DECOLINE II

Inline Coating of 3-Dimensional Parts for both Decorative and Functional Applications

SINGULUS TECHNOLOGIES – Innovations for New Technologies

SINGULUS TECHNOLOGIES develops technologies for economical and resource-efficient production processes. The core competencies are vacuum thinfilmtechnologies, wet-chemical processes, surface technologies and thermal processing technologies. SINGULUS TECHNOLOGIES taps new work areas with these competencies and develops innovative solutions. For all processes and applications, SINGULUS TECHNOLOGIES uses its know-how to continually improve both automation and process technologies as well as the integration of production steps and cultivates methods to transfer these solutions to additional areas of application.

SINGULUS TECHNOLOGIES works on expanding this expertise in the existing segments to new markets and develops new ideas for innovative product solutions. SINGULUS TECHNOLOGIES is one of the world’s leading drivers of innovations for technologic areas with high growth potential. This includes renewable energies, the entire area of entertainment, ever increasing mobility, semiconductor technologies, medical as well as consumer goods of various kinds.

DECOLINE II – Enhanced Metallic Layers on 3-Dimensional Parts

Whether in the cosmetics sector or the automotive sector – metallic quality surfaces are needed more than ever in the decorative sector. However, the coating of sensitive hardware is usually an expensive step. A new, fully automated PVD coating inline system is able to operate directly from the bigpack to the finished product, saving time-consuming manual work. This is especially true for high-end cosmetic products as processes in bulk are not always possible, nor desirable from a surface protection standpoint.

SINGULUS TECHNOLOGIES offers the second generation of inline coating solutions for fully automated handling and coating of 3-dimensional parts. From loading to packaging, the process is fully automated and not one manual step is necessary – at a cycle time of only 0.4 seconds per component. This manufacturing solution is interesting for automotive, consumer goods, sanitary, mobile phones and packaging used in the cosmetics or beverage industry.

The DECOLINE II distinguishes itself with versatile options in realizing different layer configurations. Not only decorative, but also functional layers could be applied. Thinkable approaches are antibacterial coatings, EMV-shielding, electrical conductive layer (e.g. on electroplating components before the actual electroplating) or antennas. Each electrical conductive and non-magnetic metal and its alloys can be used as a metallic layer. This is a clear unique selling point, compared to batch processes, in which the selection of possible coating materials is much more limited.

The new DECOLINE II inline coating system is the next developmental level in vacuum coating and product handling:

Brilliant layers on 3-dimensional parts
Individual design variety
Elimination of batch processes
UV-curing for protection lacquer
Inline spray coating & metallization
Fully automated processing
High productivity and flexibility
Low cost of ownership
Environment-friendly

Basic Concept of DECOLINE II

The different spray coating modules and the vacuum sputtering module of the DECOLINE II are interlinked by an innovative flexible inline concept. The DECOLINE II distinguishes itself from the traditional batch processes and satisfies with its inline concept all the prerequisites to revolutionize the existing production of 3-dimensional parts. By using high-quality coatings the decorative and functional properties of the coatings are significantly improved.

Base Coat Lacquering System

UV-base lacquering system
Solvent allowance up to 50 %
6-axis painting robots, up to two 6-axis painting robots per painting booth possible
Fast production change
Flexible IR and UV configuration
Primer coat extension possible
Recycling of lacquering material possible
Significant cost reduction by most efficient material consumption

3-Dimensional Sputtering

Cycle time per carrier: down to 6 seconds
Up to 18 parts on one carrier
Part rotation during sputtering process
Bottom edge metallization
Equipped with two cathodes in L-shape
Target materials e.g.: Al, Cu, Cr, Zr, CuAl, Ag, Au, Stainless Steel
Different gold color targets available
Perfect layer uniformity and high deposition rates, even on complex 3-dimensional substrate shapes
Reliable and clean sputtering process
Highest coating quality, high uptime and no environmental impact
Chromium VI-free applications

Top Coat Lacquering System

UV-base lacquering system
Clear lacquer application
Colored lacquer application
Solvent allowance up to 50 %
6-axis painting robot
Fast production change
Flexible IR and UV configuration
Recycling of lacquering material possible
Significant cost reduction by most efficient material consumption

DECOLINE II automates the production process while considerably reducing costs, logistical efforts as well as the personnel intensity and therefore yields a return on investment in a very short period of time.

Great Individual Design Variety

Wide range of different target materials e.g. Al, CuAl, Cr, Ag, Au, and stainless steel
Different gold color targets available
UV-curable monocure top coat lacquers from high glossy and matt finish surfaces
UV-curable monocure lacquers compatible with pigments or dyes for colored base and top coat finishing
UV-curable monocures from different lacquer suppliers qualified
Wide process window for different substrate shapes and layer thicknesses
All UV-curable monocure lacquers are printable with pad printing (tampon printing) or hot stamping foil
Gradient lacquering with second 6-axis painting robot possible

Effective, Economical, Flexible

Inline metallization and spraying technology
Flexibility of design and appearance of finished products
Different materials can be metallized and lacquered, e.g. plastics, glass, metal or ceramics
Production tool with modular configuration

Human Responsibility

Separation of laquering, metallization and transportation area
Easy human operation interface
Remote service tool

Controlled, Precise, Intelligent

Fully automated production tool with integrated process control
Compact process modules with innovative media and process management
Flexible and robust substrate transport system
Consistent flow conditions from process step to process step
Easy change of sputter layer thicknesses
Universal handling and clip system, flexible and fast change of production

Clean, Safe, User-friendly

Safe for operators, environmental and reliable process
Fully integrated loading/unloading for all process modules
Reliabale and clean sputtering process, highest coating quality, high uptime and no environmental impact
Compact spray coating module, capable for primer/base coat, colored and/or scratch resistant/top coat lacquer
Integrated SINGULUS developed UV-lamps
Collection and direct recycling of over spray possible
Quick-change lacquer supply tank for lacquer color changes: Highest uptime and productivity by offline cleaning of lacquer supply tank
Excellent accessibility of the process chamber modules and chambers from all sides through the separation of process and installation modules
Optional painting robots for plug and play production