PCB Staking & Encapsulation

At Secondary Solutions Inc. (SSI), we provide precision potting, encapsulation, and PCB staking services that improve the durability, reliability, and long-term performance of electronic assemblies.

Since 1996, manufacturers have trusted SSI to apply specialty materials that secure components, protect sensitive electronics, and improve resistance to vibration, moisture, chemicals, dust, and harsh operating environments.

Whether your project requires selective component staking, full encapsulation, or precision potting, our experienced team delivers repeatable, production-ready solutions from prototype through high-volume manufacturing.

What Are PCB Staking, Potting & Encapsulation?

Electronic assemblies often require additional mechanical support and environmental protection beyond standard soldering techniques. SSI provides several methods of protecting electronic assemblies.

PCB Component Staking

Selective application of adhesive to secure larger or vibration-sensitive components to the printed circuit board. Commonly used for:

• Capacitors
• Transformers
• Inductors
• Connectors
• Heat sinks
• Heavy components
• Wire management
• Tall electronic devices

Potting

Potting fills an enclosure or cavity with a protective compound that completely surrounds electronic components. Potting protects against:

• Moisture
• Dust
• Corrosion
• Vibration
• Mechanical shock
• Chemicals
• Thermal cycling

Encapsulation

Encapsulation surrounds sensitive components with a protective material while providing electrical insulation and long-term environmental protection. Typical applications include:

• Medical devices
• Sensors
• Industrial electronics
• Automotive electronics
• Power supplies
• Control modules
• Telecommunications equipment

Operator-Controlled Precision Dispensing Systems

Every electronic assembly is different, which is why precision material placement is critical. Rather than relying solely on fully automated dispensing equipment designed for high-volume, repetitive production, SSI utilizes operator-controlled precision dispensing systems that allow experienced technicians to accurately apply customer-specified materials exactly where they are needed.

This approach provides exceptional flexibility for:

• Prototype builds
• Engineering changes
• High-mix, low-to-medium volume production
• Complex PCB layouts
• Unique component geometries
• Customer-specific application requirements
• Tight material placement tolerances

Our dispensing equipment provides precise control over bead size, material volume, and placement while allowing operators to adapt to variations that automated systems may not easily accommodate. The result is a controlled, repeatable process that combines precision equipment with experienced craftsmanship.

Our Potting & Encapsulation Capabilities

SSI supports a wide range of customer-specified material systems. Common chemistries include:

• Epoxy
• Silicone
• Polyurethane
• Acrylic
• Flexible encapsulants
• Rigid encapsulants
• Thermally conductive compounds
• Electrically insulating compounds

Every application is developed around the customer's design, environmental requirements, and long-term performance expectations.

PCB Staking Services

Properly staking larger or vibration-sensitive components significantly improves product reliability by reducing mechanical stress placed on solder joints. SSI provides precision staking for:

• Surface mount components
• Through-hole components
• Connectors
• Transformers
• Relays
• Large capacitors
• Wire bundles
• Customer-specific assemblies

Benefits

• Improved vibration resistance
• Increased mechanical strength
• Reduced solder joint fatigue
• Improved shock resistance
• Enhanced long-term reliability

Precision Material Application

Successful potting, encapsulation, and staking require more than simply dispensing material. SSI emphasizes process control throughout every stage of production, including:

• Material verification
• Surface preparation
• Controlled dispensing
• Consistent bead geometry
• Accurate material placement
• Cure verification
• Visual inspection
• Customer-specific work instructions
• Production traceability

Our disciplined approach ensures consistent results while minimizing material waste and maximizing product reliability.

Materials & Customer Specifications

Every electronic assembly has unique performance requirements. SSI routinely processes customer-specified materials, including:

• Engineering-approved adhesives
• Medical-grade compounds
• Industrial-grade encapsulants
• Customer-approved staking materials
• Low-outgassing materials
• Thermally conductive materials
• Electrically insulating compounds
• Specialty electronic adhesives

Our team follows customer documentation and approved manufacturing procedures to ensure compliance with product-specific requirements.

Quality & Process Control

Protecting sensitive electronics requires precision and consistency. SSI maintains strict process controls through:

• Material lot verification
• Controlled dispensing parameters
• Cure schedule verification
• Visual inspection
• Coverage verification
• Customer-specific acceptance criteria
• Process documentation
• Manufacturing traceability

These quality measures help ensure every assembly performs as intended throughout its service life.

Integrated Electronics Manufacturing Services

Many customers combine potting, encapsulation, and PCB staking with SSI's additional electronics manufacturing capabilities, including:

Performing multiple operations under one roof simplifies logistics, reduces lead times, and improves overall manufacturing efficiency.

Industries We Serve

Why Manufacturers Choose SSI

For nearly three decades, manufacturers have relied on SSI because we understand that protecting electronics requires precision, process discipline, and consistent execution. Our customers value our ability to combine operator-controlled precision dispensing equipment with experienced technicians who understand the importance of accurate material placement and repeatable manufacturing processes.

Manufacturers choose SSI because we provide:

• Manufacturing experience since 1996
• Prototype through production support
• Operator-controlled precision dispensing systems
• Customer-specified material processing
• Flexible production volumes
• Experienced manufacturing technicians
• Responsive customer service
• Competitive pricing
• Minnesota-based manufacturing
• Consistent quality and repeatability

Whether your project requires selective PCB staking, complete encapsulation, or precision potting, SSI delivers dependable manufacturing support that protects your products throughout their operating life.

Frequently Asked Questions

Partner with SSI for Precision Electronic Protection Solutions

At Secondary Solutions, electronic assembly protection is more than dispensing material onto a circuit board—it's about applying the right material, in the right location, using a controlled process that delivers long-term reliability. By combining precision dispensing equipment with experienced operators, we provide the flexibility, accuracy, and manufacturing discipline needed to support today's demanding electronic products.

Whether you're developing a new medical device, industrial controller, sensor assembly, or commercial electronic product, SSI has the expertise to help protect your investment and improve product reliability.