From the cockpit of an aircraft to the circuitry inside an electric vehicle, modern electronics are pushed to their limits. High temperatures, moisture, vibration, and chemical exposure can rapidly deteriorate sensitive components if not properly protected.
That’s why many manufacturers rely on industrial coatings for electronics: expertly-applied layers that provide protection without compromising performance. These coatings not only defend against wear and corrosion but also enhance conductivity, insulation, and thermal control.
For more than 50 years, Coating Systems, Inc. has partnered with OEMs across various industries—including aerospace, automotive, and electronic equipment—to ensure their components perform at their best, regardless of the environment.
Understanding how industrial coatings protect components can help manufacturers make better decisions about performance, reliability, and long-term value.
How Industrial Coatings Protect Electronic Devices
1. Shielding Against Corrosion
Corrosion is a silent killer of electronics. Even trace amounts of moisture or oxygen can cause oxidation and short circuits in conductive metals. Industrial coatings create a protective barrier that prevents water, salts, and corrosive gases from damaging internal components.
Fluoropolymer coatings, such as PTFE (polytetrafluoroethylene), are especially effective due to their exceptional chemical resistance and low surface energy.
These coatings ensure that metal connectors, terminals, and housings maintain conductivity and structural integrity over years of service.
At Coating Systems, our fluoropolymer and epoxy-based coatings are applied to deliver consistent film thickness, excellent adhesion, and superior moisture protection. These same technologies are trusted across aerospace, defense, and automotive electronics to prevent oxidation and corrosion-related failures.
2. Optimizing Thermal Management
Electronic components produce heat when operating. If this heat isn’t managed correctly, it can shorten their lifespan or cause a critical failure.
Thermal management coatings distribute and dissipate heat, preventing hot spots that can damage sensitive circuitry. High-temperature fluoropolymers and PTFE coatings maintain their performance well above 300°F, providing reliable protection in applications that experience constant thermal cycling.
Coating Systems applies advanced materials engineered to withstand high operating temperatures while maintaining flexibility, dielectric strength, and a flawless surface finish.
Whether it’s circuit boards in an electric vehicle or sensors in a manufacturing line, the right coating ensures performance and a longer service life.
3. Improving Wear Resistance
Many electronics, such as connectors, housings, and actuator components, rely on repeated motion, contact, or assembly. Over time, friction and abrasion can wear away unprotected surfaces, leading to malfunctions or costly part replacements.
Wear-resistant coatings, like dry film lubricants or PTFE-based systems, create a low-friction, self-lubricating layer that minimizes abrasion and sticking.
Coating Systems’ proprietary CSILON 2000 coating, for example, offers a uniform, ultra-thin film that reduces torque, twisting, and surface damage during assembly or operation.
Components glide smoothly through automated feed systems—saving time, reducing waste, and improving quality control.
4. Providing Electrical Insulation
Electrical insulation is crucial in devices that must manage high voltages or dense circuit layouts. Without a stable dielectric layer, small gaps between conductors can lead to short circuits, arcing, or even fires.
Epoxy, acrylic, and urethane coatings are commonly used to create electrically insulating barriers that also resist humidity and chemical intrusion. These coatings provide uniform coverage even on complex geometries, maintaining long-term reliability throughout the device.
For over five decades, Coating Systems has delivered coating processes that meet stringent tolerance requirements, protecting sensitive electronic assemblies while maintaining their functionality. This level of control enables manufacturers to achieve high-voltage isolation and long-term durability, even under the most extreme conditions.
5. Increasing Chemical Resistance
Electronic devices often operate in settings where chemical exposure is unavoidable—from factory floors and laboratories to food processing plants and chemical handling systems. Uncoated materials can degrade rapidly when exposed to solvents, acids, or cleaning agents.
Chemical-resistant coatings for devices prevent surface degradation and maintain structural integrity. Fluoropolymer coatings, for example, are inert and highly resistant to corrosive compounds, while epoxy-based finishes offer strong chemical shielding with excellent adhesion.
Coating Systems’ experience with PTFE, epoxy, and fluoropolymer coatings ensures that every component, whether a sensor housing, connector, or control unit, performs under chemical exposure.
The Coating Systems Difference
Not all coatings are created equal. Success depends on selecting the right material, properly preparing the surface, and using the appropriate application method. We specialize in functional coatings that are engineered for performance—not just appearance.
Our process involves detailed substrate analysis, surface preparation (including sandblasting or solvent washing), and controlled coating applications to meet exact performance requirements. Each batch is inspected with advanced DOSS visual inspection systems, ensuring accuracy, consistency, and quality.
Whether your goal is corrosion prevention, electrical insulation, or chemical resistance, our team partners with you to select the right solution for your specific electronic application.
Frequently Asked Questions
Industries including aerospace, automotive, defense, chemical processing, and consumer electronics rely on industrial coatings to protect sensors, control units, and circuit components from damage.
Common materials include epoxy, urethane, acrylic, and fluoropolymer coatings such as PTFE. Each offers distinct advantages depending on whether corrosion protection, heat resistance, or insulation is the primary goal.
Most protective coatings are designed to be non-conductive, though specialized formulations can maintain partial conductivity when required. The correct choice depends on the intended electrical function of the coated part.
Yes. Specific coatings, such as fluoropolymers and epoxies, provide a combination of dielectric strength and moisture protection, making them suitable for multi-functional protection.
Yes. PTFE-based and fluoropolymer coatings maintain integrity at temperatures above 300 °F, making them ideal for electronics exposed to continuous or cyclical heat.
Coatings are very thin—typically between 0.0002 and 0.0007 inches—to maintain dimensional tolerances and avoid interference with assemblies.
In most cases, professionally applied coatings offer long-lasting protection. However, components subjected to severe abrasion or chemical exposure may require periodic re-coating to maintain performance.
Partner With Coating Systems for Electronics Protection
Protecting sensitive electronics requires more than chemistry—it takes specialized knowledge of how coatings interact with materials, heat, and environmental stress.
Coating Systems, Inc. applies coatings that perform where failure isn’t an option. Whether you need corrosion resistance, insulation, or chemical protection, our team develops solutions tailored to your exact materials and environment.
Ready to get started?
Contact us today to discuss your next project and discover how our custom coating services can enhance reliability and extend the life of your components!