Adhesives, Sealants & Industrial Bonding worked example

Squeeze-Out Waste at 99% compression control: a worked example

What does the result look like when compression control reaches 99%? The full calculation is worked below with real intermediate numbers. a process engineer needs to reduce excess squeeze-out without starving the joint

The inputs for this scenario

  • Applied bead volume per bond: 0.42 ml/bond (unchanged)
  • Bond count: 950 bonds (unchanged)
  • Compression control: 99 % (raised for this scenario; the documented default is 90)
  • Retained adhesive yield: 82 % (unchanged)

Working through the calculation

  • Applying the documented formula (Applied adhesive volume = applied bead volume per bond × bond count) to the inputs above produces each figure below.
  • At this operating point the engine returns 324 ml retained for retained adhesive volume, the number this scenario is built around.
  • At this operating point the engine returns 399 ml retained for applied adhesive volume.
  • At this operating point the engine returns 3.99 ml retained for compression variation loss.
  • At this operating point the engine returns 71.1 ml retained for squeeze-out waste volume.

How this compares with the baseline

  • Against the tool's baseline example, where compression control sits at 90% and the headline result is 294 ml retained, this scenario comes in 10% above the baseline at 324 ml retained.
  • A figure at this level is achievable when compression control is genuinely sustained, not just peaked for a shift. It treats compression control and retained yield as flat multipliers; it does not model joint geometry or bead spread, so real squeeze-out can vary with gap and substrate flatness.

Results at a glance

  • Retained adhesive volume: 324 ml retained (headline result)
  • Applied adhesive volume: 399 ml retained
  • Compression variation loss: 3.99 ml retained
  • Squeeze-out waste volume: 71.1 ml retained

Run it with your numbers

  • Every input above is editable in the live Squeeze-Out Waste calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.