Floating roller peel

Peel resistance is the force required to separate two bonded surfaces through a peeling motion. This force is measured using a tensile test system equipped with a peel fixture. The aim is to determine the average load needed to separate the flexible component from its rigid counterpart.

Unlike fixed-angle methods such as 90-degree or 180-degree peel tests, the floating roller peel test uses a freely rotating roller to maintain a uniform peel angle while guiding the flexible substrate. This setup closely replicates real-world conditions, especially for multilayer laminates or flexible-rigid constructions.

Peel testing is vital in industries where bonding performance affects safety, function, and compliance. Typical applications include:

Each use case demands a controlled, repeatable method to verify adhesive strength, guide material selection, and support quality assurance.

Several international standards define procedures for floating roller peel testing:

• ASTM D3167 – Common in aerospace and defence, this method evaluates the peel resistance of metal-to-metal and metal-to-flexible bonded systems.
• ISO 14676 – Targets structural adhesives on aluminium or rigid substrates, often with environmental conditioning.
• ISO 4578 – A general-purpose standard for testing flexible bonded assemblies in packaging and automotive sectors.
• EN 1464 – A European standard for 90-degree peel testing with a roller fixture, widely used in plastic film testing for electronics and automotive components.

These standards support tailored test design based on materials, usage environment, and regulatory needs.

Carrying out this test requires attention to detail and strict adherence to the procedure. Key steps include:

• Sample preparation – Clean and bond the test materials using consistent pressure and dwell time. Ensure adhesives are fully cured before testing.
• Fixture setup – Secure the sample in a motorised test stand fitted with a floating roller fixture. Clamp the rigid substrate while routing the flexible material over the roller.
• Test execution – Apply a constant crosshead speed to peel the flexible layer away while force data is recorded in real time.
• Data capture – Use test software to generate force-displacement curves, calculate average peel force, and highlight anomalies or weak points.

To ensure accurate and safe testing, the following components are required:

• Motorised test stand with controlled speed (e.g. Mecmesin MultiTest-i, MultiTest-dV, or OmniTest)
• Floating roller fixture (typically 500 N rated and compliant with ISO 10373-1)
• Calibrated loadcells (commonly in the 50 N to 500 N range)
• Data acquisition software such as VectorPro®

Safety considerations:

• Align samples properly to avoid uneven loading
• Use protective guards to shield operators from moving parts
• Check all fixtures, connections, and test parameters before beginning

Peel strength is typically reported in newtons per metre (N/m) or per 25 mm of bond width (N/25mm), depending on the industry standard. From the force-displacement graph, the following characteristics are analysed:

• Mean peel load – The average force sustained during steady-state peeling
• Failure modes – Adhesive (clean separation), cohesive (internal failure), or substrate (material rupture)
• Force profile consistency – A smooth trace suggests consistent adhesion; fluctuations may indicate bonding issues or material variability

Engineers use these outputs to determine compliance with internal specifications or industry regulations.

Floating roller peel testing is employed to verify both material selection and process stability in various high-performance sectors:

• Identification cards – Compliance with ISO 10373-1 ensures multi-layer cards remain bonded during use and environmental exposure.
• Aluminium panels – Structural bonding in transport and aerospace components is validated using ISO 14676.
• Laminated packaging – Peel strength testing to ISO 4578 ensures packaging integrity and food safety compliance.
• Medical assemblies – Bonding reliability is tested under tensile load and moisture for tubing, dressings, and diagnostic components.
• Aerospace composites – Used to assess delamination resistance in multi-layer panels exposed to load cycles and temperature variation.

These examples illustrate the test’s critical role in ensuring both safety and performance in demanding applications.

With decades of experience in materials and force measurement, Mecmesin offers robust and configurable systems that meet industry test standards while adapting to application-specific needs.

Precision testing aligned with industry standards

Mecmesin’s equipment is engineered to comply with ASTM, ISO, and EN testing protocols. Whether used in aerospace, medical, or packaging sectors, these systems deliver repeatable results in accordance with defined methodologies.

Reliable, configurable solutions for adhesive testing

Our systems include:

• Custom roller fixtures to accommodate unique sample geometries
• Programmable test routines to reduce operator error
• Traceable data capture and export functionality for auditing and documentation

These features help engineers generate accurate, consistent test results for every project.

Whether you are designing a new test, specifying a fixture, or interpreting your data, Mecmesin’s technical experts are here to help. We offer application advice and configuration support to ensure your peel testing process meets industry requirements and delivers reliable results.