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 Conformal Coating vs. PCB Potting-What’s the Difference?

Conformal Coating vs. PCB Potting-What’s the Difference?


To protect PCBs from harmful elements including humidity, chemicals, and heat. potting and conformal coating are essential PCB manufacturing procedures. Diodes, capacitors, fuses, and resistors are just a few of the components. that are commonly found on PCB surfaces.We usually heard conformal coating and potting. So what about conformal coating vs potting ? Damage to any one electronic component could result in the failure of the entire PCB. because the PCB’s overall functionality depends on each individual component. Extreme heat, excessive humidity, or extreme cold can all produce disintegration problems. Low insulation resistance, conductor corrosion, and, eventually, a loss in PCB component longevity. As a result, we must take action to keep these components safe and in the PCB for long-term use. Yet how? Excellent, now pour them and conformal coat them to demonstrate their utility.

Both potting and conformal coating apply organic polymers. that offer thermal and chemical resistance as well as electrical insulation. There are some distinctions between them, though. and we’ll go into more detail below for your better understanding.

How Does PCB Potting Work?

PCB potting enhances the mechanical stability of the assembly. reduces the risk of short circuits, improves thermal dissipation. and offers electrical insulation properties. It is commonly used in applications where the PCB exposed to harsh environments. high humidity, corrosive substances, or extreme temperatures.

PCB potting is a process of encapsulating or filling a PCB with a liquid or semi-solid compound. typically an epoxy resin or silicone-based material. The potting material poured or injected into the open spaces and cavities of the PCB assembly. creating a protective barrier around the components and circuitry.

The process of PCB potting


The PCB inspected and prepared for potting. This includes cleaning the board to remove any contaminants or residues. that may affect the adhesion or performance of the potting material.

Enclosure Selection:

An appropriate potting compound or resin based on the specific requirements of the PCB assembly. such as desired level of protection, temperature resistance, chemical resistance, or mechanical properties.


If the potting material is a two-part system. the resin and hardener mixed together in the correct proportions. according to the manufacturer’s instructions. This ensures proper curing and optimal performance of the potting compound.


The mixed potting compound poured or injected onto the PCB assembly. It is important to ensure that the potting material adequately fills all the voids, gaps, and spaces. covering the components and circuitry completely.


The potting compound allowed to cure or harden. The curing time and conditions vary depending on the specific potting material used. It could involve exposing the assembly to ambient temperature, applying heat. or using a curing agent to accelerate the process.


Once the potting material has fully cured, any excess material or flash removed. and the PCB inspected for any visual defects or irregularities.

PCB Potting Types

There are several types of PCB potting materials available. each with its own characteristics and suitability for different applications. Here are some common types of PCB potting materials:

Epoxy Resin:

Epoxy-based potting compounds are widely used. due to their excellent adhesion, mechanical strength, and chemical resistance. They offer good protection against moisture, dust, and vibrations. Epoxy resins are available in various viscosities. and filled with additives to modify properties like thermal conductivity.


Silicone-based potting compounds provide flexibility, good thermal stability, and resistance to extreme temperatures. They well known for their high electrical insulation properties. and excellent resistance to moisture and chemicals. Silicone potting is often used in applications requiring high temperature resistance. or exposure to harsh environments.


Polyurethane potting compounds offer a good balance of properties. including mechanical strength, chemical resistance, and thermal stability. They provide effective protection against moisture, humidity, and moderate mechanical stress. Polyurethane potting is commonly used in automotive, aerospace, and industrial applications.


Acrylic-based potting compounds well known for their fast curing time. and good electrical insulation properties. They offer adequate protection against moisture and can withstand moderate temperatures. Acrylic potting is often used in applications. where rapid processing or reworkability required.

UV Cure:

UV-curable potting compounds are a specialized type. that cures quickly when exposed to ultraviolet light. They offer fast processing times and can be advantageous for applications . where curing time needs to minimized. UV-cure potting materials are typically used for small-scale or delicate PCB assemblies.


It’s important to select the appropriate potting material. based on the specific requirements of your PCB assembly. such as environmental conditions, temperature range, chemical exposure. mechanical stress, and desired electrical properties. Consulting with potting material manufacturers or suppliers. that can help in determining the most suitable potting material for your application.


How Does Conformal Coating Work?

Conformal coating is a protective coating applied to the surface of a PCB. to provide a thin and uniform protective layer. It works by creating a conformal barrier that adheres to the contours of the PCB. covering the components, traces, and solder joints.

The process of applying conformal coating :

Surface Preparation:

The PCB is thoroughly cleaned to remove any contaminants. such as dust, oils, or residues that could interfere with the adhesion of the coating. This step ensures that the coating adheres properly to the PCB surface.

Coating Selection:

The appropriate type of conformal coating material . that selected based on the specific requirements of the PCB assembly. Common types of conformal coatings include acrylics, silicone, urethanes, and epoxy-based coatings. Factors such as environmental conditions, operating temperature range, chemical resistance. and desired level of protection influence the choice of coating material.


The conformal coating applied to the PCB surface using various methods. such as brushing, spraying, dipping, or selective coating. The application method depends on factors like the size and complexity of the PCB assembly. coating material viscosity, and production requirements.


After the coating applied, and allowed to cure or dry. The curing process varies depending on the type of coating material used. Some coatings cure at room temperature. while others may require elevated temperatures or exposure to UV light for curing.

Inspection and Post-Curing:

Once the coating has fully cured. the PCB inspected for uniform coverage and any visual defects. such as bubbles, voids, or uneven thickness. Any necessary touch-ups or rework performed at this stage.

Conformal coating provides a protective layer. that helps shield the PCB assembly from various environmental factors. including moisture, dust, dirt, chemicals, and temperature fluctuations. conformal coating vs potting . It prevents the formation of electrical shorts, corrosion, and surface contamination. that can lead to malfunction or premature failure of the electronics.

The conformal coating forms a protective film that conforms to the contours of the PCB. adhering to the surface and creating a barrier against external elements. It offers electrical insulation, enhances mechanical strength. conformal coating vs potting  and improves the PCB’s resistance to humidity, temperature, and chemical exposure. Conformal coating is commonly used in industries. such as automotive, aerospace, consumer electronics, and industrial applications. where PCBs subjected to challenging environments.

Conformal Coating Types

There are several types of conformal coatings available. each with its own characteristics and suitability for different applications. Here are some common types of conformal coatings:


Acrylic conformal coatings are widely used due to their ease of application. good moisture resistance, and excellent electrical insulation properties. They offer good protection against humidity, chemicals, and fungus. Acrylic coatings are typically easy to remove and rework if necessary.


Silicone-based conformal coatings provide excellent temperature resistance. ranging from very low to high temperatures. They offer superior flexibility and are suitable for applications. where extreme temperature variations expected. Silicone coatings provide good protection against moisture, chemicals, and UV radiation.


Urethane conformal coatings offer good chemical resistance and mechanical protection. They have excellent moisture resistance and. provide a durable protective barrier against environmental factors. Urethane coatings well known for their high resistance to solvents, fuels, and abrasion.


Epoxy-based conformal coatings provide superior mechanical strength and protection against harsh environments. They offer excellent chemical resistance, electrical insulation properties. and adhesion to a wide range of substrates. Epoxy coatings are typically harder and more rigid. compared to other types of conformal coatings.


Parylene is a unique type of conformal coating. that deposited as a vapor and forms a thin, pinhole-free film. It provides exceptional moisture and chemical resistance, as well as excellent dielectric properties. Parylene coatings offer high clarity and do not add significant thickness to the PCB assembly.

UV Cure:

UV-curable conformal coatings applied in liquid form and cured using ultraviolet light. They offer fast curing times and advantageous for applications. where rapid processing or reworkability required. UV cure coatings provide good moisture and chemical resistance.


The selection of the appropriate conformal coating depends on various factors . such as the specific requirements of the PCB assembly, environmental conditions. temperature range, chemical exposure, desired level of protection, and reworkability. Consulting with conformal coating manufacturers or suppliers. that can help in determining the most suitable coating material for your application.

Conformal Coating vs Potting

Conformal coating and PCB potting are both methods used to protect PCBs. that from environmental factors and enhance their reliability. However, they differ in their application, coverage, and level of protection. Here are some key differences between conformal coating and PCB potting:


Conformal Coating vs Potting

Conformal Coating vs Potting of Application Method:

Application Method of Conformal Coating:

Conformal coating is typically applied as a thin layer on the surface of the PCB using methods. such as brushing, spraying, or dipping. The coating adheres to the contours of the PCB. covering the components and traces . while leaving the PCB open for inspection, rework, and repairs if needed.

Application Method of PCB Potting:

PCB potting involves filling or encapsulating the entire PCB assembly. with a liquid or semi-solid compound. The potting material poured or injected into the open spaces and cavities of the PCB. covering the components and circuitry completely.

Conformal Coating vs Potting of Coverage and Encapsulation:

Coverage and Encapsulation of Conformal Coating:

Conformal coating provides a thin and uniform protective layer. that conforms to the surface of the PCB. It covers the exposed components, traces, and solder joints. while leaving other areas open and accessible.

Coverage and Encapsulation of PCB Potting:

PCB potting completely encapsulates the PCB assembly within the potting material. It fills all the voids, gaps, and spaces on the PCB, providing a complete barrier of protection.

Conformal Coating vs Potting of Level of Protection

Level of Protection of Conformal Coating:

Conformal coatings offer protection against environmental factors. such as moisture, dust, dirt, chemicals, and temperature variations. They provide a moderate level of protection. typically guarding against moderate levels of exposure.

Level of Protection of PCB Potting:

PCB potting provides a higher level of protection compared to conformal coatings. It creates a robust barrier that shields the PCB from moisture, dust, vibration. mechanical shock, and extreme temperatures. Potting materials offer more comprehensive protection. making them suitable for harsh environments and high-risk applications.

Conformal Coating vs Potting Reversibility and Reworkability

Reversibility and Reworkability of Conformal Coating:

Conformal coatings removed or reworked if necessary. They can be chemically stripped or mechanically. removed to allow for repairs, modifications, or troubleshooting of the PCB.

Reversibility and Reworkability of PCB Potting:

PCB potting is typically irreversible. Once the PCB assembly potted. it becomes challenging to remove or modify the potting material . without damaging the components or the board itself. Potting is a permanent process intended for long-term protection.

The choice between conformal coating and PCB potting. depends on the specific requirements of the PCB assembly. the level of protection needed, the accessibility requirements for repairs or modifications. and the environmental conditions in which the PCB will operate.

Polycase Enclosures for PCB Potting and Conformal Coating

Polycase is a manufacturer that specializes in producing enclosures for electronic applications. They offer a range of enclosures suitable for PCB potting and conformal coating. These enclosures designed to provide protection and support for PCB assemblies. while accommodating the specific requirements of potting and conformal coating processes. For PCB potting applications, Polycase offers enclosures with features such as:

Potting-friendly designs:

Polycase provides enclosures with features like internal ribs, standoffs. and slots that facilitate the potting process. These design elements help ensure proper potting material flow. minimize air entrapment, and optimize potting material distribution.

Sealing options:

Polycase enclosures often include gasketed lids or sealing. options to maintain the integrity of the potting material after encapsulation. These features help prevent moisture ingress, dust penetration. and environmental contaminants from affecting the PCB assembly.

Material compatibility:

Polycase offers enclosures made from materials that are compatible with common potting compounds. such as epoxy or silicone. These materials selected to withstand the curing. and thermal expansion/contraction processes associated with potting.

Easy access:

When it comes to conformal coating applications, Polycase provides enclosures with features like:

Enclosures designed for conformal coating may have removable or hinged lids. that allow for convenient access to the PCB assembly during the coating process. This accessibility ensures efficient coating application and post-coating inspections.

Venting options:

Some Polycase enclosures include venting features like vents or vents with filters. These options help control pressure differentials and allow for proper outgassing . during the conformal coating process.

Chemical resistance:

Polycase enclosures are typically constructed from materials. that offer good chemical resistance, ensuring compatibility with various conformal coating materials. This resistance helps protect the enclosure itself from potential damage . or degradation caused by the coating process.

It’s important to review Polycase’s product catalog or consult with their representatives. to identify the specific enclosures suitable for your PCB potting or conformal coating needs. Polycase offers a range of enclosure sizes, styles, and customization. options to accommodate different PCB sizes and application requirements.

When it doesn't seem appropriate to use PCB potting

While PCB potting provides many benefits. it may not always be the best solution for every application. Here are some scenarios when it may not be suitable to use PCB potting:

Accessibility requirements:

PCB potting can make it difficult or impossible. to access and repair components on the PCB assembly. If future repairs, upgrades, or modifications expected. it may be better to use a conformal coating or an enclosure with removable lids or panels.

Weight limitations:

Some potting materials can add significant weight to the PCB assembly. which may not be acceptable in applications with weight restrictions. such as aerospace or automotive. In such cases, a conformal coating may be a more suitable option. since it adds minimal weight to the assembly.


PCB potting can be more expensive compared to conformal coating. especially for small production runs. Potting requires specialized equipment, material, and labor. which can increase the overall cost of the PCB assembly. Conformal coating, on the other hand. Applied using simple and cost-effective methods like spraying or brushing.

Thermal management:

Some potting materials may not be suitable for applications. where thermal management is critical. Potting materials with high thermal conductivity can help dissipate heat. but they may also add weight or require additional design considerations. In such cases, other thermal management solutions. such as heat sinks or fans, may be more appropriate.

Electrical insulation:

Potting materials can also affect the electrical performance of the PCB assembly. If the potting material is not an excellent electrical insulator. it can cause electrical shorts or interfere with signal transmission. In such cases, a conformal coating may be a better option. since it provides a thin and uniform insulation layer. without affecting the electrical properties of the PCB assembly.


It’s important to carefully evaluate the specific requirements of your application . and consult with a PCB expert to determine the most appropriate solution for your needs.

When using pcb doesn't seem acceptable conformal coating

If using a PCB or applying a conformal coating does not seem acceptable. for your specific application, alternative solutions to considered. Here are a few options to explore:


Instead of potting or conformal coating. you can use enclosures specifically designed to protect the PCB assembly. Enclosures provide physical protection against environmental factors. such as moisture, dust, and mechanical stress. They can also offer EMI/RF shielding and thermal management features. Selecting an appropriate enclosure with the desired features and IP (Ingress Protection) rating. That can provide effective protection for your PCB assembly.

Sealed Connectors and Gaskets:

In situations where specific components or connectors need protection. you can opt for sealed connectors and gaskets. These components offer localized protection by creating a barrier. against moisture, dust, and other contaminants. Sealed connectors and gaskets used in combination with an enclosure or directly on the PCB.

Potting or Conformal Coating Specific Areas:

Instead of potting or coating the entire PCB assembly. you can selectively pot or coat specific areas that require additional protection. This approach allows for easier accessibility to certain components. while still providing protection to critical areas.

Environmental Testing and Design Improvements:

Conducting environmental testing on the PCB assembly can help identify vulnerabilities and areas. that require additional protection. Based on the test results, design improvements implemented. to enhance the PCB’s resilience to specific environmental factors. This could involve modifications to the PCB layout, component selection. or the addition of conformal coating on specific sensitive areas.

Custom Solutions:

In some cases, custom solutions required to meet the unique demands of the application. This could involve collaborating with specialized manufacturers or engineers to develop tailored solutions. that address the specific challenges and requirements of your project.



It’s essential to thoroughly assess the specific needs and constraints of your application. and consult with experts in PCB design and protection. to determine the most suitable alternative solution.

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