependent behaviour of the wetting angle can also be measured and documented. H2O, diiodmethane or ethylene glycol are used as test media.

With measuring the contact angle of all three test media followed by application of the “Young equation”, the polar or disperse ratio of the surface energy is calculated.

Microscope

For the optical evaluation of the process result, we use the Leica video microscope. High-resolution images, different lighting modes, filter elements and a wide range of image processing methods allow for thorough documentation of the process.

SEM

When the light microscope reaches its resolution limits, we resort to our SEM "TM 3.000" from Hitachi. Especially for plasma etching processes, the resolution range of a SEM is indispensable for process development.

Coat thickness measurement

With coating processes, the focus is on coat thickness as the major factor. Plasma coat thicknesses are in the nanometre [nm] until low micrometer [µm] range. For process determination or quality assurance, we measure the coat thickness in a “tactile” manner:

During the coating process, a test glass is included in the respective batch. A mask is applied so that the test glass is coated in part only: After the process, the mask is removed, revealing a clean stage between coated and non-coated test glass.

On our in-house DEKTAK 150 by Veeco, a diamond needle now travels automatically across the stage, measuring the coat thickness achieved. The range of resolution is from approx. 0.5 nm to approx. 200 µm.

Another application for measuring the coat thickness is the quality assurance of parylene coats. The properties of the parylene coats strongly depend on the coat thickness.

This measurement is used not only for coating processes but also for etching processes. The method determines the etching rates and measures homogeneities / distributions in the plasma system.

Tensile testing machine

Improving the adhesion of bonded joints is a major part of plasma cleaning and plasma activation applications. Our laboratory is equipped with the peripherals for all straight-forward bonded joints (sample preparation, chemical apparatuses, mixers, annealing furnace, ....) Furthermore, you can bring us your special equipment (UV bonding, clamping devices, ...) so that we can develop optimum gluing and bonding processes for you.

On our tensile testing machine by Zwick, we can do tensile tests, shearing tests etc. Join us for a day in our laboratory so that we can run various tests in cooperation and evaluate them directly on site.

Inclined plane

The inclined plane is used for evaluation of anti-friction coats. The component to be tests is fixed on a movable plane with a test weight. Measurement is done by automatic inclination of the plane from 0°…< 90°. At the moment when the component becomes unsteady and begins to slide, the measurement stops and the so-called "slip angle" is read.

Test inks

In many applications, the decisive factor is the so-called "surface energy", simply put: how much the surface of a component wants to build up a bond to the adhesive / lacquer / casting compound or the like.

So-called "test inks” are the easiest way to measure the surface energy. A liquid with a defined surface energy is applied to the component. In dependence on the behaviour of the liquid after application (rolling off, wetting, or spreading of the test ink), the value of the surface energy is determined.

We produce and fill the test inks in-house. They are available from 28 mN / m to 105 mN / m.

Test Tinten (Testtinten) Set 8 ungiftig farbig Flaschen

Colorimeter

The spectrophotometer sph900 enables an objective determination of the colour state between a colour sample and a given colour standard. The 45°/0° measurement geometry – measurement at 0°, circular illumination at 45° – corresponds to DIN standard 5033. Our spectrophotometer is equipped with a high-resolution and high-contrast O-LED display. The external flexible measuring head has a small measuring spot and therefore also allows the measurement of small samples, such as our low pressure indicators.

The spectral measurement enables us to guarantee excellent quality and long-term reproducibility of our low-pressure indicators.

Plasma indicator

Plasma indicators are adhesive labels coated with a carbon polymer.
The different coat thicknesses are applied in dependence on the process duration. If the plasma process was successful, the carbon polymer will dissolve, leaving an area white. This is the first feature which proves at a glance that a plasma treatment was successful. Till now, this proof required a lot of technical effort.

Small parts bulk coating

With small parts bulk coating, we can offer you efficient and low-cost surface coating services for large volumes of small components.

Our dedicated systems ensure smooth processes. Rely on our expertise to get excellent results.

With our comprehensive know-how in the field of small parts bulk coating, we not only provide contract surface coating services but also are at our customers’ side with good advice and creative new ideas.