One of the most effective and popular methods for safeguarding PCBs against moisture, dust, chemicals, and temperature extremes is conformal coating.
But what exactly is conformal coating for electronics, and why is it so important? Today we are going to delve into what it is, and why you should consider protecting your PCBs in this way.
What Is Conformal Coating for electronics?
Conformal coating is a thin, protective, non-conductive layer applied to PCBs and other electronic components. Its main purpose is to protect delicate circuits from harsh environmental conditions without compromising on their performance.
Unlike potting or encapsulation, conformal coatings are designed to “conform” closely to the contours of the PCB and its components, offering protection while maintaining a lightweight and space-efficient form which is hardly detectable on the PCB.
Why Is Conformal Coating for electronics Important?
Modern electronics are often exposed to challenging conditions. At Active-PCB, we manufacture PCBs for OEMs in diverse sectors such as automotive electronics, aerospace equipment, medical devices, as well as consumer gadgets used outdoors.
Conformal coating for electronics provides:
- Moisture and humidity protection: Preventing corrosion and short circuits.
- Chemical resistance: Shielding sensitive components from chemical splashes and airborne contaminants.
- Temperature stability: Helping circuits endure extreme heat or cold.
- Dust and debris protection: Keeping particles from interfering with operation.
- Enhanced reliability and lifespan: Reducing the risk of field failures and maintenance costs.
In short, a properly applied conformal coating can significantly extend the life and improve the reliability and durability of your PCB assemblies.
Types of Conformal Coating Materials
Choosing the right type of conformal coating depends on your application. The main categories include:
- Acrylic Resin which is easy to apply and repair and offers good moisture and humidity resistance.
- Silicone Resin which is ideal for high-temperature environments and flexible applications.
- Urethane Resin which provides excellent chemical resistance and is commonly used in aerospace and automotive industries.
- Epoxy Resin which is tough and highly protective, but can be harder to rework.
- Parylene which is vapor-deposited for uniform coverage and offers superior protection, but at a higher cost.
Each material has its own advantages and trade-offs, so it’s crucial to match the coating type to your product’s specific needs.
Methods of Applying Conformal Coating
There are several ways in which you can apply conformal coatings:
- Brushing: Ideal for small production runs or touch-ups.
- Spraying: Suitable for medium to high-volume production; provides even coverage.
- Dipping: Excellent for full immersion and consistent thickness, ideal for high-volume production.
- Selective Coating: Automated systems apply coating only where needed, minimising waste.
The choice of application method often depends on production scale, complexity of the PCB design, and cost considerations.
What to Consider When Using Conformal Coating for protecting electronics
The surface of the PCB must be properly prepared, as cleanliness is critical for adhesion and performance. The PCB must be masked so areas like connectors and sockets are kept free from coating.
The coating needs to be even and of the right thickness. Too thick can cause stress; too thin may not protect sufficiently.
Proper curing of the coating ensures long-term performance; methods vary depending on material (e.g., air-drying, heat curing, UV curing).
Common Industries That Rely on Conformal Coating for their electronics
At Active-PCB, we have customers operating in diverse industries. Some of those that we serve, who rey on conformal coating to protect their electronics are:
- Automotive: Protects electronic control units (ECUs) from heat and fluids.
- Aerospace and Defense: Ensures reliability under extreme pressure and temperature.
- Medical Devices: Safeguards sensitive equipment from bodily fluids and sterilisation processes.
- Consumer Electronics: Extends the life of wearable and outdoor devices.
Conformal coating is an essential part of PCB manufacturing and design for any application that demands durability and reliability. By carefully selecting the right coating material and application method, and following best practices, manufacturers can significantly improve product quality and performance.
At Active-PCB Solutions, we understand the importance of PCB protection. Our expert team offers precision conformal coating services designed to meet the toughest industry standards.
Get in touch with us today to learn how we can help protect your next project!
