Novel Method for Failure Modes Detection in UV-Cured Clear Coated Polymer for Automotive Interior Mechatronic Devices

Area of Science:

• Materials Science
• Manufacturing Engineering
• Surface Science

Background:

• Coating automotive interior plastic parts is challenging due to low surface energy and material sensitivity.
• Customer demands focus on functional and aesthetic surface quality, making defect detection critical.

Purpose of the Study:

• To propose a novel methodology for detecting failure modes in UV clear-coated automotive interior polymer parts.
• To identify key manufacturing factors influencing surface defects.

Main Methods:

• A multi-step manufacturing process involving plastic injection molding, primer coating, laser engraving, and UV clear coating was analyzed.
• Failure modes were investigated using surface tension tests, adhesion tests, optical 3D measurement, EDX, and microscopy.
• A Design of Experiments (DoE) based on the Taguchi technique was employed to analyze factor influence.

Main Results:

• Mold temperature and laser engraving current were identified as significant factors affecting surface defect occurrence.
• Potential contamination of molding tools was also identified as a defect source.
• The proposed methodology successfully reduced the defect rate from 50% to 0.9% in a case study.

Conclusions:

• The developed methodology effectively detects and helps mitigate surface defects in automotive interior polymer parts.
• Optimizing specific manufacturing parameters is crucial for achieving high-quality coated plastic components.