When a UV curing oven is used to form a product, not only do formations like inks, coatings, or adhesives dry and harden almost instantly, but the durability, function, surface properties, and aesthetics of the final product get enhanced as well.
In the following sections, we will elaborate on how UV curing works and discuss the different types of ultraviolet curing ovens that are available for metal part manufacturing.
We’ll explain what each one is used for, describe the components that make them up, and tell you what to consider before purchase.
Ultraviolet (UV) curing uses intense ultraviolet light to create a photochemical process that can instantly cure (i.e., dry) coatings, adhesives, and inks.
During the UV curing process, liquid monomers and oligomers get exposed to ultraviolet energy within a curing oven.
Ultraviolet curing is one of the best processes to use when printing metal parts. Similarly, it is also the ideal drying method for printing and improving luxury materials.
However, ultraviolet curing is not limited to automated printing of luxury parts. It also has many applications in adhesive productions.
For instance, the UV curing process is used in the production of:
The prevalence of UV curing in both printing and adhesive production is mainly due to the benefits of the unique chemical process that it relies on.
As mentioned earlier, the UV curing process uses ultraviolet light to induce a reaction upon the reactive coatings of formulated products, which causes them to solidify in a matter of seconds.
The UV light that is used during the curing process is made up of four groups.
Each of these parts of the spectrum is characterized by distinctive features and functions:
The main advantage of using UV curing during the manufacturing process is the reduction in time of production. It results in a reduction in shipping time and increased customer satisfaction levels.
Faster production times also equal fewer manufacturing errors since airborne objects (such as dust and flies) get less of a chance to settle on the product during production.
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Other advantages to ultraviolet curing include a more efficient and eco-friendly production process. Less space is required for the items that are waiting to dry, and there is less wastage of parts (scrap) due to fewer errors.
Finally, there is an overall increase in the physical properties of inks, coatings, and adhesives.
Curing with UV light requires three things for a proper cure to take place: the right wavelength (light), the right intensity, and the right amount of time.
However, the different types of ultraviolet light employed within these chambers produce different effects that achieve varying results.
In other words, all curing ovens are not made the same as they do not all use the same UV light wavelength. UV curing ovens are most distinguishable by the types of ultraviolet lamps they use to produce UV light.
Since there are three different types of UV lamps that can be used for this purpose, there are, in essence, three types of curing ovens.
These include:
Here is a brief description of each type of these lamps.
Arc lamps, or electrode lamps, are the most common types of UV lamps used in curing ovens. This is because their advantages include simplicity, versatility, flexibility, and a low price point.
The intensity level of an arc lamp can be increased or lowered by adjusting its quartz tube, mercury and filler material levels, and using different voltage levels.
An arc lamp that is fitted within a UV curing chamber usually comes with a reflector that helps redirect the ultraviolet light it produces away from the manufactured part, so as not to burn it during the curing process.
These lamps use microwave energy instead of electricity to stimulate mercury.
Using microwave energy helps to reduce the decomposition of the lamp and tends to produce more ultraviolet output than UV lamps that use electricity as their power source.
However, microwave lamps usually come in a restricted range of sizes, making them only useful for smaller curing applications.
UV LEDs use semiconductor chips instead of mercury in a quartz tube to create UV light.
LEDs have extremely long lifetimes and produce a more consistent UV output than arc and microwave lamps.
Since LED lamps produce the longest wavelength on the UV spectrum, they are safe to work with. Moreover, they are also the ideal choice for curing heat-sensitive materials, such as paper, plastic, wood, and heat-sensitive electronic components.
The types of ultraviolet curing ovens that we’ve described can be used for a variety of applications. They find their purpose within a number of industries.
These include:
The next section will cover some of these applications in greater detail.
UV curing ovens are used in a wide range of manufacturing applications because they increase production efficiency and minimize defects and errors during the drying process.
For instance, UV curing is indispensable in the production of various electronic devices, medical equipment, as well as automotive parts and plastic components.
Let’s look at each of these.
Manufacturers use UV curing ovens to produce numerous medical tools and devices.
The most common include:
The coatings, inks, and adhesives contained within these products and devices are fortified during UV curing.
As with other products, the production time and cost associated with making them greatly decreases when using a UV curing oven.
These are the main reasons the UV curing process is ideal for curing medical equipment.
Next, UV curing ovens are used for aesthetic and functional applications in automotive manufacturing.
They are popularly used to cure adhesives, inks, and coatings for the following products:
UV-treated coatings and inks have good scratch and chemical resistant properties and also provide solid adhesion for durable and long-lasting parts.
As such, they are an excellent choice for automotive parts that must endure harsh conditions such as intense heat, chemical corrosion, and wear and tear.
The use of ultraviolet curing ovens in the plastic component industry has rapidly increased in the past few years.
Curing ovens that use UV LED lamps are particularly widely used, as they reduce the heat transfer that would normally cause defects in plastic parts.
There are many plastic products that are processed in this way, such as:
Typically, these parts are either printed with UV-curing paints or sprayed with transparent coats before undergoing the curing process to avoid any possible defects due to the excessive absorption of UV energy into the plastic.
The possible defects include a brittle structure and discoloration.
On the other hand, when cured through UV light, UV-protective coatings become scratch-resistant and look much more aesthetically pleasing.
In the production of electronic components, component marking, adhesive bonding and assembly, masking, sealing, and gasketing are all done using an ultraviolet curing oven.
So are conformal coating, and encapsulating electronic parts and products.
Below, you will find some specific electronic applications that employ UV curing:
The speed at which electronic components can be cured with UV lighting, along with the low-temperature output of the curing lamps used, helps increase their production levels.
At the same time, the risk of possible damage to sensitive elements is minimized.
Now that we’ve provided an overview of the various products that benefit from undergoing treatment in a UV curing oven, in the next section, we will go over the elements that make up that piece of machinery.
All such ovens consist of an irradiation chamber, UV lamps, and curing materials (i.e., adhesives, ink, coatings) that create a system that hardens and dries manufactured parts quickly and efficiently.
A standard UV irradiation chamber is made of 11 primary components, not counting the actual chamber (enclosure) itself.
All of the following parts are necessary to get the full manufacturing benefits the UV curing process offers.
Desiccator: A sealable enclosure that protects the chemical process (drying and hardening) that is stimulated by UV light upon a particular material by securing a dry airflow.
Nebulizer: A machine used to turn liquid into spray. In the case of an ultraviolet curing oven, it helps keep the atmosphere moist and cool by spraying mist into it at specific intervals.
Baffles: Vanes and panels that help direct the flow of liquid or gas within an enclosure.
Relative humidity (RH) meter: A device used to measure the amount of moisture within a material.
Temperature meter: It measures the atmospheric temperature inside the chamber.
Particle sizer: A machine used to measure the intensity of UV light particles upon an object.
UV Lamps: Lamps that give off ultraviolet light that instantly cures inks, coatings, and adhesives used in various manufactured product parts.
Band-pass filters: A special filter that allows ultraviolet light to pass through a sensor while at the same time blocking any visible or infrared light which would contaminate the UV curing process.
UVC-transmitting plastic window: A window that allows UVC light to pass through a material. Without this special window, that highly energetic form of light cannot pass through a solid object and therefore cannot cure it.
Reflective aluminum surface: The surface of a UV chamber is typically made of aluminum, and this kind of metal helps to reflect and redirect excessive ultraviolet light away from the material so as not to burn or warp it during curing.
Bio sampler: A glass collection device that collects airborne microorganisms from dust so they do not get a chance to settle and pollute any of the material that is being cured.
Proper airflow is of utmost importance during the curing process as it keeps drying times consistent. This is why additional pumps are usually added within a UV curing oven. They are situated around the nebulizer to generate a balanced aerosol spray and to better control airflow.
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There is also usually a set of valves around the bio sampler, placed there to push undesired airborne contaminants towards it and get rid of them in a timely fashion.
While the above information may seem superfluous for those looking to purchase a UV curing oven, knowing which components are necessary to ensure a proper UV cure is vital for making a smart and safe buying decision.
In the next section, we will discuss some of the most important considerations for purchasing and using a curing oven.
The first thing to consider before obtaining a UV curing oven is whether or not it will add value to your manufacturing process.
In the following sections, we’ll go over some factors that will likely affect your decision.
A UV curing oven will offer you the following advantages:
Speed: UV curing ovens can cure coatings, inks, and adhesives faster than any other curing technology or process.
Small oven enclosure: Ultraviolet curing ovens take up less space than other curing ovens. They also save waiting space since they can cure items instantaneously, so there is no need to secure a separate area dedicated for drying.
Coating enhancements: UV curing offers several unique enhancements to manufactured materials such as increased durability, an aesthetically pleasing finish (gloss), greater strength and elasticity, and improved adhesion.
Low-heat substrate: The low-heat wavelengths of UV light ensure that surfaces and materials like plastic parts and sensitive electronic equipment do not get damaged during curing.
However, in spite of its many benefits, this type of oven won’t always prove suitable for your needs. Some of the main drawbacks of using a UV curing oven are as follows:
Weak penetration: Curing depth is limited when using an ultraviolet curing system as UV light is unable to sufficiently penetrate opaque materials and blindspots.
Expensive coatings: To be cured by UV light, most materials need to be coated with UV-friendly coatings, which are by and large much more expensive than the more standard kinds used for curing manufactured materials by different means.
The second set of considerations when using an ultraviolet curing oven pertains to safety.
The major safety areas that one must take precautions with when using a UV curing oven include:
All of these potential problem areas require the implementation of the appropriate safety measures.
For instance, protections against accidents related to handling dangerous materials and chemicals like those in UV coatings and inks include wearing PPE, ensuring proper ventilation and well-developed procedures for containing potential spills.
On the other hand, thermal safety presumes the use of an effective cooling system and heat-dissipating materials, as well as the regular cleaning of components, to prevent overheating.
Additionally, a fire extinguisher should always be on site in case of any accidents.
Need gas ovens as well? Read more about them here.
When purchasing a UV curing oven, you have to be ready to implement these preventative measures.
If you’re interested in a more in-depth look at protection tips and practices for safe UV curing, take a look at the UV Curing Safety Manual.
The final list of considerations for UV curing ovens pertains to their features.
The components that should be included in a UV curing oven have already been mentioned in the previous section, so the following list will only include general things to look for before purchasing an ultraviolet curing oven.
The quality of the components that make up a UV curing oven will have a direct impact on how fast and efficient the curing process is. Using the optimal components increases the operational time of the UV curing system, by minimizing downtime.
Particular care must be taken when choosing UV lamps, as the quality of the UV light shapes the entire curing process.
A high-quality UV lamp will last longer, use less energy, and ensure a fast cure.
One of the main things to look for in a UV lamp is an efficient design that promotes cooling, as this will increase the output power without degrading the lamp in the process.
A good UV curing system will allow you to change power output levels as needed, and give feedback regarding cooling and power supply conditions.
It will give operators the ability to turn different portions of the system on or off, in order to accommodate different parts with varying sizes.
UV curing ovens are designed to speed up the curing process, so avoiding delays due to difficult and untimely maintenance issues is a priority.
Some of the major questions you should ask when inspecting a UV curing oven include:
Effective cleaning and maintenance are essential for maintaining safety and optimal output.
One of the main considerations when it comes to the maintenance of any UV curing oven is whether it can be serviced if something goes wrong, or if it will need to be changed or replaced as soon as problems arise.
Even the highest quality UV curing system will run into a problem eventually, so you want to choose a vendor/supplier that offers both mechanical and technical support.
They should at least provide operating manuals and technical documentation.
It is also a good idea to opt for suppliers that have their own service staff or repair center.
Also, it’s a good sign if they provide test equipment and onsite support while the oven is being manufactured. It shows they will provide customer support after the sale.
If a UV curing oven is able to provide value to your manufacturing process, is safe to work with, and is backed with a solid support and service structure, you can be sure that you’re making a good purchasing decision.
UV curing ovens speed up manufacturing and shipping, as they reduce the time it takes for items to be dried and hardened.
Other advantages of UV curing include reduced application flaws and errors, improved space management, and product enhancements.
There are several types of curing ovens, each with their distinguishing features and ultraviolet light output. Since they will either reduce or speed up curing times, you should strongly consider following the purchasing considerations mentioned above before making your decision.
Above all else, consult your UV curing oven vendor to see which one will best suit your needs and goals. They are the experts and have tons of experience constructing and matching the right UV curing oven to the right manufacturing application, so make sure to choose a reliable one.
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