The Role of Protective Coatings in Unmanned Aerial Vehicle (UAV) Applications

Unmanned Aerial Vehicles (UAVs) are deployed in some of the harshest environments in the world - from high-altitude, sub-zero conditions to desert heat and salt-laden air. UAVs rely on lightweight but complex structures, advanced sensors, and mission-critical electronic systems that must operate without fail under these stresses. Internal electronics are vulnerable to corrosion, electromagnetic interference and environmental degradation whilst exteriors are at risk of contamination and visual detection.   

Protective coatings serve as a critical barrier on these surfaces, allowing UAVs to maintain high availability, minimise maintenance cycles, and ensure reliability in intelligence, surveillance, reconnaissance (ISR), and critical missions.

MIL-SPEC Standards

MIL-SPEC (Military Specification) refers to standardised requirements established by the U.S. Department of Defense (DoD). These standards ensure that materials, coatings, and processes meet strict reliability and durability thresholds for military use.

For protective coatings, MIL-SPEC standards typically define:

• Environmental durability (temperature extremes, salt fog, humidity, abrasion).
• Chemical resistance (fuels, oils, decontamination agents).
• Corrosion protection.
• Application processes and testing methods.

By adhering to MIL-SPEC, coatings ensure interoperability, consistent quality, and mission-critical reliability.

Protective Coatings for Electronics

Conformal Coatings

Conformal coatings are thin protective films (25–250 μm) applied directly to PCBs and assemblies to prevent corrosion, contamination and electrical faults, even in the most challenging of environments. They are typically based on acrylic, silicone or polyurethane chemistries, and each material is selected to suit specific operational requirements. The value of conformal coatings lies in their ability to deliver robust environmental protection without adding weight or interfering with compact electronic layouts.

Conformal coating examples in UAV Applications:

• Avionics & Flight Control Systems
  The flight control computer, IMUs (Inertial Measurement Units), and autopilot modules in UAVs are mission-critical. Conformal coatings protect these systems from humidity, vibration, and contamination, ensuring stable control throughout long missions.
• Communications Systems
  Secure data links and SATCOM modules are protected by conformal coatings, preventing downtime due to corrosion or condensation during long-endurance flights.
• Naval-Launched UAVs
  For systems which operate from ships, conformal coatings provide vital protection against salt fog and spray, enabling repeated operations in corrosive maritime environments.

Potting and Encapsulation in UAVs

Potting and encapsulation embed electronic components in protective materials, such as silicones, epoxies, or polyurethanes, fully surrounding them to provide vibration damping, mechanical stability, and thermal management.

In UAV applications, silicone foams are often selected over heavier epoxies because they deliver all the benefits of other potting materials while keeping weight to a minimum. They provide vibration damping and shock absorption and have a wide thermal stability range allowing them to perform across high-altitude cold environments, desert climates and shipborne operations. Moisture resistance and chemical tolerance make them particularly suitable for naval or expeditionary platforms where cleaning agents, salt, rain and fuel residues are common.

Examples of Silicone Foam Potting in Military UAVs:

• Flight Control Units (FCUs) and IMUs
  In small UAVs, silicone foam protects flight control boards from vibration, shock, and environmental exposure during transport.
• Sensor Payloads
  High-resolution cameras, infrared sensors, and radar modules often use foam-encapsulated electronics to minimise vibration to improve image stability.
• Radio and SATCOM Modules
  Lightweight foam potting protects communication modules against shock and moisture while maintaining the UAV’s strict weight budget for extended flight endurance.
• Naval UAV Electronics
  Ship-launched UAVs experience high vibration and salt-laden air exposure. Silicone foam potting prevents moisture ingress and corrosion, ensuring the UAV’s avionics and sensors remain reliable after repeated launches.

Conductive Coatings

Conductive coatings are metallic or carbon-loaded coatings applied to housings and enclosures to create electromagnetic interference (EMI) and Radio Frequency Interference (RFI) shielding and protect sensitive systems.

Conductive coatings are thin metallic or carbon-based layers applied to UAV electronic enclosures, housings, or internal surfaces to provide electromagnetic interference (EMI) shielding, electrostatic discharge (ESD) protection, and radio frequency interference (RFI). As UAVs carry multiple high-frequency systems in very close proximity, such as radar, satellites, GPS, datalinks and target acquisition sensors, the likelihood of interference is high unless shielding is integrated into the aircraft design.
 

Conductive Coating Uses in Military UAV:

• Payload housings in ISR Drones: Conductive coatings prevent RF interference between cameras, radar, and communications systems.
• Naval UAVs: Nickel-based coatings protect electronics from EMI while resisting corrosion from salt spray.
• Stealth or EW UAVs: Conductive coatings on composite fuselages reduce electromagnetic emissions, preserving low observability and protecting sensitive onboard electronics.
• Flight control and communication modules: Conductive coatings provide lightweight EMI shielding for small tactical UAVs, protecting critical communication and control units.

Protective Coatings for Paintwork

The Role of CARC Paint on UAVs

CARC (Chemical Agent Resistant Coating) remains a core paint system across military airframes because it delivers corrosion resistance, abrasion durability and chemical protection without affecting aerodynamics or adding unnecessary weight.

Top coats such as NanoVere Super CARC can be applied over paints to extend repaint cycles and enhance durability. They provide abrasion, chemical, and UV resistance, preventing structural degradation from saltwater, UV exposure, and sand impact. Their matte finish also improves low observability and overall camouflage effectiveness.

Military UAV Examples:

• Tactical ISR UAVs: CARC coatings protect lightweight aluminum and composite airframes during field deployment in desert, jungle, or maritime environments.
• Shipboard UAVs: Corrosion resistance is critical when UAVs are launched or recovered in salt-laden maritime conditions.
• High-altitude surveillance drones : UV-resistant CARC coatings help preserve surface integrity and camouflage patterns during extended missions at altitude.