In 1998, DATRON engineers took an innovative leap — replacing the spindle of their in-house milling machine with a metered pump — and created their first dispensing system. This early prototype evolved into a standard product line, led by the PR0500, which went on to define DATRON’s success in the precision bead dispensing market for over 25 years.
Over half of DATRON’s installations were built to handle the industry’s toughest challenge: dispensing highly filled, abrasive materials such as EMI shielding gaskets containing silver, nickel, copper, or carbon. The key to that success was DATRON’s patented gear pump synchronized with the machine’s motion control system. Thanks to the two independently driven gears, the pump delivered an even, consistent bead with precise control of volume, height, and width— even at variable speeds and in critical start/stop areas.
This innovative approach established DATRON as a leader in difficult-to-dispense applications. Drawing on decades of experience, DATRON took the next major step in 2024 with the introduction of the DATRON evo 600 — a complete redesign that redefines performance standards in industrial dispensing.
A New Design for a New Era
As parts have become smaller and more intricate, industries now demand higher precision, greater speed, and reliable 24/7 production capability. While DATRON’s earlier systems were known for their accuracy, the time had come for a generational leap. The DATRON evo 600 was designed to meet several key goals:
- Significantly increase dispensing speed and accuracy
- Introduce a modern, high-performance control platform
- Create a more intuitive, touchscreen-based user interface
- Enable seamless integration with common CAD/CAM systems
- Establish a global material parameter database
- Integrate a touchless optical scanning system for part measurement and 100% inline control of the bead height
- Simplify production cell integration
- Enhance ergonomics for operator comfort
Performance that Redefines Speed and Precision
High-volume production requires speed — without compromising accuracy. The DATRON evo 600 delivers both. Equipped with a new servo drive system, it dispenses more than twice as fast as the former system. The legacy system’s axes reached 16 m/min; the DATRON evo 600 races ahead at up to 50 m/min.
This leap in speed is accompanied by enhanced precision, with repeatability improved from ±50 microns to ±20 microns. Acceleration and deceleration have also been optimized, allowing full-speed motion in shorter distances, a critical advantage when dispensing small, complex geometries.
As Project Manager for Dispensing Dirk Iller notes, “One of our German customers runs a three-shift operation with thousands of parts. Every second counts, and with the DATRON evo 600, the time savings are enormous.”
The result: lower cost per part, higher accuracy, and faster cycle times.
Redesigned from the Ground Up
To achieve this level of improvement, DATRON’s R&D team started with a clean slate. Beyond performance, the new design offered practical benefits: it allowed for the use of modern, widely available components. This reduced costs, improved supply chain flexibility, and allowed DATRON to maintain consistent inventory levels while enhancing system performance and reliability.
Smart Control, Familiar Interface
When DATRON developed its next control platform for CNC machining, it made perfect sense to adapt it for dispensing. The touchscreen interface, built on familiar smartphone gestures like tap, swipe, and pinch, makes operation intuitive and reduces training time.
Optional features such as an integrated camera, touch probe, or confocal scanner make setup fast and precise. Shared components with DATRON’s CNC systems simplify manufacturing, reduce costs, and ensure robust spare parts availability.
For long production runs, DATRON can even pre-program and validate parts before installation — allowing customers to move into full production just days after setup.
Streamlined Programming with CAD/CAM Integration
Instead of developing new proprietary software, DATRON opted to utilize popular CAD/CAM tools such as Fusion 360 and Mastercam. Users can easily export G-code directly from their existing workflows and import it into the DATRON evo 600, eliminating the need for additional training or software investments. Dispensing-specific strategies — such as bead start and stop points or ramped transitions — are then applied directly in the next control interface.
Intelligent Material Management
Every gasket or adhesive has unique dispensing characteristics. Previously, these parameters were embedded within each program, making them difficult to find or reuse. The DATRON evo 600 introduces a centralized global database of dispensing parameters, allowing operators to store, label, and recall material settings instantly, even years later.
Touchless Optical Precision
As part designs shrink, precision becomes critical. Mechanical probes can’t reliably measure uncured or flexible beads. DATRON added a confocal optical sensor to address this challenge by measuring parts and beads without physical contact. This is done before or after dispensing.
Using the sensor before dispensing enables automatic correction for part variations. Utilizing the sensor after the bead is dispensed validates the dispensed bead and eliminates the need for offline measurement.
Dirk explains: “With the confocal system, we can measure every 0,03mm (30µ) at a measuring speed of 20m/min. Customers get instant feedback on bead quality — it’s a huge advantage.”
Ready for Automation and Human Operation
The DATRON evo 600 was engineered for easy integration into automated production cells. The system can be purchased without an enclosure for robotic or automated lines, or with a protective housing for stand-alone use. Safety features include side-mounted light curtains that instantly stop the machine if the light barrier is interrupted.
This flexible design enables a single DATRON evo 600 to transition seamlessly from prototype work to full-scale automated production at a later date.
Operator-Focused Ergonomics
Accessibility and comfort were key design considerations. The DATRON evo 600 features an open, step-in design that provides operators with direct access to the work area and an easily accessible side-mounted touchscreen. No obstructing panels — just efficient, ergonomic operation.
A New Benchmark for Dispensing Technology
After a year of development, DATRON unveiled the DATRON evo 600 on April 23, 2024, at its headquarters in Germany. The system is engineered for 24/7, high-volume production with unmatched speed, precision, and reliability.
Dirk proudly summarizes: “We have the shortest cycle time possible. As far as I know, no competitor can dispense faster.”
Applications of the DATRON evo 600
The DATRON evo 600 excels in demanding, high-precision industries, including:
- EMI Shielding Gaskets – For protecting electronic devices from radio frequency interference. The geared pump design excels with abrasive, metal-filled materials used in aerospace, military, radar, and 5G telecommunications applications.
- Fuel Cells – Precise micro-beads for assembling up to 100 bipolar plates, ensuring accuracy of the final assembly. The speed of the machine is a viable alternative to the high investment costs associated with injection molding.
- Touch Displays – Aesthetic precision for bonding glass panels and frames.
- Injection Molded Housings – Plastic and metal enclosures requiring exact gasketing.
- Optical Sensor Assemblies – Precision bonding of glass components where the dispensed bead can be viewed afterwards.
The Future of High-Performance Dispensing
The DATRON evo 600 represents a major leap forward in speed, accuracy, and integration. Built for the manufacturing challenges of today and tomorrow — from EMI shielding to hydrogen fuel cells — it sets a new standard for automated precision dispensing.
Congratulations to DATRON’s R&D team for this remarkable advancement — a true evolution in dispensing technology.
