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Adhesive bonding has become increasingly popular in the manufacturing industry due to its many advantages. However, the need to completely fill the joint gap with adhesive for optimum force transfer remains a significant challenge. To ensure full gap filling and therefore joint integrity, safety critical applications often require the adhesive to flow beyond the bonded edges. Due to inadequate design of this process, the adhesive volume that escapes is often more than 30–50% of the adhesive volume. This current practice represents a suboptimal way of proceeding, which the current paper may mitigate.