Surface Energy Chart by Material (Dyne Levels for Plastics, Films, Metals and Packaging)
This reference chart is used by engineers and technicians to evaluate adhesion, wetting, and printability across different materials.
Surface energy values vary depending on material type, treatment level, storage conditions, and aging.
For this reason, charts should be used as a practical reference only, and actual production decisions should always be confirmed on the real substrate using dyne test pens or test fluids.
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 (if recently treated) | 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 |
Need to verify surface energy on your actual material?
While reference charts provide useful guidance, production conditions can vary.
Using Accu Dyne Test Pens allows you to confirm whether your substrate is ready for printing, coating, or laminating.
Surface Energy Variability
Surface energy values shown represent typical industrial ranges under controlled conditions. Actual values may vary significantly depending on storage, aging, contamination, handling, and additive migration.
Values presented are representative of materials within approximately 3 to 6 months of manufacture, stored under proper conditions.
However, in real production environments, surface energy is not static. It can decrease over time, especially in materials such as polyethylene (PE), polypropylene (PP), and coextruded films.
This is especially critical for materials such as polyethylene (PE) and polypropylene (PP), where surface energy can decay over time.
In these cases, many converters use 30–72 dyne test pens to verify treatment levels before printing or laminating.
For this reason, reference charts should never replace actual measurement. Surface energy should always be verified on the substrate using dyne test pens or test fluids before printing, coating, or laminating.
| 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 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.
This is why verification with dyne test pens or test fluids is essential before any critical printing or converting process.
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 using dyne test pens |
| 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
Surface energy should always be verified on the actual substrate prior to printing, coating, or laminating.
Recommended tools:
- Dyne Test Pens (for fast, on-site verification)
- Dyne Test Fluids (for more precise or very low surface energy materials such as PTFE and silicone)
Selecting the correct measurement method depends on the material type, surface condition, and required accuracy.
Frequently Asked Questions
What is surface energy?
Surface energy is a measure of how well a liquid can wet a surface, which directly affects adhesion.
What dyne level is required for printing?
👉 As a general rule, surface energy should be 8–10 dynes higher than the surface tension of the ink or coating.
Why does surface energy decrease over time?
Due to additive migration, contamination, and environmental exposure.
How do you measure surface energy?
Using dyne test pens or dyne test fluids.
Typical Dyne Levels for Common Materials in Printing & Packaging
– Polyethylene (PE): 31–33 dynes/cm
– Polypropylene (PP): 29–31 dynes/cm
– PET (Polyester): 43–46 dynes/cm
– PVC: 39–41 dynes/cm
– Aluminum Foil: 45+ dynes/cm👉 Measure accurately using professional dyne test pens.
A surface energy chart is a useful starting point, but real-world performance depends on actual conditions.
Explore our dyne test pens and surface energy testing tools to ensure reliable adhesion in your production process.
