Issue link: https://iconnect007.uberflip.com/i/1540984
66 SMT007 MAGAZINE I NOVEMBER 2025 A RT I C L E by S a s k i a H o g a n , M a c D e r m i d A l p h a E l e ct ro n i c s S o l u t i o n s H igh-performance electronics must endure every- thing from rain, dust, and oil to extreme tempera- tures, shock, and vibration. These reliability demands now share the stage with other priorities such as size reduction, lightweighting, and environmental sus- tainability. Combined with constant pressure to cut costs, accelerate production, and boost manufac- turing efficiency, material suppliers are racing to develop advanced conformal coatings that deliver it all: compatibility with finer-pitch circuitry, durabil- ity, eco-friendliness, and manufacturing efficiency. The history of protective coatings spans more than a century, beginning with early epoxies and advancing to sophisticated chemistries engineered to meet evolving reliability and manufacturing requirements. Building on this foundation, Electro- lube® UVFlex™. UVFlex is set to represent the next phase in coating innovation. It combines rapid cur- ing and robust mechanical performance with envi- ronmental responsibility, delivering exceptional surface insulation resistance (SIR), thermal cycling durability, and component coverage while remain- ing solvent-free, PFAS-free, and 30% bio-based. Advances in Conformal Coating Materials and Methods Comparative testing demonstrates that UVFlex surpasses traditional acrylic, silicone, and urethane coatings on finer-pitch circuitry exposed to severe environmental stress, including thermal cycling from -40 to +125°C, 85°C/85% RH aging, and con- densation exposure. The Road to Modern Conformal Coatings Protecting circuits with a polymeric barrier is not a new concept: Thomas Edison experimented with phenolic insulators back in the 1800s. However, the real breakthroughs came in the 1960s, when NASA engineers recognized the need to protect mission- critical electronics from moisture and contaminants. At that time, PCBs were either left bare or cov- ered with thick, two-component epoxies, which were prone to cracking under large temperature swings. Fractured solder joints were common, and repairs were painfully difficult, requiring hardened epoxy to be chipped away. By the 1980s, conformal coatings were standard in high-reliability military and aerospace applications. At that time, most coatings required oven curing to