Drafted in collaboration with Avery Dennison Performance Tapes ADvantage Converter Network member, Sur-Seal
These are times of great opportunity and great challenge for the Aerospace industry. Demand is growing overall, and customers are particularly keen on aircraft that deliver greater performance and sustainability. However, global supply chain disruptions in recent years have many manufacturers and suppliers reconsidering the need to diversify their preferred material solutions. And companies across many industries, including Aerospace, are facing workforce shortages that are forcing them to find ways to optimize their processes.
These trends have trickled down and throughout the industry. Companies that respond will be poised to grow profitably through the 2020s and beyond. As the consulting firm Deloitte notes in its 2024 Aerospace and Defense Industry Outlook, “Aerospace and defense companies should embrace new technologies and innovation to help navigate upcoming challenges and capitalize on growth opportunities.”
The analysts at Deloitte were referring primarily to new digital technologies — and the rapid adoption of such technologies surely should be a priority for the industry. But we believe other technologies can help Aerospace manufacturers overcome some key pain points in their manufacturing, and profitably produce aircraft that are aligned with the trends impacting the industry.
One such technology is pressure-sensitive adhesive (PSA) tapes. PSA tapes are used widely in industries such as Automotive, Appliances, Building and Construction, Electronics, General Industrial, Personal Care and Transportation. Generally, tapes are seen as an alternative to mechanical fasteners (such as screws, nuts and bolts, rivets) or liquid-applied adhesives. In fact, PSA tapes can do much more than simply bond materials — a key point that we’ll cover later in this article.
As a bonding solution, however, tapes excel. They’re growing in use in Aerospace, as they offer engineers a variety of advantages.
A typical tape construction consists of three parts: a filmic or paper carrier, an adhesive, and a protective liner. Depending on the needs of the application, a tape may be single-sided (a single layer of adhesive laminated to the carrier) or double-sided (a layer of adhesive on either side of the carrier). Double-sided tapes can also feature differential adhesives, which are useful when bonding dissimilar materials.
The adhesives at the foundation of these tapes are available in a wide range of chemistries. Avery Dennison, a leading global tape manufacturer based in Painesville, Ohio, offers hundreds of formulations in its product portfolio. Adhesives can thus be fine-tuned, to a very high degree, for the needs of an application. In fact, Avery Dennison frequently works closely with individual customers to custom-engineer adhesive formulations in its ISO-certified laboratory.
It’s also quite common for tapes to be “converted.” They may be merged with functional materials such as flame-retardant fibers; rubber, plastic, graphite and foam seals; EMI/RFI shielding; silicone gap pads; and thermally conductive materials. Conversion also often involves precision forming or die-cutting, producing a tape-based solution based on a customer’s exact needs.
Expertise in conversion is provided by companies such as Sur-Seal, an ISO 9000 and AS 9100-certified manufacturer based in Cincinnati. Sur-Seal has extensive experience in numerous industries, including Aerospace, Automotive, Energy, Heavy Equipment, Military and Transportation. The company converts a wide range of MilSpec and ASTM-certified materials.
PSA tape manufacturers such as Avery Dennison and tape converters such as Sur-Seal often collaborate on projects that address customer opportunities. Besides the materials, these companies can provide a high level of scientific, engineering and process expertise. The sum is thus even greater than the parts: With both manufacturers contributing materials and expertise, the customer is ensured an optimal adhesive-based solution.
Owing to their many advantages, PSA tapes are used in numerous applications in modern aircraft.
Securing these flexible films to rigid substrates with mechanical fasteners is not an option. PSA tapes, however, can do the job easily. A PSA can be formulated to bond to aluminum, painted surfaces, and substrates with differing surface energies, making it ideal for this application.
These tapes are also designed for easy removal. This can be a particular advantage if it’s decided to replace carpeting during an aircraft’s maintenance, repair and overhaul (MRO).
Single-coated tapes may also be used to seal off aircraft acoustic insulation materials. These materials typically consist of glass, polyester, nylon or other tough, fibrous materials. The carriers for these tapes can be made of similar materials.
Finally, PSA tapes can be used to bond structural vibration-damping tiles directly to an aircraft’s fuselage interior. Adhesives used for this application can be formulated with specific rheological properties that aid in the damping function.
This list only scratches the surface of the potential applications for PSA tapes in modern aircraft. And as the aerospace industry grows with technologies such as electric and hybrid-electric propulsion, drones, satellites and crewed spacecraft, the PSA tape industry is poised to grow with it.
With so many adhesive chemistries, functional materials and constructions available, choosing the right tape for an aerospace application requires a thorough process. At a high level, an engineer must consider four factors:
The fact is, PSA tape selection often requires deep expertise with the application, adhesive chemistries and properties of various materials. Many applications additionally require capabilities such as material forming and die cutting. Aerospace manufacturers often do not possess such expertise and capabilities in-house.
However, companies such as Avery Dennison and Sur-Seal do possess them. Sharing this expertise and these capabilities is a routine aspect of their work with customers.
As the Aerospace industry is poised for a bright future, now is the time to evaluate new technologies such as PSA tapes. We welcome the opportunity to discuss your current materials and bonding solutions and investigate how PSA tapes might be a key part of how your business responds to industry trends. Avery Dennison and Sur-Seal want to be part of your profitable future.
Kent Manufacturing is now integrated with Sur-Seal
