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68 SMT007 MAGAZINE I NOVEMBER 2025 drive off solvents, a process that slowed production and consumed substantial energy. Silicones were the leading choice due to their inherent flexibility and high-temperature tolerance, though their permeabil- ity to water vapor and gases could allow corrosion to develop more quickly than with other chemistries. They also tended to outgas volatile organic com- pounds (VOCs), limiting their use in optoelectronic applications where VOC residues are undesirable. By the 2000s, production speed and automated assembly became primary drivers of coating tech- nology. Single-component, solvent-based coatings simplified application, urethanes added toughness and moisture resistance, and UV curing enabled films to harden within seconds, dramatically reduc- ing energy consumption compared to oven curing. Today, performance demands are higher than ever. Modern conformal coatings must withstand wide temperature fluctuations, moisture, chemicals, and other contaminants, while also preventing elec- trochemical migration (ECM), which is the formation of metal dendrites that can create short circuits, and create a risk that increases with finer-pitch circuitry. At the same time, RoHS, REACH, and VOC regula- tions are driving the need for safer, more sustain- able coating chemistries. Market Pulse: Conformal Coatings in High-stakes Industries Conformal coatings are seeing steady growth in demand. The global market is projected to expand from approximately $1.1 billion in 2024 to more than $2.1 billion 1 by the early 2030s, driven by increased adoption in automotive, aerospace, and defense sec- tors. Acrylics currently hold the largest market share at approximately 47% 2 , while UV-curable coatings, particularly those based on urethane acrylates, rep- resent the fastest-growing category, expanding at a compound annual growth rate (CAGR) of 7%, due to their rapid curing and throughput advantages. Automotive electronics are expected to remain a key growth driver as vehicles increasingly rely on electronics for critical functions, from engine con- trol units (ECUs) to advanced driver assistance sys- tems (ADAS). Conformal coatings protect these electronics from harsh operating conditions, such as extreme temperatures, moisture, salt spray, cor- rosive gases from air pollution, dirt, and dust, while also helping manufacturers meet stringent automo- tive qualification and reliability standards. Similarly, in aerospace and defense, electronics are essential for mission-critical systems, including surveillance, navigation, communication, and mis- sile guidance. Conformal coatings provide a pro- tective barrier against moisture and contaminants, while electrically isolating components from high voltages. This helps prevent electrochemical migra- tion (ECM), a failure mechanism where metal ions move between conductors under the influence of moisture and an electric field. ECM can cause den- dritic growth that leads to short circuits and, in severe cases, catastrophic failures such as fire. Emerging Challenges in Conformal Coating Technology Conformal coatings are available in a wide range