What Is The Best Waterproof Coating For Electronics

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What is the best waterproof coating for electronics?


Introduction

Why should

the PCBA brush conformal coating

Electronic devices and components exposed to moisture, humidity,

condensation, or direct water contact are susceptible to corrosion,

electrical leakage, and reliability failures. Protecting circuits and

assemblies with waterproof coatings and encapsulants is critical for

applications where electronics will encounter wet environments.

But with the wide variety of waterproofing materials available, how do

engineers choose the optimal protective coating? Key factors to consider

include the application requirements, coating properties, material

compatibility, application methods, and qualification testing.

This article provides a detailed overview of waterproof coating

technologies for electronics along with guidance on selection criteria and

best practices. With an understanding of the different coating options and

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their capabilities, designers can make informed decisions on

implementing the best waterproofing protection regimes for their

products.

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Waterproofing Requirements

The first step is identifying the specific waterproofing needs based on the

application and operating environment:

 Liquid exposure: Will the electronics encounter direct water

submersion, pressurized sprays, splashing, or only incidental

moisture?

 Duration: Is water exposure occasional and temporary, or

continuous for extended periods?

 Chemical compatibility: Does the coating need to withstand specific

fluids like saltwater, acids, or hydrocarbon oils?

 Temperature range: What are the temperature limits for material

performance?

 UV and abrasion: Will the coating experience wear, UV radiation, or

chemical degradation factors?

 Repairability: Does the application require repairable/reworkable

waterproofing?

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 Electrical properties: Are dielectric strength, surface insulation, and

other electrical properties important?

 Application method: Can the coating be cast, brushed, sprayed,

or dip applied?

With an understanding of the environmental stresses and product

requirements, the waterproof coating type can be selected.

Coating Properties

There are a wide variety of waterproof electronics coatings that seal

components and PCB assemblies from moisture ingress and corrosion.

Here are key performance properties to consider when comparing

options:

Solvent and Curing

 Solvent-cured: Use evaporation and chemical reaction of solvents to

harden coating after application.

 UV-cured: Cure rapidly upon exposure to UV irradiation. Minimal

solvents.

 Heat-cured: Apply as liquid or paste, then cure with oven baking

process.

 Room temperature cure: Cure at room temperature using catalytic

chemical reactions.

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Permeability

 Impermeable: Cannot be penetrated by water molecules. Provides

highest reliability.

 Conformal: Thin coats follow PCB topology but allow slow moisture

diffusion. Reliance on isolation layers.

 Permeable: Absorbs moisture but provides temporary water

resistance. Used with venting strategies.

Thermal and Mechanical

 Operating temperature: Upper limit before coating degrades,

typically 120°C to 230°C.

 Coefficient of thermal expansion (CTE): Match to substrate to

reduce stress and delamination.

 Hardness and mar resistance: Resists abrasion, nicks, cuts. Shore D

65-85 typical range.

 Adhesion: Bond strength to substrate, measured in psi. 500 psi

minimum recommended.

 Flexibility: Ability to bend without cracking. Important for flex

PCB applications.

Electrical

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 Dielectric strength: Voltage withstand rating, reported in V/mil.

500-1500 V/mil target.

 Dielectric constant: Impacts impedance and capacitance for coating

thickness. 2.5-4.0 typical.

 Insulation resistance: Resistivity in Ω or TΩ reflecting conduction

losses.

 Dissipation factor: Dielectric losses from polar molecules under AC

excitation. Lower is better.

Material Types

Some of the main classes of waterproof electronics coatings include:

Acrylics

 Simple, low cost resin coatings

 Fast room temperature cure

 Medium hardness and flexibility

 Moderate temperature rating

 Easy application by dip, spray, or brush

Urethanes

 Tough, abrasion resistant coatings

 Single or two part chemistries

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 Temperature, UV, and chemical resistant

 Excellent adhesion and flexibility

 Can be rigid or rubber-like

Silicones

 Inorganic silicone polymers

 Very broad operating temperature range

 Excellent moisture and UV resistance

 Conformal thin film coats with high elasticity

 Moderate dielectric strength

Epoxies

 Strong adhesion and environmental resistance

 Range of flexible to rigid coatings

 Excellent dielectric properties

 Withstand rugged use conditions

 Room temperature or heat cure options

Parylenes

 Unique vapor deposited polymer films

 Extremely conformal thin coats

 Superb dielectric strength and moisture barrier

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 Expensive process with high capital costs

This covers some of the major coating material types. Comparing options

within each category based on specific needs is key.

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Waterproof Coating Methods

PCBA Conformal

Coating

There are several approaches to protect electronics from water exposure:

Conformal Coatings

Conformal coatings provide thin layers that follow the contours of

components and PCBs. Common coating methods include:

 Spray: Automated selective spray systems or manual aerosol cans

deposit controlled coats.

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 Brush: Manual application allows selective brushing but can leave

voids.

 Dip: Full immersion followed by controlled withdrawal leaves a thin

uniform coat.

 Vapor deposition: Parylene coatings are applied as gaseous

monomers that polymerize onto surfaces.

Typical conformal coat thickness ranges from 25-75 μm. While offering

some water resistance, conformal coats rely on the PCB soldermask layer

as the primary water barrier.

Conformal epoxy coating applied over PCB assembly

Potting Compounds

Potting fills the entire electronics enclosure with a thick protective resin

encapsulant:

 Casting: Liquid resins poured or injected then cured to harden

 Compression: Potting compounds compressed around components

 Impregnation: Vacuum draws resin into complex assemblies

Typical potting thickness from 2mm up to 25mm. Provides excellent water

resistance but limits access for rework.

Electronic device encapsulated with thick potting material

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Sealed Housing

For the most critical applications, electronics can be entirely sealed within

a watertight enclosure:

 Plastic or metallic housings: O-ring or gasket sealed, often with

added potting material

 Hermetic housings: Use welded or soldered metal enclosure with

added desiccant to maintain <1% internal humidity

This provides protection for continual or extreme submersion but with

higher cost. Regular seal inspection and maintenance may be required.

Accessing internals becomes difficult.

Electronics assembly sealed within a hermetic metal enclosure

Selection Criteria

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Choosing an optimal waterproofing approach requires tradeoffs across

many factors:

Exposure Level

 For temporary moisture or rain exposure, conformal coating

provides adequate protection.

 Applications with prolonged submersion will require potting

material or a fully sealed housing.

Mechanical Properties

 Conformal coats maintain flexibility for dynamic components and

flex PCBs.

 Brittle potting compounds require fixed rigid support.

Thermal Properties

 Conformal coats allow convection and air cooling of electronics.

 Thick potting compounds act as a thermal insulator requiring other

cooling methods.

Electrical Performance

 Conformal coats have limited dielectric strength and higher

capacitance.

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 Potting better withstands voltage exposures but may require

insulation displacement.

Repairability

 Conformal coats can be selectively reapplied after rework.

 Encapsulants prevent access to components without full removal.

Weight

 Thin conformal coats minimize weight impact.

 Dense potting resins increase weight, which may be prohibitive.

Cost

 Adding conformal coat has lower material cost but process impact.

 Potting resins and sealed housings have higher material expense.

With an understanding of these considerations against application

requirements, the optimal coating method can be selected.

Qualification Testing

Verifying a chosen waterproof coating will meet product reliability

requirements under real-world conditions is critical. Typical qualification

tests include:

Coating Cure Validation

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 Measure shore hardness to confirm full cure

 Exposure to excess working time to check for tackiness or soft spots

 Thermal shock or rapid temperature ramping

 Sample cross-sectioning to validate uniform cure

Adhesion Testing

 ASTM D3359 crosshatch tape tests

 Initial adhesion and after thermal cycling

 Pull-off adhesion tests before and after liquid exposure

Electrical Properties

 Dielectric breakdown voltage

 Insulation resistance

 Combing resistance under bias voltage

 Capacitance changes from coating

Fluid Exposure

 Salt spray fog per ASTM B117 standard

 Thermal shock and moisture cycling

 Water submersion and chemical compatibility

 Flammability testing after exposure

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The specific test conditions and performance requirements will depend on

the product specifications and reliability models. But following a thorough

qualification protocol matched to application conditions ensures the

coating will function as needed.

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Application Best Practices

Conformal Coating

Properly applying waterproof electronics coatings is vital for achieving

protection. Key guidelines include:

Surface Preparation

 Ensure PCBs are clean and dry before coating

 Remove contaminants like rosin residue

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 Lightly abrade glossy soldermask

 Apply adhesion promoter if needed

Process Controls

 Maintain ambient conditions like temperature and humidity

 Use clean tools dedicated for coating

 Have proper PPE and ventilation

 Carefully measure mixing ratios for multi-part coats

Coverage Assurance

 Mask connectors or test points to avoid coating

 Ensure full coverage on all components and PCB edges

 Apply multiple coats for thick buildup if needed

Curing

 Gradually ramp oven temperature for heat cure coatings

 For UV cures, match wavelength to coating reaction

 Validate full cure with testing before proceeding

Coating Repair

 Spot repair thin coats rather than full removal

 Have contingency plan for thicker encapsulant removal

 Plan accessibility provisions into design


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Adhering to structured processes ensures the chosen coating consistently

provides reliable waterproofing protection.

Summary

Protecting electronic products from water exposure threats requires

selecting the optimal protective coating for the specific application

conditions and requirements. Key takeaways include:

 Carefully consider liquid exposure levels, coatings properties,

material compatibility, reparability needs, and other criteria.

 Determine if thin conformal coating, thick potting encapsulant, or

sealed housing provides the right level of protection.

 Match candidate coatings to physical, electrical, and environmental

reliability requirements.

 Qualify top coating options with standards-based testing tailored to

end use stresses.

 Follow robust process controls and best practices during coating

application.

By understanding the wide range of waterproofing options and how to

select the best fit, engineers can implement effective water protection

regimes for electronics operating in wet environments.

FQA

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What are some typical applications requiring waterproof coatings on

electronics?

Typical applications are outdoor equipment, marine electronics,

automotive systems, appliances, IoT sensors, medical devices, industrial

controls in washdown environments, and consumer electronics where

liquid resistance is valued.

When is it preferable to use a thick potting encapsulant versus a thin conformal

coating?

Potting makes sense for full submersion applications where conformal

coats would allow moisture diffusion over time. Use thin coats when

flexibility, repairability, weight impact, or thermal dissipation are critical.

What electrical factors should be considered when selecting a waterproof

coating?

Key electrical factors are dielectric breakdown voltage rating, insulation

resistance, dielectric constant, dissipation factor, and surface resistivity.

Match coating properties to PCB layout clearances and any high voltage

exposures.

How is a waterproof coating qualified for use in a particular product?

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Typical qualification steps are evaluating coating cure consistency,

verifying adhesion strength before and after reliability testing, measuring

electrical properties, and exposing samples to simulated end use

environments like salt fog or liquid submersion.

What are some best practice guidelines for applying waterproof electronics

coatings reliably?

Best practices include proper surface preparation, process controls on

ambient conditions and mixing, full coverage verification, controlled

ramps for heat cures, validating full cure prior to further assembly, and

having repair contingencies planned for.

Related Posts:

1. How to Waterproof Your PCB ?

2. What is Conformal Coating on PCBs?

3. What is EMI Coating?

4. Reasons why you should consider RFI Coating

https://www.raypcb.com/why-should-the-pcba-brush-3-resisting-lacquer/

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