Automotive Applications in Quality Control

Automotive manufacturers and suppliers alike understand the importance of increasing efficiency and reliability and decreasing failures and waste. Quality control is the name of the game.


BTG Labs offers an innovative way to do just that, with The Surface Analyst.


A fast, easy, accurate and non-destructive instrument that measures surface cleanliness, to prepare for bonding, coating, sealing, painting, printing, or cleaning right on the manufacturing floor.

Below are two applications examples of many, for the Surface Analyst in automotive manufacturing:


Application 1: Bonding of Dissimilar Materials and “Light-Weighting”


One challenge manufactures face with vehicle light weighting is how to effectively join dissimilar materials to ensure structural integrity. The most sensitive factor in bonding is process control of the material’s surface. Without a properly prepared surface, bonds will fail.

The Surface Analyst allows automotive manufacturers who are bonding dissimilar materials to develop a proper surface preparation process for each material and then verify that the process has been effective to ensure the bond will hold. The Surface Analyst increases bonding reliability and repeatability, and eliminates scrap and re-work.


Application 2: Using FIPG instead of rubber gaskets


Thanks to advancements in powertrain manufacturing, sealing processes have improved assembly efficiency. Formed-in-place gaskets (FIPG) are replacing traditional mechanical fasteners as they are more cost effective, stronger, and easier to apply. However, adhesive bonding rather than mechanically fastening presents different challenges and requires new protocols. For this process to maintain efficiency, testing of surface preparation for adhesive bonding is a top necessity.

The Surface Analyst provides manufactures with the confidence they need to securely bond FIPG and RTV applications.

Watch how to control your surface preparation process on an FIPG application.



The Surface Analyst Solution

Typical Surface Analyst Applications for the Automotive Industry


  • Readiness of high-performance specification composites for bonding
  • Cleanliness of sealing surfaces in aluminum castings prior to bonding


  •  Appropriate flame treatment of TPO used in bumper fascias, door panels, etc.
  • cleanliness levels required for FIPG (formed-in-place gaskets)
  • clean surfaces on engine block for RTV sealing


  • Bonding strength of composite materials
  • And optimize the wash process for machined parts
  • Surface treatments such as grit-blasting, atmospheric plasma treatment, and solvent wiping
  • Contaminants (such as mold releases) on machined parts and determine how much can be tolerated


  • Brake and rotor contamination and coatings
  • Surface preparation prior to coating automotive glass
  • Surface prep such as plasma treatment


  • Proper finishing of automotive interiors
  •  Successful bonds