Plastic Coating Applications
Conformal Coating
Precision protective coatings for printed circuit boards and electronic assemblies.
As electronic devices continue to become smaller, faster, and more powerful, protecting sensitive electronic assemblies from moisture, corrosion, chemicals, dust, and harsh operating environments has become essential to long-term reliability.
Secondary Solutions specializes in the precision application of spray-applied conformal coatings that protect printed circuit boards (PCBs) and electronic assemblies without affecting their electrical performance. These thin protective coatings create a durable environmental barrier that extends product life while improving reliability in demanding applications.
Since 1996, Secondary Solutions has successfully processed well over 100,000 conformal coating operations, partnering with OEMs, PCB assemblers, contract manufacturers, and product developers serving the medical, military, industrial, agricultural, telecommunications, and commercial electronics industries.
Whether your project requires prototype quantities or high-volume production, our experienced technicians deliver consistent, repeatable coating applications supported by documented manufacturing processes and rigorous inspection procedures.
What is Conformal Coating?
Conformal coating is a thin polymeric film applied over printed circuit boards and electronic assemblies to protect sensitive components from moisture, humidity, corrosion, salt spray, dust, chemicals, mold, fungus, condensation, thermal cycling, and electrical leakage while allowing the electronics to function normally.
Our Conformal Coating Process
Every project is built around repeatable, documented manufacturing processes. Our typical process includes:
- Incoming inspection
- Surface preparation and cleaning verification
- Precision masking of connectors, switches, test points, and keep-out areas
- HVLP spray application
- Controlled curing
- UV inspection
- Visual inspection
- Touch-up (as required)
- Demasking
- Final inspection
Conformal Coating Materials
Secondary Solutions applies a range of coating chemistries depending on the environmental and performance requirements of each application:
- Acrylic
- Silicone
- Polyurethane
- Epoxy
- UV-curable
- Customer-specified coating systems
SSI routinely processes customer-approved materials from leading suppliers and helps customers select the most appropriate chemistry for the application.
Precision Masking
Many assemblies contain connectors, edge contacts, test points, grounding locations, heat sinks, or mechanical interfaces that must remain coating-free.
SSI develops repeatable masking processes for prototypes through high-volume production. Low-volume work is often hand-masked for flexibility, while production programs benefit from custom masking fixtures that reduce labor and improve consistency.
Industries We Support
Why Customers Choose SSI
- Fast response times
- Production flexibility
- Competitive lead times
- Customer-specific masking processes
- Consistent coating quality
- Experienced technicians
- Responsive engineering support
- Scalable production
- Personalized service
Quality
- Documented work instructions
- UV inspection
- Visual inspection
- Lot traceability
- Process documentation
- First Article Inspection (FAI)
- Customer-specific inspection criteria
- Coating coverage verification
- Production records
Prototype Through Production
SSI supports your program at every stage, including:
- Prototype development
- Engineering samples
- Product validation
- Pilot production
- Process qualification
- Production ramp-up
- Full production manufacturing
- Engineering change implementation
Production Experience
Since 1996, SSI has processed well over one million coating application units, including more than 100,000 conformal coating operations. Our coating applicators have individual, hands-on application experience of 25,000–30,000 hours and 28,000–35,000 hours. Because these numbers are only what we have tracked since we started keeping records, actual production experience is even higher.
Frequently Asked Questions
What is the purpose of conformal coating?
To protect electronics from environmental contaminants such as moisture, dust, chemicals, and corrosion while allowing the assembly to function normally.
What coating materials do you offer?
Acrylic, silicone, polyurethane, epoxy, UV-curable, and customer-specified coating systems.
Do you support prototype quantities?
Yes. We support prototypes through full production manufacturing.
Can SSI apply customer-supplied materials?
Yes. We routinely process customer-approved materials from leading suppliers.
How do you inspect coated assemblies?
Through UV inspection, visual verification, and customer-specific quality checks.
Let's Discuss Your Project
If your product requires reliable environmental protection for printed circuit boards or electronic assemblies, Secondary Solutions can help.
Contact SSI to discuss your conformal coating requirements, request a quotation, or speak with one of our manufacturing specialists.
More in Plastic Coating Applications
EMI / RFI Spray Shielding
Conductive spray shielding to suppress electromagnetic and radio-frequency interference.
Plastic Coating Applications
Functional and decorative coatings applied with controlled, consistent results.
UV Applications
UV-cured coatings and processes for fast, durable, high-performance finishes.
PCB Staking & Encapsulation
Liquid material such as silicone is dispensed beneath tall, surface-mounted components to anchor and protect them — a complement to conformal coating protection.