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Return To ShopSurface Energy Chart by Material
Surface Energy Chart by Material
Dyne Levels for Plastics, Metals, Films, Foils and Coextruded Structures
This reference chart is used by engineers and technicians to evaluate adhesion, wetting, and printability across different materials.
Surface Energy Chart
| Category | Material | Typical Dyne Level (dynes/cm) | Condition | Needs Treatment? | Recommended Method | Notes |
|---|---|---|---|---|---|---|
| Metals & Glass | Glass | 60–72 | Clean surface | No | Cotton applicator | Helps detect contamination |
| Aluminum | 40–60 | Oxidized surface | Sometimes | Cotton applicator | Sensitive to oils | |
| Steel | 42–55 | Industrial surface | Sometimes | Cotton applicator | Cleanliness is critical | |
| Stainless Steel | 40–50 | Passive layer | Sometimes | Cotton applicator | May contain oils | |
| Plastics (High Energy) | PET | 42–46 | Standard | Rarely | Dyne pens | Stable surface |
| Nylon (PA) | 46–50 | Standard | No | Dyne pens | High adhesion | |
| PVC | 38–42 | Flexible/Rigid | Sometimes | Dyne pens | Depends on formulation | |
| Plastics (Low Energy) | Polypropylene (PP) | 29–31 | Untreated | Yes | Dyne pens | Requires corona treatment |
| Polyethylene (PE) | 30–33 | Untreated | Yes | Dyne pens | Difficult to print | |
| HDPE | 30–32 | Untreated | Yes | Dyne pens | Common in packaging | |
| LDPE | 30–33 | Untreated | Yes | Dyne pens | Used in films | |
| PTFE (Teflon) | 18–20 | Inert | Very Difficult | Dyne test fluids | Non-stick surface | |
| Silicone | 20–24 | Elastomer | Very Difficult | Dyne test fluids | Very low surface energy | |
| Films & Packaging | BOPP Film | 30–32 | Untreated | Yes | Dyne pens | Labels and packaging |
| BOPP (treated) | 38–42 | Corona treated | No | Dyne pens | Ready for printing | |
| PET Film | 42–46 | Treated | No | Dyne pens | Stable | |
| PE Film | 30–33 | Untreated | Yes | Dyne pens | Requires treatment | |
| Metallized Film | 38–44 | Coated | Sometimes | Dyne pens | Depends on coating | |
| Foil (Stamping) | Hot Stamping Foil | 34–38 | Fresh transfer | Yes | Dyne pens | Low adhesion surface |
| Hot Foil (aged) | 32–36 | After storage | Yes | Dyne pens | Surface energy may decrease | |
| Cold Foil | 36–42 | UV adhesive | Sometimes | Dyne pens | Better wetting than hot foil | |
| Cold Foil (cured) | 34–40 | Fully cured | Sometimes | Dyne pens | Depends on UV system | |
| Foil (with overprint varnish) | 38–44 | Coated | No | Dyne pens | Improved adhesion | |
| Coextruded Films | PE Coextruded (untreated) | 30–33 | Fresh | Yes | Dyne pens | Similar to standard PE |
| PE Coextruded (treated) | 38–42 | Corona treated | No | Dyne pens | Printable surface | |
| PE Coextruded (aged) | 32–38 | Migration | Often | Dyne pens | Surface energy loss over time | |
| PE Coex (with slip additives) | 30–36 | Variable | Yes | Dyne pens | Unstable surface | |
| PE Coex (EVA surface) | 36–40 | Modified layer | Sometimes | Dyne pens | Improved adhesion | |
| PE Coex (PA/Nylon surface) | 42–50 | High-energy layer | No | Dyne pens | Excellent adhesion | |
| Multilayer Film (EVOH core) | 30–42 | Depends on outer layer | Yes/No | Dyne pens | Outer layer defines behavior | |
| Coatings & Surfaces | Acrylic Coating | 38–42 | Dry | No | Dyne pens | Good adhesion |
| UV Coating | 36–42 | Cured | Sometimes | Dyne pens | May require treatment | |
| Varnish (OPV) | 38–44 | Overprint | No | Dyne pens | Stable surface | |
| Ink Film (dry) | 36–42 | Printed | Sometimes | Dyne pens | Depends on ink system |
Surface Energy Variability
Surface energy values shown represent typical industrial ranges under controlled conditions. Actual values may vary due to storage, aging, contamination, and additive migration.
Values shown are representative of materials within approximately 3 to 6 months of manufacture, stored under proper conditions.
New vs Aged Material – Surface Energy Example
| Material | Condition | Typical Dyne Level | Result |
|---|---|---|---|
| Polypropylene (PP) | Fresh (recently treated) | 40 dynes | Good adhesion |
| Polypropylene (PP) | Aged (after storage) | 34 dynes | Poor adhesion |
| Coextruded Film | Fresh production | 40 dynes | Printable |
| Coextruded Film | Aged / migration | 32–36 dynes | Inconsistent adhesion |
| Hot Stamping Foil | Fresh transfer | 36–38 dynes | Marginal adhesion |
| Hot Stamping Foil | After storage | 32–34 dynes | Likely failure |
Surface Energy Life Cycle
Production / Treatment → Proper Storage → Aging / Additive Migration → Lower Surface Energy → Adhesion Failure
Surface energy is not always permanent. Over time, materials may lose surface energy due to additive migration, contamination, handling, and environmental exposure.
Even if a material initially meets the required dyne level, it may fall below acceptable levels after storage.
Recommendation: Always verify surface energy before printing, coating, or laminating using dyne test pens or test fluids.
Troubleshooting Guide
| Problem | Cause | Solution |
|---|---|---|
| Ink not sticking | Low surface energy | Increase dyne level |
| Adhesion fails over time | Migration | Re-test |
| Foil issues | Low adhesion | Use primer |
| Inconsistent results | Coex structure | Identify surface |
Key Rule
👉 Surface energy must be 8–10 dynes higher than ink surface tension
Measurement Recommendation
👉 Always verify using:
- Dyne Test Pens
- Dyne Test Fluids
