Reliable Surface Treatment for Defense and Space Manufacturing
Defense and space components must bond, seal, coat and perform reliably, even when exposed to fluids, solvents, vibration, temperature changes and changing pressure conditions.
Tantec develops plasma and corona surface treatment solutions that clean and activate material surfaces before bonding, sealing, potting, coating, painting and printing.
The result is improved wettability and a more controlled, consistent and repeatable production process.
When adhesion becomes a critical process parameter
Your surface may look clean. But is it ready to bond?
Low surface energy, microscopic contamination, release agents and variations between material batches can prevent adhesives, sealants, potting compounds, inks and coatings from wetting the surface correctly.
The result may be weak bonds, uneven coatings or an unstable production process.
Plasma and corona treatment modify the outermost surface without changing the bulk properties of the component. Depending on the material, geometry and process, treatment can remove selected organic contamination, increase surface energy and improve wettability before the next production step.
This creates better conditions for reliable adhesion and makes surface preparation easier to control and repeat.
Surface preparation for demanding defense and space applications
Missile and aerospace composite bonding
Missile and aerospace components often combine lightweight composites, polymers, metals and other advanced materials.
Composite casings, fins, radomes and structural assemblies may require surface treatment before adhesive bonding, sealing or coating. Improved wettability helps the adhesive spread across the treated area and supports a more consistent bonding process.
Because materials and performance requirements vary, the complete material and adhesive combination must always be tested.
Connectors, cable assemblies and potting
Connectors and cable assemblies may be exposed to moisture, chemicals, vibration and temperature changes.
Plasma and corona treatment can prepare cable insulation, connector housings and internal interfaces before bonding, sealing, printing or potting. This can improve adhesion between the component and the applied material and create a more controlled process.
Technologies can be adapted to selected grades of PTFE, fluoropolymers, PE and PVC, subject to application testing.
Electronics and sealed electronic modules
Sensitive electronic modules are often protected using adhesives, sealants, conformal coatings or potting compounds.
These protective materials can only perform as intended when they wet and adhere correctly to the underlying surfaces.
Plasma treatment can prepare housings, circuit boards and selected internal components before encapsulation, coating or sealing. This supports consistent coverage and reliable adhesion in electronic modules exposed to moisture, vibration, fluids or changing temperatures.
UAV and drone manufacturing
UAVs and drones combine lightweight composites, polymer housings, sensors, antennas, batteries and electronic modules in compact assemblies.
Plasma and corona treatment can prepare selected surfaces before structural bonding, sealing, coating or permanent marking. Treatment can be focused on defined areas and integrated into automated production where consistent results and controlled process parameters are required.
Ballistic helmets and protective composites
Ballistic helmets and protective equipment depend on lightweight composite structures and securely bonded components.
Surface treatment can prepare selected areas before bonding edge trims, mounting components, padding systems or other assembled parts. It can also improve adhesion before coating, painting or permanent marking.
Because ballistic materials and constructions are safety-critical, the treatment process must always be developed and validated without compromising the performance of the underlying composite.
Additional bonding, sealing and coating applications
Structural and assembled components
Plastics, composites, metals and glass can be activated before adhesive bonding.
Improved wettability helps the adhesive spread across the treated area and supports a more consistent bond between the assembled components.
Sealing against demanding environments
Interfaces can be treated before applying gaskets, sealants, potting compounds or protective coatings.
Reliable surface preparation is especially important when an assembly may be exposed to fluids, solvents, vibration, temperature changes or pressure changes.
Coating and painting
Housings, covers, panels, optical components and metal parts can be cleaned and activated before coating or painting.
Treatment can help reduce defects caused by poor wettability or surface contamination and create a more consistent coating process.
Printing and permanent marking
Plasma and corona treatment can improve ink adhesion before applying identification, instructions, traceability codes or functional printing.
This is particularly relevant for plastics and cable insulation with low surface energy.
Treatment of complex parts and geometries
Defense and space components are rarely limited to simple, flat surfaces.
Recesses, curved profiles, internal areas, three-dimensional parts and mixed-material assemblies may all require controlled surface treatment.
Tantec offers atmospheric plasma, corona and vacuum plasma technologies. The right method depends on your material, component geometry, treatment area, required cycle time and production setup.
Atmospheric plasma is suitable when a defined area requires precise, local treatment.
The technology can be integrated into manual workstations, robot cells or automated production lines.
Corona treatment is suitable when three-dimensional plastic parts, profiles, cables or larger areas require fast treatment at atmospheric pressure.
The electrode configuration can be developed around the component and the defined treatment area.
Vacuum plasma is suitable when complex geometries, multiple surfaces or several components must be treated in a controlled low-pressure process.
It is often considered for batch treatment and parts with surfaces that are difficult to reach using a local treatment method.
The technology and process parameters should always be validated using the actual material and the subsequent adhesive, sealant, coating, potting compound or ink.
A dry and controlled alternative to traditional pretreatment
Plasma and corona treatment use electrical energy to prepare the surface.
In suitable applications, these technologies can reduce or replace chemical primers, solvent-based cleaning or flame treatment.
Potential production benefits include:
- Improved wettability before bonding, sealing, potting, coating, painting or printing
- More consistent surface preparation from part to part
- Defined and repeatable treatment parameters
- Treatment of plastics, composites, metals, glass and cable insulation
- Integration into manual, automated or inline production
- Reduced handling and storage of chemical pretreatment products where replacement is technically possible
- Easier documentation and control of the treatment process
Actual results depend on the material, contamination, geometry, downstream process and required performance.
That is why testing comes first.
Start with your component, not a standard assumption
The most reliable way to select a surface treatment process is to test the actual application.
Tantec offers free application testing.
- Application review
We review your materials, component geometry, current process and adhesion challenge.
- Sample treatment
Your components are treated using relevant plasma or corona technologies and defined process parameters.
- Evaluation and documentation
We evaluate the treated surface using relevant methods such as dyne testing, contact angle measurement or customer-defined adhesion tests.
- System design and integration
Based on the validated process, we define a standard or application-specific solution for your production environment.
- Training and service
We support implementation, operator training, process control and ongoing service.
Test your defense and space application
Have a component that is difficult to bond, seal, coat or print?
Send us your material or component and let us test how it responds to plasma or corona treatment.
If your application is confidential, the scope and handling of information and samples can be agreed before testing.
Why defense and space manufacturers work with Tantec
- More than 50 years of experience with plasma and corona surface treatment
- Standard and application-specific solutions for laboratory, batch and inline production
- Application testing and process validation before equipment selection
- Equipment developed and manufactured in Denmark
- Global sales, technical support and service network
- Solutions for manual workstations, robot cells and automated production
Tantec works with quality-driven manufacturers that need more than a machine.
We help define and validate the surface treatment process around your material, component and production requirements.
| Chemical Primers | Flame Treatment | Plasma & Corona Treatment | |
|---|---|---|---|
| Uniform treatment of hard-to-reach areas | – | – | ✓ |
| FDA approved | ✓ | ✓ | ✓ |
| Compatibility with robotic arms | ✓ | ✓ | ✓ |
| Inline integration in conveyor system | – | ✓ | ✓ |
| 360° treatment at once | ✓ | – | ✓ |
| Speed of operation | Low | Medium | High |
| Price of operating | High | Medium | Low |
| Environmental impact | High | High | Low |
| Labor costs | High | Medium | Low |
| Risk for workers | High | Medium | Low |
| Cost of implementation | High | High | Medium |
| Uniform treatment of plain surfaces | ✓ | ✓ | ✓ |
FAQ Find Answers to Frequently Asked Questions
Which aerospace materials can be treated with Tantec systems?
Tantec systems can treat an extensive range of aerospace materials including all polymers and plastics (PP, PE, TPE, Carbon Fiber, ABS, PC etc.), carbon fiber and glass fiber composites, metals (aluminum, titanium, stainless steel, specialty alloys), ceramics, glass and optical materials, elastomers and rubber compounds, and multi-layer or hybrid structures. Different materials may require specific treatment parameters, which Tantec’s technical team can help optimize for aerospace specifications.
Why is vacuum plasma treatment preferred for aerospace applications?
Vacuum plasma treatment is ideal for aerospace and space components because it provides uniform treatment across all surfaces, including hard-to-reach areas on complex 3D parts. The vacuum environment eliminates contaminants, ensures consistent results critical for mission-critical applications, and prevents oxidation during treatment. This is particularly important for sensitive components like sensors, printed circuit boards, optical assemblies, and electronic systems that will function in the vacuum of space.
Can you treat heat-sensitive aerospace components without damage?
Yes, both plasma and corona are non-contact, low-temperature processes ideal for heat-sensitive aerospace materials. Atmospheric plasma and corona treatment cause minimal temperature rise (typically less than 10-20°C). Vacuum plasma can be optimized for temperature-sensitive applications by adjusting power levels and treatment duration. This makes the technology suitable for delicate optical components, sensitive electronics, and thermally-sensitive polymers used in aerospace applications.
How does surface treatment improve adhesion for space-grade materials?
Many aerospace materials – composites, polymers, carbon fiber, and specialty metals – have naturally low surface energy, making adhesion challenging. Surface treatment modifies the molecular structure of the outermost layer by introducing functional groups (hydroxyl, carboxyl) that increase surface energy, remove organic contaminants, and activate the surface. This creates strong, stable chemical bonds between adhesives, coatings, or inks and the substrate, ensuring reliability even under vacuum, radiation, and extreme temperature fluctuations encountered in space.
What experience does Tantec have with aerospace and defense manufacturers?
With more than 50 years of experience in surface treatment innovation, Tantec’s equipment has been used by aerospace and defense manufacturers worldwide to prepare materials for demanding missions. The company offers a global network of engineers and partners who provide training, technical support, and process validation specifically for aerospace applications, ensuring customers achieve optimal surface treatment results and long-term mission reliability.
Can Tantec’s machines treat carbon fiber composites and honeycomb structures?
Yes, our systems are specifically designed to treat advanced aerospace materials including carbon fiber composites, honeycomb panels, and multi-layer structures. Both atmospheric and vacuum plasma systems can effectively prepare these materials for bonding, coating, or sealing applications. The non-contact, dry process is ideal for delicate composite structures, and the treatment can be customized based on the specific material composition and performance requirements.
Which technology is best for complex geometries?
Vacuum plasma is often considered when several sides, recesses or complex three-dimensional surfaces must be treated in one batch. Atmospheric plasma or corona can be preferable for defined areas or inline processes. Testing determines the best fit.
How does surface treatment help components survive the space environment?
Space presents unique challenges including vacuum conditions, extreme temperature cycling (-160°C to +150°C), high-energy radiation, atomic oxygen erosion, and absence of atmospheric pressure. Proper surface treatment ensures that adhesives, coatings, and protective layers maintain their integrity under these conditions. It prevents outgassing in vacuum, ensures thermal control coatings remain effective, protects against radiation damage, and prevents cold welding of metal surfaces – all critical for long-term mission success.
Can surface treatment be integrated into an existing production line?
Yes. Plasma and corona systems can be configured for manual workstations, robot cells and automated inline production. Integration depends on the component, treatment area, cycle time, handling concept and required process control.
How does surface treatment reduce long-term costs in aerospace applications?
Surface treatment extends aerospace component lifespan by ensuring reliable adhesion of protective coatings, reducing failures due to delamination or corrosion. This translates to reduced maintenance intervals, fewer part replacements, improved fleet reliability, and decreased downtime. The initial investment in treatment equipment is offset by eliminating chemical pre-treatment costs, reducing warranty claims, and improving overall product quality and durability – particularly critical in aerospace where failure costs are extremely high.
Is surface treatment environmentally compliant with aerospace industry standards?
Yes, plasma and corona treatment are considered green technologies that align with aerospace industry sustainability goals and increasingly stringent environmental regulations. They are dry, chemical-free processes that generate no hazardous waste, eliminate VOC emissions, require no chemical disposal, and consume minimal energy compared to wet chemical alternatives used traditionally in aerospace manufacturing.