5 Structural Adhesives Myths Disproved

Myth #1: Structural Adhesives Don’t Hold

Skepticism that structural adhesives can work in applications requiring strong and durable
bonds is a common mistake in joint design. Engineers typically have more experience with
traditional joining methods like welding, spot welding, screws and rivets. They often rely on
these methods without ever considering the advantages of structural adhesives. Changing
from a traditional joining method to a structural adhesive can be unconformable at first but
understanding how structural adhesives work helps build confidence and could help identify
performance and cost advantages.
Depending on your circumstance and specifications structural adhesives may outperform
traditional joining methods in many applications. Adhesive bonds distribute loads throughout
the bond line, eliminating stress concentrations at spot welds, screws or rivets (Figure 1) to
improve the joint strength and durability of the part. Structural adhesives also have better
aesthetics because they do not require refinishing steps or leave protrusions.

Figure 1. Stress distribution of rivets or spot welds (left) and structural adhesive bonds
(right). The red dotted line is the midline of the overlap joint. The blue arrows represent
how the stress is being distributed within the bondline. Stress concentrations are
created by rivets or spot welds as seen by the ascending blue arrows.

Structural adhesives are similar in strength when compared to welds, and more than twice as
strong as spot welds, bolts and rivets (Figure 2). As a result, structural adhesives are an ideal
choice for even the most demanding applications. For example, structural adhesives have
been used to bond high performance aerospace components and carbon fiber drive shafts. In
one 3M test, a structural adhesive was strong enough to hold 14,550 lbs. suspended in the air
over 18 hours (watch video) through a winter night in Minnesota.
Manufacturers often have the additional option of combining structural adhesives with
traditional joining methods. For example, in the transportation industry structural adhesives
are often combined with spot welds or rivets.
 Figure 2. Overlap shear strength of different attachment methods.
Data was collected by 3M, https://multimedia.3m.com/mws/media/646994O/3ms-tough-stuff-white-paper.pdf,
https://multimedia.3m.com/mws/media/1054052O/acrylic-adhesives-recent-advancements-white-paper.pdf

Materials that cannot be effectively joined by traditional methods can be bonded with
structural adhesives. Structural adhesives have had a large role in lightweighting because they
enable the bonding of thin gauge metals and composite materials. Structural adhesive bonding
does not require drilling holes and they do not cause thermal distortions that damage thin
gauge metals. Composite materials cannot be welded or effectively drilled into but can be
joined by structural adhesives.
Structural adhesives are polymers and have different properties when compared to traditional
joining methods. For example, structural adhesives can make flexible bonds, reducing stresses
due to part movement and thermal expansion. This makes structural adhesives ideal for joining
dissimilar materials including metals, plastics, composites and wood. Structural adhesives can
also help to dissipate energy, making them ideal for vibration and impact resistance.

Myth #2: Holding Pieces Together is All That Matters

There’s more to bonding and adhesion than just selecting the right product and applying it to
your part. It is also a good idea to evaluate the whole process while also considering the
operating conditions of the final part. 3M adhesive specialists use a comprehensive evaluation
framework to help our customers assess their needs. The process starts by listening to design
and materials engineers to understand the requirements of that particular structural adhesive
application. Finding out more about each customer’s unique process, current goals and
challenges helps provide more holistic solutions for customer evaluation. The most common
challenges fall into the following categories:
Production Challenges:
 • Need to shorten overall cycle time
• Concerns of high scrap or rework rates
• High levels of work in process (WIP)
• Moving to a more automated process to address a shortage of skilled labor

Evaluating your entire production process can help identify process steps where changes
could help an adhesive work and perform better. This can also lead to areas where you might
reduce time or labor, like the time spent inserting mechanical fasteners or refinishing weld
distortions. 3M adhesive specialists can help reduce scrap by testing adhesive alternatives to
your substrates and suggesting products or modifying process steps. Rework can also be
reduced by selecting adhesives with longer open times that enable repositionability.
Production cycles can be shortened, while also reducing WIP, by utilizing fast-cure or heat-
cure adhesives that reach handling strength more quickly and enable parts to be moved within
the process faster. As engineers look to automate the dispense process, our specialists can
offer ideas that could help reduce and reallocate labor by mapping out different automation
options.
Labor Challenges:
• High turnover creates demand for standard operating procedures (SOPs) and
optimizing processes for consistency
• Process training
• Worker fatigue and injuries
Labor is an important part of the production process and should also be evaluated. Replacing
mechanical fasteners with structural adhesives may help reduce worker fatigue related to
applying mechanical fasteners (screws, bolts, rivets). Reducing the number of welds in an
assembly process can help reduce not only the specialized and expensive labor of welding
itself, but also the grinding and refinishing required to make the weld aesthetically pleasing.
3M adhesive experts can help in this evaluation and recommend easy-to-use adhesives and
tapes.
Design Challenges:
• Pressure to reduce cost or weight
• Need to create more streamlined designs by removing metal attachments
• Using new difficult-to-bond materials such as LSE plastics
• Assemblies that need to reduce noise and vibration or withstand harsh conditions
• Issues with bond line read-through that occur while using your current adhesive
• Changing or challenging conditions of final end-use of the assembly
Finally, reviewing an assembly and its expected environment helps engineers evaluate the
process used to make it. Can a joint be redesigned for greater strength by changing the stress
modes, or do you need to bond new materials such as composite substrates or low surface
energy (LSE) plastics? 3M adhesive experts can help your design engineering teams evaluate
these and other possibilities, including adhesive options that don’t run or drip. There are also
available product options that help eliminate bond line read-through or reduce noise and
vibration. Challenging end-use conditions such as heat, cold, humidity or chemical
environments can also be solved with the correct adhesive selection. A review of testing
protocols and the ability to perform tests on specific substrates to determine whether a
solution may be “over-engineered” is an important step in the overall selection process. 3M
can provide on-site testing that will simulate the temperature, humidity and stress levels that a
specific assembly will experience.
3M adhesives specialists have worked with and advised customers in nearly every industry,
application and location – we can help evaluate and help you improve your unique assembly
and application.
• Watch how 3M structural adhesives helped one customer reduce labor hours by 50%*
• Watch how 3M adhesives products helped one customer see 5x* faster assembly than
competitors
• Watch how 3M structural adhesives helped one customer increase output from 35% to
98%*
* Results are specific to each unique customer process and adhesive application. Individual results may
vary.

Myth #3: “I Tried One so I’ve Tried Them All”

After a failed attempt to use a structural adhesive for an application, the decision to trial
another adhesive for either the same application or a different one can be difficult. This can be
especially true if design engineers may have historically had success with more traditional
methods of attachment (bolting, riveting, welding, etc.). Before giving up on structural
adhesives, it is important to investigate why the previous option(s) failed to meet all
expectations. Understanding how and why the previous structural adhesive application was
unsuccessful can provide insight into attributes that are needed in subsequent adhesive
selection.
An assembly created with structural adhesives can fail to meet expectations for several
reasons. These reasons can be process-dependent, end use-dependent, or a combination of
the two.
Process-dependent issues can include any of the following:
• Surface preparation: cleanliness, surface energy modification, etc.
• Dispensability: viscosity, sag behavior, etc.
• Curing times: open time, time to handling strength, time to full cure.
End-use-dependent topics can include any of the following:
• Mechanical properties: modulus, elongation, etc.
• Adhesion strength to chosen adherends in various stress modes: shear, tensile, impact,
etc.
• Environmental resistance: temperature and humidity extremes, solvents or fluids, etc.
Once the failure analysis is complete and it is understood why the previous adhesive failed, it
is important to investigate other adhesives that have the newly discovered and required
attributes. 3M’s structural adhesive portfolio covers the breadth of differing chemistries and
has the depth within each to tailor the attributes of the adhesive to match the needs of the
application.
There are three main chemistry families within the 3M structural adhesives portfolio: acrylic-
based, epoxy-based and polyurethane-based. Each of these chemistries have generalities that
can be applied to adhesives within a specific family.
• Acrylic-based adhesives, for example, will typically cure and build strength at a much
faster rate than epoxies or polyurethanes. This rate of strength build provides a
convenience advantage when considering the process of creating a joint. The acrylic-
 based chemistry can be split into three main sub-categories: methyl methacrylate
(MMA), low odor and low surface energy bonders.
• Epoxy adhesives will typically have higher overall strength and superior environmental
resistance that are great attributes to have when considering the performance in the
end-use state. The epoxy-based chemistry can be split into three main sub-categories:
rigid, flexible and toughened.
• Polyurethane-based products are useful when bonding composite-based materials
where energy absorption is required. This chemistry class can be split into three main
sub-categories: polyurethane reactive (PUR) hot melts, flexible and semi-rigid.
Figure 3 provides a comparison of the main chemistries and their sub-categories against six
different product attributes. The product attributes contrast the processing characteristics (x-
axis) against the physical characteristics (y-axis) of each structural adhesive family and ranks
each attribute within that family as good (red circles), better (yellow circles), or best (green
circles).
The processing characteristics are a set of attributes that make using and applying the
adhesive more convenient from a production perspective. These attributes are shelf life (SL),
rate of strength build (RoSB) and minimal surface preparation required (MSPR). Shelf life is
important for understanding how long a product can remain viable at a production facility and
how frequently the adhesive would need to be ordered. A longer shelf life associated with a
product will be an advantage and score higher on the convenience scale (best). Rate of
strength build describes how fast an adhesive will build strength after a bond has been made.
Typically, the faster the adhesive can build bond strength the more quickly the resultant part
can be moved to the next process step, reducing the work-in-progress (WIP) and increasing
production throughput (best). Finally, the amount of surface preparation required for an
adhesive to achieve optimal performance plays a vital role in the time associated with the
assembly process. Certain adhesive families require extensive surface preparations or
treatments (good) to obtain optimal adhesion and final joint performance whereas other
adhesive families require very little preparation (best).
The physical characteristics are a set of attributes that provide an indication of how an
adhesive will behave when stressed in different ways or exposed to different environmental
conditions. These attributes are shear strength (SS), peel strength (PS) and environmental
resistance (ER). For the purpose of this graphic, higher strengths and resistances will equate to
the best overall performance and rating. The scores provided here are generalities of the
product family and are meant to be directional in nature. With that said, adhesives will perform
their best and provide the highest strengths when stressed in shear mode and on properly
prepared adherends. Peel strengths are a good indicator and proxy for how much energy an
adhesive can absorb before failure. Finally, the types of environmental conditions can range
from short term (seconds-minutes-hours) to long-term (days-weeks-months) temperature,
humidity or solvent/fluid exposures. Higher ER ratings indicate the best chance of surviving
the exposure while retaining the original strength of the joint.
 10

Physical Characteristics - Performance in End-Use

Best Toughened Epoxies
Better SL SS

(shear (SS) & peel (PS) strength, environ. resistance (ER))

Good PS
RoSB
8 MSPR ER MMA Acrylics

Flexible Epoxies SL SS
RoSB PS
SL SS
MSPR ER
6 RoSB PS
MSPR ER
LSE Acrylics SL SS
SL SS Low Odor
Semi-Rigid RoSB PS
RoSB PS SL SS Acrylics
Polyurethanes MSPR ER
MSPR ER Rigid Epoxies RoSB PS
4 MSPR ER
SL SS
SL SS RoSB PS
Flexible PUR Hot Melts Instants &
RoSB PS MSPR ER
Polyurethanes Anaerobics
MSPR ER SL SS
2 RoSB PS SS
SL
MSPR ER RoSB PS
MSPR ER

0
0 2 4 6 8 10
Process Characteristics - Convenience of Use
(shelf life (SL), rate of strength build (RoSB), minimal surface prep required (MSPR))

Figure 3. A schematic of the main types of structural adhesives and how they
directionally compare to each other when considering both process characteristics and
physical characteristics. This chart can help determine which adhesive family to lead
with when the application requirements are known and prioritized. Within each sub-
category (e.g., toughened epoxy, MMA Acrylic, PUR, etc.) there are different open
times not listed here.
The 3M structural adhesives portfolio offers an extensive assortment of options that can span
low-to-high modulus, short-to-long open times, self-leveling to non-sag dispensability and
much more. Understanding the prioritized requirements of an application is an important first
step. This prioritized list should be based on the criticality of the bonded assembly coupled
with the production requirements. Systematically thinking through the entire bonding process
can help ensure the correct adhesive solution is chosen and the resultant bonding application
is a confidence-building success.

Myth #4: All Structural Adhesives are Epoxies

An adhesive, in its most fundamental description, is any material that binds two or
more things together for the duration of its useful lifecycle. With innovations in new
materials and the breakneck speed at which modern consumer goods are being
designed and manufactured, there is a demand for new and better ways to assemble
these products.
Adhesives are finding more and more uses in modern day manufacturing for their
benefits like lightweighting, sealing, vibration damping, lower susceptibility to
corrosion and better aesthetics, to name a few. For these reasons adhesives are
increasingly being used in the automotive, transportation and metal fabrication
industries as well as in the manufacture of aircraft, furniture, appliances, medical
devices, consumer electronics, general manufacturing and much more.
In the world of adhesives, structural adhesives provide extremely high bond strength
and can carry considerable load for the bonded assembly - it is meant to become an
integral and permanent part of the assembly. A structural adhesive can produce
strength up to several thousand pounds per square inch (psi) in overlap shear,
depending on the materials bonded. It can also bond to a wide variety of substrates
including metals, plastics, composites, woods, elastomers and, with a unique
formulation, even hard-to-bond materials such as polyolefins and silicone elastomers.
Structural adhesives are therefore used in many applications where strength and
durability are critical.
Structural adhesives are commonly classified according to their base chemistry. Epoxy
is perhaps the most-recognized term people associate with structural adhesives.
Indeed, many people use this term to generically refer to any adhesive that exhibits
high strength, but for clarity, the name epoxy derives from the chemistry. By no means
is it the only material that can impart structural strength to assemblies; other common
structural adhesive families include acrylics, 1- and 2-part urethanes, cyanoacrylates
and anaerobic adhesives. 3M offers a wide selection of products from each of these
adhesive categories. Each has its own strengths and limitations. Understanding the
capabilities of these adhesives gives you freedom and flexibility to choose the best
adhesive to best suit individual bonding applications. Remember, when one adhesive
does not quite meet your bonding requirements, look further into the portfolio of
structural adhesives. With a wide range of chemistries and properties, one is sure to
solve each unique bonding challenge.
3M Structural Adhesives Families
Epoxy Adhesives
Key Strengths: High bond strength and durability.
Epoxy adhesives are extremely strong and durable in demanding conditions including
outdoor weathering and harsh chemical exposures. They are available in two-part room
temperature curing or one-part heat curing formulations.
• Highest overall strength under various stresses including shear, peel, tensile and
impact
• Best resistance to high temperatures, solvents and harsh environments
• Bonds to a wide variety of materials: bond strength to metals is outstanding, but
epoxies also bond many common engineering plastics, composites, woods,
glass and ceramics
• Cured adhesive can be soft and flexible, rigid, or extremely tough to suit
different applications
• Withstand vibration, impact and fatigue
• Low shrinkage
• Available in the widest variety of open times to suit most applications
 • Example Uses:
o Instrumentation for defense, automotive and oil and gas industries –
applications that require rigorous quality and performance in harsh
environments
o Sporting goods – due to high load and high impact over a small bond
area
o Renewable energy, passenger rail car – applications requiring high
performance with environmental considerations
• Popular Products:
o 3M™ Scotch-Weld TM Epoxy Adhesive DP420NS - General purpose,
tough and strong, best for bonding metals
o 3M™ Scotch-Weld TM Epoxy Adhesive DP100 Plus – Flexible, clear, fast
curing
o Plus 38 other 1-part or 2-part products with a wide range of open and cure
times to fit your applications

Acrylic Adhesives
Key Strengths: Robustness and fast curing
Acrylic adhesives bond exceptionally well to most plastics including low surface
energy (LSE) plastics, difficult-to-bond paints and coatings, and to metals that may be
somewhat oily. This versatility enables engineers and manufacturers more design
flexibility when it comes to assembly of parts consisting of different materials.
• Exceptional in bonding plastics, including LSE plastics
• Least sensitive to surface preparation
• Least sensitive to off-ratio mixing
• Faster cure rate than epoxy or urethane adhesives
• Toughened formulations with good impact resistance
• May contain spacer beads to maintain consistent bond line
• User-friendly, low odor options available
• Example Uses:
o Panel-to-frame – bond to a wide range of plastics and metals for
processes that don’t allow rigorous cleaning
o Enclosures – potential for process improvement due to speed of cure
with a durable bond; also bonding of parts that will go through a powder
coat process
o LSE plastics – the best chemistry to bond to LSE plastics with little to no
surface prep
• Popular products:
o 3M™ Scotch-Weld TM Low Odor Acrylic Adhesive DP8805NS – Low
odor, fast curing, strong and tough, bonds many materials
o 3M™ Scotch-Weld TM Structural Plastic Adhesive DP8010 – Excellent
bonder to many engineering plastics plus LSE plastics
 o 3M™ Scotch-Weld TM Metal Bonder Acrylic Adhesive DP8407NS –
Metal bonder, resists powder coating temperatures, strong and tough
o Plus 14 other products with a range of open times to fit your applications
Urethane Adhesives
Key Strengths: Flexible and strong
Urethane chemistries are ideal for creating strong, flexible bonds between dissimilar materials.
Urethanes excel at bonding to composites, wood and concrete as well as a variety of
engineering plastics and some metals.
• Better aesthetics without a visible bond line due to low shrinkage
• Bonds provide the strength or flexibility to resist shock, vibration and impact loads
• Variety of open times available to suit process needs
• Example Uses:
o Composite panel bonding with a class A surface – no read-through of adhesive
o Glass bonding – adhesive’s low modulus allows for fluctuations in temperature
o Potting applications requiring flexible adhesive
• Popular products:
o 3M™ Scotch-Weld TM Multi-Material Composite Urethane Adhesive
DP6310NS General purpose, bonds especially well to composite materials,
good impact strength at high and low temperatures, relatively fast setting
o 3M™ Scotch-Weld TM Urethane Adhesive DP604NS – Flexible and fast
setting, best for bonding plastics
o Plus 11 other products to fit your applications

PUR Adhesives
Key Strengths: Fast holding power with flexibility
PolyUrethane Reactive (PUR) adhesives are one-part formulations that combine the initial
speed of a hot melt adhesive with the strength of a structural adhesive. They bond
exceptionally well to wood, glass, ceramics and many plastics including nylon.
• Rapidly reaches handling strength
• Eliminates clamping of parts
• One-part adhesive requires no mixing
• Variety of open times to suit process requirements
• Example Uses:
o Panel and stiffener bonding for appliances – due to fast cure and ability to gap
fill
o Woodworking – offers improvements over traditional wood glue
o Electronics – due to fast curing and viscoelasticity
o Glass and plastics bonding – flexible and elongating, fast cure
• Popular products:
o 3M™ Scotch-Weld TM PUR Adhesive TS230 – General purpose, bonds well
to plastic, wood and glass, longer open time
o 3M™ Scotch-Weld TM PUR Adhesive EZ250060 – Wood bonder, plasticizer
resistant, medium set speed
o Plus 17 other products with a range of open times to fit your applications
Instant Adhesives
Key Strength: Speed
Instant adhesives, also known as cyanoacrylates, are one-part products that attain handling
strength in a matter of seconds. They are excellent for bonding rubber, including LSE
elastomers such as EPDM and silicone. They also bond well to common engineering plastics,
LSE plastics, metals and wood. They are best suited for small parts assembly.
• One-part formulations requires no mixing
• Reaches handling strength in seconds
• Eliminates clamping of parts
• Excellent bonder of elastomers
• Can bond to LSE plastics and elastomers when used with a primer
• Clear and colorless
• Example Uses:
o Small plastic and metal parts assembly
o Rubbers and elastomers such as door seal or rubber soles for orthopedic
devices
o Decorative wood trims
• Popular products:
o 3M™ Scotch-Weld TM Plastic & Rubber Instant Adhesive PR100 – General
purpose, especially for plastics and rubbers
o Plus 25 other special purpose products with a range of viscosities to fit your
applications

Anaerobic Adhesives
Key Strength: Keep nuts and bolts from loosening
Commonly known as threadlockers, Anaerobic adhesives are one-part adhesives that cure in
the absence of oxygen; this group also includes gasket makers, pipe sealants and
hydrauylic/pleumatic sealants. They augment the strength of a threaded metallic joint,
preventing loosening due to excessive vibration. Specialized formulations can also be used as
retainer adhesives for bonding non-threaded shafts, or as a temporary gasket for flanges.
• Lock and in some cases seal
• One-part adhesive that requires no mixing
• Threadlockers are color coded to easily identify strength rating
• Resist vibration and galvanic corrosion
• Example Uses:
o Thread locking and in some cases thread sealing
o Tube-in-tube retaining compound to replace keys, splines or set screws
o Gaskets
• Popular product:
o 3M™ Scotch-Weld TM Threadlocker TL42 – medium strength thread locker
resists pressure and vibration for long term durability
o Plus 18 other specialized products with varying strengths to fit your applications
 Figure 4. 3M Structural Adhesives grouped by family.

Myth #5: “I’m On My Own to Figure This Out”

One of the most important things to remember is that you are not alone. Just as design
engineers are experts on the products they are creating, there are bonding experts who can
help you with selecting the right adhesives to make it possible. When you think of 3M, some
memorable brands and products come to mind, including 3M™ Post-It™ Notes, 3M™
Command™ Strips and 3M™ Cubitron™ Abrasives. All of these products have one thing in
common: they have an adhesive component. Adhesives are core to some of 3M’s most iconic
brands because 3M has been designing and innovating in adhesive categories for decades.
3M’s global engineering and development teams have expertise in material science and a 40+
year history in developing 3M™ Scotch-Weld™ Structural Adhesives. 3M engineers invented
both the flexible and toughened epoxy product categories. Our people are experts in material
and adhesive science who regularly work with multiple bonding product options from tapes to
spray, hot melts to structural adhesives.
If cost control and the bottom line are an important part of a design engineer’s overall
decision, 3M has global technical and bonding support teams with the knowledge, expertise
and local resources to help you bring concepts to life cost-effectively. 3M’s engineers,
scientists and inventors share customers’ inquisitive nature and passion to create something
newer and better.
In addition to global teams, 3M employs over 45 global application engineers who offer
custom testing and reporting for customers of all sizes, industries and locations. They can test
the strength performance of multiple adhesives using specific substrates under different heat,
humidity and force tests. They can also help design engineers evaluate specific joint designs
for better adhesive performance.
Another valuable resource 3M has recently built to help support adhesive customers are three
automation-focused labs located in the United States, Germany and China. In these labs,
customers and 3M engineers come together to test out adhesive options using different
manual and automated equipment ranging from table-top dispense stations to sophisticated
screen and jet printing dispensers. 3M also works with customers who need assistance with
more sophisticated Finite Element Analysis (FEA) and data modeling. FEA has emerged as a
powerful tool for predicting assembly performance and it can be used to compare structural
adhesives to traditional joining methods and provide confidence in the joint design.
Finally, online and video-based training services and real-time chat support allow quick and
easy access to engineers with answers. Whether you’re a design engineer who is new to
adhesives or trying a new adhesive category for the first time, 3M has a team of over 75
bonding specialists across the globe who can offer design teams an introduction to using
structural adhesives. 3M works with customers of all sizes, from start-ups with a handful of
employees to large multi-national manufacturers across a variety of industries. No design
challenge is too specific or unique.
If you are interested in working together to address any bonding needs or challenges you have
call 1-800-362-3550, email 3mproducts.adhesives.us@mmm.com or visit
3M.com/structuraladhesives to learn more.
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