How PSA Tapes Perform Better Than Metal (Mechanical) Fasteners
Mechanical fasteners have long been a common bonding method for a large and diverse range of products. They vary in type, from metal fasteners like screws, rivets, staples, and bolts to brackets, retaining rings, pins, and even many different types of welds. While they work for many products—they are often strong, can be completed by robots during the manufacturing process, and are suitable for a wide range of sheet metal thicknesses—they aren’t always the best bonding option.
Over the years, many OEMs have swapped mechanical fasteners for pressure sensitive adhesive (PSA) tapes, and for good reasons. In many applications, they consistently outperform and outlast mechanical fasteners and provide other benefits in finished products.
If you are facing issues with the mechanical fasteners you use in your applications or are simply looking for a more flexible design option, consider PSA tapes as an alternative. Why are PSA tapes often superior to mechanical fasteners?
PSA Tapes Increase Your Material Options
Mechanical fasteners create localized stress at bonding points, meaning the materials are susceptible to wear points and fracture if they are not able to withstand the stress created by the bond. To counter this, products must be made from thicker gauge materials to avoid attachment failure.
PSA tapes evenly distribute the bond across the area in which they are applied, avoiding localized stress points while still maintaining a secure bond. This allows for lighter weight and thinner materials to be used without fear of them breaking due to the stress on the bond.
PSA Tapes Help Avoid Corrosion
PSA tapes also allow you to bond dissimilar surfaces with one another, particularly different types of metals. When certain metals are bonded together using welds and metal fasteners, galvanic corrosion can occur. This occurs when two different metals come in contact with one another in the presence of an electrolyte; steel will corrode aluminum, etc. Even if a galvanized (zinc) coating is used, it will eventually fade, and corrosion will occur. PSA tapes prevent this corrosion because they form a barrier between the two metals, which are attached to the tape , not to each other.
PSA Allow for a Clean Finish
PSA tapes are always hidden inside the bond-line. . Unlike screws, rivets and spot welds, which detract from aesthetic appeal or must be designed to be hidden PSA tapes by their very nature never need to be hidden, masked, or covered up. They significantly improve the exterior appearance of electronic devices, appliances, vehicles, and many other consumer products. They also do not require holes to be drilled or punched in order to bond the materials, which can create unsightly bonding areas and reduce the structural integrity of products.
PSA Tapes Handle Noise, Vibration, and Harshness
Demanding environments often produce noise, vibration, and harshness (NVH) that can negatively impact fasteners, rivets, and welds over time. In certain applications, NVH also reduces the performance and comfort of those using the product. Many PSA tapes dampen noise and vibrations, absorbing the energy they create and dissipating it across the entire bond. While NVH will cause metal fasteners to rattle and fatigue over time, weakening the attachment and allowing sound and vibration to pass, PSA tapes will dramatically reduce or eliminate the NVH outright. This increases the comfort of using the product while maintaining a strong bond over time.
Simpler and Faster Assembly
Mechanical fasteners require more tools, steps, and training to apply during the assembly process. These tools and skills take time to learn, and some (like welding) are hard to master. PSA tapes are easy to apply, require very little training and special tools, and can be applied much faster than any mechanical fastener. Training for employees can be kept to a minimum, and there are very few lingering fumes, chemicals, or cleanup involved. Using PSA tapes means no holes need to be drilled, no welds need to be made, and no extra steps need to be taken during the assembly process.
PSA Tapes Are Stronger
PSA tapes increase in strength over time. They are less likely to fail when compared to mechanical fasteners and go through rigorous testing for their ability to withstand tensile, shear, cleavage, and peel stress. Many material options are also resistant to heat, UV light, moisture, chemicals and solvents, shock and impact, and many other environmental factors. Certain PSA tapes (like very high bonding tape) are also able to absorb significant dynamic loads over the entire bond lines. Unlike mechanical fasteners, which can loosen and fail under heavy loads and forces (from high winds and harsh environments) PSA tapes will continue to hold strong in nearly any application.