The Lowdown on Infrared Curing

Q: Why is the curing process so critical in today’s manufacturing?

A: Curing is a vital component of the manufacturing process because it directly affects the performance, quality and durability of the products being produced. Effective curing ensures that materials reach their desired mechanical properties, chemical resistance and environmental durability without defects, which can ultimately lead to poor product performance or failure in service. As curing is typically one of the final steps in the manufacturing process, its precision is paramount to delivering both product quality and process efficiency.

Q: Why is using infrared (IR) curing technologies increasing in the automotive, aerospace and general industrial markets?

A: IR curing is a versatile, agile and precise method that can be used with a range of materials, including substrates that conventional thermal curing processes might compromise. Its focused heating minimizes the risk of overheating, which can be the differentiator when working with materials that are sensitive to high or fluctuating temperatures. By adjusting intensity, manufacturers can ensure energy is targeted and absorbed primarily by the coating rather than the substrate, preventing excess heat exposure of the underlying material and reducing the risk of warping, degradation or other structural damage. IR Curing quickly brings materials to the desired temperature and allows for rapid cooling, reducing cycle times and limiting exposure of heat-sensitive materials to elevated temperatures, preserving their physical and chemical properties.

Q: How does it work? What’s the science behind IR curing?

A: Specialty lamps emit electromagnetic radiation in the infrared spectrum (wavelengths longer than visible light, but shorter than microwaves), which when absorbed by a coating or material, directly excites the molecular bonds, converting the energy to heat from within. That heat causes rapid evaporation of solvents and accelerates chemical reactions fundamental to the curing process, such as polymerization, catalyzation or cross-linking. In contrast to indirect heating, characteristic of convection and other traditional curing methods, IR curing provides direct heating, enabling materials to reach optimal curing temperatures quickly and uniformly, and reducing the risk of incomplete curing, thermal degradation or other curing defects.

Q: How do IR curing efficiencies directly correlate to savings on the shop floor?

A: Transitioning to a full or partial IR curing solution offers many practical and substantial benefits, including:

Reduced curing cycle times = increased throughput

• • Traditional curing methods, such as convection ovens or autoclaves, often require extended time for products to reach the desired level of curing, particularly for complex or difficult materials.
  • Shorter curing cycle times accelerate production rates and contribute to higher yield, enabling manufacturers to make more, in less time.

Decreased energy consumption = lower utility costs

• • Environmental regulations and operational cost considerations drive the need for more sustainable manufacturing processes. IR curing is inherently more energy efficient than traditional methods, offering direct heating and shorter curing times, eliminating the need to expend costly energy heating large volumes of air or entire ovens.
  • The smaller carbon footprint and lower emissions characteristics of IR curing systems support organizational efforts toward environmental and sustainability goals, which are increasingly prioritized in the industry.

Higher precision and improved process control = less waste

• • IR curing allows for more precise control, particularly with specialty materials (composites, carbon fiber), ensuring parts receive the exact amount of energy required for optimal curing. The process minimizes the risk of over- or under-curing, which could result in defects and compromise material integrity.
  • The consistency and accuracy of IR curing processes prevent irregularities, reduce the need for rework or scrap and result in less material waste.

Space and maintenance savings = lower service costs

• • Typical IR curing systems are more compact than conventional ovens, saving valuable space on the production floor and making it easier to integrate into existing manufacturing lines.
  • IR boost ovens may be incorporated upstream of traditional convection systems to condense curing lines and expedite processes.
  • IR curing systems have fewer moving parts and lower maintenance requirements, reducing downtime and overall service costs.