Comparison of Dispensing Technologies
Fluid dispensing technology includes methods for the controlled conveying, dispensing, and application of liquid to highly viscous materials. These include, for example, adhesives, sealants, oils, greases, potting compounds, as well as conductive and solder pastes.
Which dispensing system is suitable for a particular application depends, among other factors, on the material, the required dispensing volume, repeatability, cycle time, and degree of automation.
One-component (1C) materials
One-component materials, also referred to as 1K materials, are supplied ready to use. No separate components need to be mixed before processing.
- ready for immediate processing
- no defined mixing ratio required
- comparatively simple system setup
- suitable for manual and automated dispensing processes
Two-component (2C) materials
Two-component materials, also referred to as 2K materials, consist of two separately stored components. They are combined in the specified mixing ratio only during the dispensing process.
- separate supply of components A and B
- defined mixing ratio required
- components combined immediately before dispensing
- mixed, for example, using a static mixer
- AdhesivesFrom low-viscosity cyanoacrylates to highly viscous structural adhesives.
- SealantsControlled application of sealing beads, dots, and defined contours.
- Potting compoundsFor filling, potting, and protecting electronic or mechanical components.
- Oils and greasesTargeted lubrication and controlled material application in assembly and maintenance processes.
- CoatingsControlled application of small quantities or defined coating layers.
- Conductive, thermal interface, and solder pastesPrecise dispensing of paste-like materials in electronics and assembly processes.
In time-pressure dispensing, the material is forced out of a reservoir by applying pressure. The dispensed volume is primarily controlled by the applied pressure and the dispensing time.
This method is suitable for a wide range of liquid and paste-like materials and is used in both manual dispensing workstations and automated applications.
- simple system setup
- flexible in use
- suitable for many 1C materials
- suitable for manual and automated dispensing
The dispensing material is supplied, for example, from a cartridge, syringe, bulk cartridge, or pressure vessel.
A defined pressure is applied to the material or material reservoir.
The dispensing controller or machine control releases the material flow for a defined period of time.
The material is applied to the component through a dispensing tip, nozzle, or dispensing valve.
In a time-pressure dispensing system, the actual dispensing volume is not determined by pressure and time alone. The following factors can also affect the process:
- Material viscosity
- Material temperature
- Diameter and length of the dispensing tip or nozzle
- Material pressure
- Dispensing time
- Fill level and material supply
- Back pressure at the dispensing point
The more stable these process parameters remain, the more consistent and repeatable the dispensing results will be.
Two-component materials can also be processed using the time-pressure principle. Components A and B are supplied separately and then brought together in the required mixing ratio.
Mixing typically takes place immediately before dispensing using a suitable static mixer, which is connected directly to the cartridge outlet.
For applications with particularly high requirements for a consistent mixing ratio, volumetric 2C dispensing may be the more suitable solution.
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In volumetric dispensing, the amount of material is determined by a defined displacement volume. Unlike time-pressure dispensing, the dispensing volume is not generated primarily by pressure and valve opening time, but by the controlled movement of a displacement element.
The most suitable pump principle depends, among other factors, on the material viscosity, required dispensing volume, the presence and abrasiveness of fillers, and the specific requirements of the dispensing process.
In a progressive cavity pump, a helical rotor rotates eccentrically inside a stator. This creates defined conveying cavities that continuously and uniformly transport the material from the inlet to the outlet.
The material is conveyed comparatively gently. Thanks to the highly uniform material output, this principle is particularly suitable for:
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- small to very small dispensing volumes
- precise bead applications
- continuous dispensing processes
- materials in the medium-viscosity range
- automated 1C and 2C applications
In a gear pump, two intermeshing gears continuously convey the material through the pump in defined volumetric chambers.
The gear pump principle is characterized by a uniform material flow and high pressure stability. This makes it particularly suitable for demanding bead applications and highly viscous materials that need to be dispensed at high process speeds with consistent repeatability.
Typical applications include:
- high-viscosity adhesives and sealants
- continuous adhesive beads
- high flow rates
- fast automated dispensing processes
- applications with high material back pressure
- repeatable dispensing
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In a peristaltic pump, the dispensing material is conveyed through a flexible tube. Rollers compress the tube sequentially, moving the material in the direction of flow.
A key advantage is that the material comes into contact only with the tubing, while the pump mechanism and drive remain isolated from the medium. This simplifies cleaning and material changes and makes the principle particularly suitable for sensitive, aggressive, or contamination-critical materials.
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Typical characteristics:
- the material comes into contact only with the tubing
- easy material changes
- minimal cleaning effort
- well suited for low- to medium-viscosity materials
- dispensing volume can be controlled via pump speed and operating time
- suitable for continuous or intermittent dispensing
| Comparison | Progressive cavity pump | Gear pump | Peristaltic pump |
|---|---|---|---|
| Operating principle | An eccentrically rotating rotor and stator form defined pumping chambers. | Two intermeshing gears convey the material through defined volumetric chambers. | Rollers sequentially compress a flexible tube to move the material through the pump. |
| Key strengths |
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| Dispensing volumes | Particularly well suited for small to very small dispensing volumes. | Well suited for small to larger continuous flow rates. | Well suited for small to medium flow rates, depending on the tubing and pump size. |
| Viscosity | Particularly suitable for low- to medium-viscosity materials and, depending on the configuration, also higher-viscosity materials. | Particularly suitable for medium- to high-viscosity materials. | Primarily suitable for low- to medium-viscosity materials. |
| Fillers | Filled materials can be processed. For abrasive fillers, the rotor and stator must be selected accordingly. | Filled materials can be processed depending on particle size and abrasiveness. Highly abrasive materials can increase wear. | Filled materials can be processed depending on the tubing, particle size, and material properties. |
| Pressure stability | high | very high | medium |
| Bead dispensing | Very well suited for fine, uniform, and continuous beads. | Very well suited for fast, pressure-stable adhesive bead dispensing, particularly with higher-viscosity materials. | Suitable for continuous material dispensing where extremely high dispensing accuracy is not required. |
| Wetted components | The material comes into contact with the rotor, stator, and fluid path. | The material comes into contact with the gears and fluid path. | The material comes into contact only with the tubing. |
| Cleaning & material changeover | Cleaning of the wetted pump components is required. | Cleaning of the wetted pump components is required. | Particularly easy, as in many applications only the tubing needs to be replaced. |
| 2K dispensing | Very well suited for precise 2K dispensing and small mixed volumes. | Very well suited for continuous 2K dispensing with a defined mixing ratio. | Generally possible, depending on the requirements for mixing ratio accuracy and dispensing precision. |
| Example | 2K-Micro-Dos | 2-K-DOS | Peristaltic dispensing system |
In addition to the dispensing principle itself, the method of material application also plays an important role.
In jet dispensing, the material is applied to the surface without direct contact between the dispensing nozzle and the component. Individual droplets are ejected onto the workpiece from a defined distance.
This method is particularly suitable for fast automated processes, hard-to-reach dispensing points, and applications where contact with the component should be avoided.
Learn more about jet dispensing: View category
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Selecting the right dispensing technology depends on factors such as the material, viscosity, required dispensing volume, component geometry, and desired level of automation. We can assess your application and recommend a suitable solution.
FAQ - Frequently asked questions about dispensing technologies
With time-pressure dispensing, the material quantity is primarily controlled by the material pressure and dispensing time. With a volumetric system, a defined material volume is delivered by a displacement element.
This depends on the application and process conditions. Volumetric systems can offer very high repeatability when properly designed. Time-pressure systems can also operate reproducibly, but react more strongly to changes in viscosity, temperature, pressure and material supply.
Yes. Both time-pressure and volumetric systems can be designed for high-viscosity materials. Important factors include material properties, delivery pressure, dispensing volume and the components used.
Yes. Both components can be supplied separately and then mixed together. For applications with particularly high requirements for a constant mixing ratio, volumetric 2K systems are often used.
Time-pressure and volumetric dispensing primarily describe how a defined quantity of material is generated or delivered. Jet dispensing, on the other hand, mainly describes the contactless method of material application.
Key factors include material type, viscosity, required dispensing volume, repeatability, cycle time, container size, 1C or 2C processing and the desired level of automation.