Plastic Coating Applications
EMI / RFI Spray Shielding
Precision spray-applied conductive coatings for plastic enclosures and electronic assemblies.
Electronic devices continue to become smaller, faster, and more powerful. As operating frequencies increase, protecting sensitive electronics from electromagnetic interference (EMI) and radio frequency interference (RFI) has become essential to product performance, regulatory compliance, and long-term reliability.
Secondary Solutions specializes in the precision application of spray-applied conductive coatings that transform non-conductive plastic housings into electrically conductive enclosures capable of attenuating unwanted electromagnetic emissions.
Since 1996, we have partnered with OEMs, injection molders, contract manufacturers, and product developers to provide high-quality EMI/RFI shielding solutions for medical devices, military equipment, industrial electronics, telecommunications products, and commercial electronic assemblies.
Whether your project requires prototype quantities or high-volume production, our experienced technicians deliver consistent, repeatable coating applications that meet demanding cosmetic and functional requirements.
What is EMI/RFI Shielding?
Electromagnetic Interference (EMI) is unwanted electrical noise generated by electronic devices that can interfere with nearby equipment. Radio Frequency Interference (RFI) is a specific type of EMI occurring within the radio frequency spectrum.
Plastic enclosures provide excellent mechanical protection but offer virtually no electrical shielding.
Spray-applied conductive coatings create a continuous conductive layer on the interior surfaces of plastic housings, allowing electrical currents to dissipate safely while significantly reducing electromagnetic emissions and improving immunity from external interference.
This process is commonly used to help products meet regulatory requirements including FCC, CE, military, aerospace, and medical device standards.
Our EMI Shielding Process
Every shielding project begins with understanding the product's performance requirements. Our process typically includes:
- Surface preparation
- Precision masking of critical cosmetic and functional areas
- HVLP spray application of conductive shielding material
- Controlled curing
- Visual inspection
- Thickness verification
- Adhesion verification (when required)
- Conductivity verification
- Demasking
- Final inspection
Each project is developed around repeatable manufacturing processes designed to produce consistent coating coverage from prototype through production quantities.
Conductive Coating Materials
Secondary Solutions applies a variety of conductive shielding materials depending on the electrical, environmental, and performance requirements of each application. Common material systems include:
- Copper coated silver (Most preferred)
- Silver coated copper
- Nickel conductive coatings
- Graphite conductive coatings
- Silver conductive coatings
- Carbon conductive coatings
- Customer-specified shielding formulations
Our team works directly with customers and material suppliers to identify the coating system that best balances shielding effectiveness, durability, conductivity, cost, and environmental requirements.
Precision Masking
One of the most critical aspects of EMI shielding is masking.
Many plastic housings require shielding on specific internal surfaces while maintaining cosmetic exterior finishes, sealing surfaces, snap features, or electrical contact locations.
Secondary Solutions develops custom masking processes that produce clean, repeatable coating boundaries while minimizing handling time and maximizing production efficiency.
Proper masking protects critical dimensions and ensures conductive coatings are applied only where required.
Industries We Support
Our EMI shielding services support products throughout numerous industries including:
Common Products We Shield
Our conductive coating services are commonly used on:
Why Spray-Applied Shielding?
Spray-applied conductive coatings provide several advantages over alternative shielding methods. Benefits include:
- Excellent shielding effectiveness
- Lower tooling investment
- Lightweight assemblies
- Compatibility with complex molded geometries
- Minimal dimensional impact
- Ideal for low and high production volumes
- Reduced manufacturing cost compared to metal housings
- Excellent cosmetic preservation
Why Customers Choose Secondary Solutions
Manufacturers choose Secondary Solutions because we understand both the science behind conductive coatings and the realities of production manufacturing. Our customers appreciate:
- Fast response times
- Production flexibility
- Competitive lead times
- Customer-specific masking processes
- Consistent coating quality
- Responsive engineering support
- Production scalability
- Personal service
Unlike many larger contract manufacturers, our customers work directly with knowledgeable manufacturing professionals who can quickly answer questions, evaluate new applications, and solve production challenges.
Quality
Every shielding application is manufactured using documented work instructions and customer-specific process controls. Our quality systems support customer requirements for:
- Visual Inspection
- Lot Traceability
- Process Documentation
- First Article Inspection (FAI)
- Adhesion Testing
- Coating Thickness Verification
- Customer-Specific Inspection Criteria
- Production Records
Our goal is to deliver repeatable, reliable shielding performance while meeting each customer's cosmetic and functional expectations.
Prototype Through Production
Whether you need five prototype housings or fifty thousand production components, Secondary Solutions can support your program. We regularly assist customers with:
- Prototype Development
- Engineering Builds
- Product Validation
- Pilot Production
- Production Ramp-Up
- Full Production Manufacturing
- Engineering Change Implementation
Our flexible manufacturing approach allows customers to move seamlessly from development into production without changing suppliers.
Production Experience
Secondary Solutions has been applying specialty coatings since 1996. Our coating applicators bring 25,000–30,000 hours and 28,000–35,000 hours of individual real-world coating application experience to every project, and our coating operations have produced well over one million units. These figures reflect the quantities we have tracked since we began recording; actual production totals are even higher.
Frequently Asked Questions
What plastics can be EMI coated?
Most engineering thermoplastics and injection molded housings can be successfully coated following proper surface preparation.
Can cosmetic surfaces remain uncoated?
Yes. Precision masking allows conductive coatings to be applied only where required while protecting visible exterior surfaces.
Do you support prototype quantities?
Absolutely. We regularly support prototype, engineering validation, pilot production, and full production programs.
Can SSI apply customer-specified shielding materials?
Yes. We routinely apply customer-specified conductive coatings and work closely with material manufacturers to ensure process compatibility.
What industries commonly require EMI shielding?
Medical devices, military electronics, aerospace, telecommunications, industrial controls, automotive electronics, wireless communications, and consumer electronics all commonly utilize conductive shielding coatings.
Let's Discuss Your Project
If your product requires reliable EMI/RFI shielding, Secondary Solutions can help.
Our experienced team provides precision spray-applied conductive coating services, repeatable manufacturing processes, and responsive customer support to help bring your product from prototype to production.
Contact us today to discuss your shielding requirements, request a quotation, or speak with one of our manufacturing specialists.
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