Top 5 Reasons for using Conformal Coatings on PCBs
How conformal coating extends the lifespan of electronic products
Electronics are everywhere. As our dependence on them grows, so too does the importance of their reliability and durability. Whether these devices are exposed to harsh industrial environments or the unpredictable outdoors, they need protection to perform consistently over time. That’s where conformal coating comes in.
Conformal coatings are thin, protective layers applied to printed circuit boards (PCBs) and electronic components to shield them from the environment. Conformal coating plays a critical role in extending the overall lifespan of electronic products.
1. Protection against moisture and humidity
One of the most common enemies of electronics is moisture. Humidity and condensation can severely damage a circuit board. Moisture creates pathways for current to flow in unintended ways, leading to short circuits, corrosion, and electrical failure.
Conformal coatings act as a moisture-resistant shield, forming a uniform layer over the PCB that inhibits water ingress. Whether you're deploying electronics in tropical climates, automotive applications where temperature fluctuations cause condensation, or marine environments with salt spray, conformal coatings prevent moisture from compromising circuit reliability.
Whilst conformal coatings do not provide an IP level of waterproofing, they work well when the moisture level is caused by condensation and humidity. If the electronic is designed to be submerged, other protective coatings such as encapsulation or nano coatings would be a better option.
2. Defence against dust, dirt, and debris
Dust and debris might seem harmless on the surface, but over time, they can cause unexpected issues in electronic assemblies. Particulates can settle between conductors, creating conductive paths or insulating layers that impact the performance of the board. In industrial environments, dirt can combine with oil, humidity, or other contaminants to form corrosive compounds that degrade components.
Conformal coatings seal off the circuit board, forming a barrier to contaminants. This is especially useful in dusty factories, agricultural equipment, or outdoor applications.
3. Chemical and corrosion resistance
In many industries, electronics are regularly exposed to chemicals, solvents, and aggressive cleaning agents. For instance, automotive electronics are subjected to oils, fuels, road salts, and engine fluids. Similarly, industrial systems might be exposed to vapours from manufacturing processes or chemical cleaning agents.
Over time, these substances can corrode and degrade components. Conformal coatings provide robust protection against a wide range of chemicals. By forming a barrier, the coating insulates sensitive components from these harmful agents, helping electronics survive longer even in harsh environments. This chemical resistance not only extends the life of the device but also reduces the risk of unexpected downtime and costly repairs.
4. Thermal extremes protection
Electronics often endure temperature fluctuations particularly in aerospace, automotive, and industrial settings. These physical stressors can cause materials to expand and contract, leading to cracked solder joints, broken components, or delamination of the PCB itself.
Certain conformal coatings can withstand and protect against these thermal stresses. The coating can act as a thermal insulator, helping to manage hot spots or shield components from extreme temperature swings. This makes it possible for electronics to perform reliably across a wider operating temperature range, extending their usable life in unpredictable or demanding conditions.
5. Vibration and mechanical stress mitigation
Many PCBs must endure vibration and physical stress – whether that be their intended design or they just need to survive after being dropped or knocked. Conformal coatings give a degree of additional mechanical strength against such vibrations.
By distributing the stress more evenly across the board, the coating helps reduce the likelihood of physical damage. For when protection is required against extreme vibrations, a RTV silicone can be used in addition to conformal coating to give an extra shock absorbing element.
Conformal coating might seem like a small detail in the manufacturing process, but it has a huge impact on the reliability, performance, and lifespan of electronic products. Whether it's shielding against moisture, blocking out dust and debris, resisting chemicals, or absorbing mechanical and heat stress, conformal coatings are essential to building robust, long-lasting electronics.
If you're designing or manufacturing electronics that need to survive the real world, conformal coating should be on your radar. Need help deciding which type of coating suits your application? Or curious about which coating technique will optimise protection and production costs? Talk to us - we’d be happy to help.