Penguin Foam UV Whitepaper

Showcased alongside contributions from Excelitas, Enercon and Inpro Technologies

Overview

Sunstar Engineering introduces the latest innovation in its Penguin Foam product family: Penguin Foam UV, a robotically applied, UV-cured Formed in Place Gasket (FIPG) material designed for high-speed, high-precision sealing. This next-generation solution cures in seconds under LED light and addresses space constraints, energy demands, and the complexity of messy, time-intensive 2K or moisturecured systems. Showcased alongside contributions from leading technology providers, including Excelitas® (LED curing systems), Enercon®️ (plasma pretreatment), and INPRO Technologies (automation integration), Penguin Foam UV sets a new benchmark for productivity, sustainability, and repeatable quality in industrial sealing.

Introduction

As manufacturers seek faster cycle times, cleaner processes, and more sustainable operations, traditional FIPG materials, especially those requiring multi-component mixing or excessive cure times, can present significant challenges. Penguin Foam UV provides a solution to these limitations with a onecomponent, UV-curable formulation that integrates seamlessly into robotic production lines. This white paper explores the technical capabilities of Penguin Foam UV, the advantages of Sunstar’s proprietary Foamply dispensing system, and the value of strategic collaborations that support turnkey implementation across industries.

Penguin Foam UV: Material Innovation

UV Curable 395 nm LED light source
Cure Time ~1 second
Curing Depth Up to 5 mm (dependent on adherend color)
Compression Set 15% @ 80 °C × 24H × 50% compression
One-Component System Simplifies handling and maintenance
Stable Foaming Achieved via mechanical foaming
Aspect Ratio (Height: Width) 1:2 for optimal sealing geometry
Foaming Ratio Foamed up to 4.3 times
Hardness 18 at Asker-C at 4.0 Times

Foamply: Dispensing Precision

Proprietary dispensing system from Sunstar Engineering
Dispense head compatible with EOA robotic mounting
Enables consistent bead geometry and repeatable application

foamply dispensing precision

Value Pillars

Fast Curing

  • Rapid LED curing
  • Inline processing with minimal dwell time
  • Enhanced adhesion with plasma pretreatment
  • Replaces slow moisture cure materials

OmniCure AC8 Series Product Photo

Sustainability

  • Reduces energy consumption
  • Space-saving footprint for lean manufacturing environments
  • Lower CO₂ emissions and environmental impact
  • One-component formulation minimizes material waste

Affordability

  • Foam ratio up to 4:1 significantly reduces material usage
  • Reduced operational costs from lower energy usage and simplified equipment
  • Minimal maintenance with single-component handling
  • Long-term ROI through increased throughput and reduced scrap

Repeatability

  • Robotic application ensures uniform bead placement
  • Stable foaming quality for consistent sealing performance
  • Reliable curing depth across varied substrates
  • Eliminates variability in manual or multi-step processes

Restorability

  • Designed for minimal waste and clean processing
  • Supports circular manufacturing goals
  • Potential for recycling or reprocessing in select applications

Ideal Applications

Penguin Foam UV and Foamply are ideal for:

  • Automotive sealing (doors, hoods, battery packs)
  • Electronics enclosures
  • HVAC and appliance gaskets
  • Custom industrial sealing solutions

Performance Validation

  • Lab-tested for mechanical durability and thermal stability
  • Field trials demonstrate superior cycle time and seal integrity
  • Comparative analysis shows significant gains over traditional FIPG systems
  • Repeatable results across varied substrates and geometries

Collaboration

Penguin Foam UV represents a bold step forward in sealing technology—combining rapid UV curing, robotic precision, and sustainable design. Showcased alongside contributions from Excelitas, Enercon, and INPRO Technologies, Sunstar Engineering delivers a complete solution that empowers manufacturers to meet today’s demands and tomorrow’s challenges with confidence.

Sunstar provides custom adhesive solutions for electronics, energy, aerospace and beyond, supported by extensive know-how and expertise.

Excelitas provides a diverse range of UV curing systems suitable for both spot and area UV curing applications. With a comprehensive selection of UV lamp and UV LED technologies, our brands—including OmniCure®, Noblelight®, Fusion UV®, and Phoseon®—offer maximum flexibility to meet the specific curing requirements of adhesives, coatings, and inks.

Enercon’s Blown-ion™ plasma surface treaters are used to prepare the surfaces for adhesion. The plasma treaters bombard surfaces with an intense, high-speed discharge of ions to clean, etch and functionalize surfaces to increase surface energy and wettability. The plasma treaters are integrated with robotics to follow a precise treatment path and are available in both single port and Multiport™ versions depending on the width of the surface being treated and the speed of the operation.

INPRO Technologies integrates automated and robotic solutions, custom UV curing systems, plasma treatment system, and static control systems. They have over thirty years of experience in providing process solutions to a broad customer base

Whitepaper May 2026 |Author: Sunstar Engineering