Conformal Coatings

Technical Needs, Gaps and Solutions

This section covers technology issues surrounding Conformal Coatings, the associated needs, technology status of those needs, as well as gaps and challenges to overcome, are summarized below in Table 1. The time period considered is from 2024 to 2034. Assessments of to address these gaps and challenges is presented in Table 2 as a set of potential solutions for each set of issues.

Technology Status Legend

For each need, the status of today’s technology is indicated by label and color as follows:

In-table color + label key	Description of Technology Status
Solutions not known	Solutions not known at this time
Solutions need optimization	Current solutions need optimization
Solutions deployed or known	Solutions deployed or known today
Not determined	TBD

Table 1. Conformal Coatings Gaps, and Today’s Technology Status with Respect to Current and Future Needs

TECHNOLOGY ISSUE	ROADMAP TIMEFRAME
Conformal Coatings
	TODAY (2024)	3 YEARS (2027)	5 YEARS (2029)	10 YEARS (2034)
CONFORMAL COATING ISSUE #1: Development and application of nano-coatings to account for miniaturization trends (environmentally friendly, sustainable coatings, such as sustainable nano-coating)
NEED	More development of nano-coating Optimization of nano-coating
CURRENT TECHNOLOGY STATUS	Solutions need optimization
	Development of halogen-free (Cl + Br) including PFAS and other fluorinated materials free.
GAP	Not many coatings available
CHALLENGE	Define/ development of more commercially viable coatings. Ever changing regulations.
CONFORMAL COATING ISSUE #2: Need non-fluorinated high temperature conformal coatings substitutes (PFAS)
NEED	Replacement of current PFAS coating with non-PFAS coating while still maintaining the same high temperature properties (up to 350°C)
CURRENT TECHNOLOGY STATUS	Solutions not known
	No replacements available.
GAP	Development of these materials. No ideal coating to meet the thermal requirements.
CHALLENGE	Few options available and they are unproven/ not suitable. Ever changing regulations.
CONFORMAL COATING ISSUE #3: Coverage of conformal coating (low coating thicknesses) (application and material related issue)
NEED	More uniform conformal coating for the low thicknesses (process related)
CURRENT TECHNOLOGY STATUS	Solutions need optimization
	Lack of understanding of what this is (knowledge gap). Edges/ corners of solder joint need to be covered. Increase the conformity of coverage. Currently a struggle with liquid systems. Vapor deposition is the best option but it is expensive. Currently industry standards do not call out material uniformity on 3D topography which is an industry issue. Current standards need to be amended.
GAP	Need conformability (every area is covered with the same thickness). Current standards need to be amended to call out material uniformity on 3D topology.
CHALLENGE	Finding the right material which will provide uniform coverage
CONFORMAL COATING ISSUE #4: Ability to test after conformal coating application
NEED	Ensuring the presence and property of conformal coating
CURRENT TECHNOLOGY STATUS	Solutions need optimization
	Some conformal coatings can be tested after material applied (e.g., some nano-coatings). Need to understand the advantages and disadvantages of these coatings. With some limitations, handheld Fourier-transform infrared (FTIR) and ultraviolet-visible (UV-Vis) tools can be utilized.
GAP	No current standard to do this type of testing which would include testing of electrical and mechanical properties of a thin coating after application.
CHALLENGE	Development of applicable and verifiable test standards for industry to use for all coating types.
CONFORMAL COATING ISSUE #5: Non-silicone CC (new type of CC or hybrid CC (2 layers of CC)- maybe a new category of CC) that can withstand 150°C to 175°C (For Automotive)
NEED	Need to move away from silicone materials. Health and safety along with housekeeping (Cleanliness concerns in factory /contamination concerns)
CURRENT TECHNOLOGY STATUS	Solutions need optimization
	There are non-silicone CC available which can withstand 150°C to 175°C for automotive.
GAP	Limited choices
CHALLENGE	Finding base chemistries that fit both high temperature that are commercially viable
CONFORMAL COATING ISSUE #6: Need more development and application of nano-coatings to account for miniaturization trends (recyclable coatings)
NEED	Recyclable nano-coatings
CURRENT TECHNOLOGY STATUS	Solutions need optimization
	Limited options at present
GAP	Not enough nano materials options at present to evaluate and develop
CHALLENGE	Finding the correct material that can be recycled

Approaches to address Needs, Gaps and Challenges

Table 2 considers approaches to address the above needs and challenges. The evolution of these is projected out over a 10-year timeframe using technology readiness levels (TRLs).

In-table color key	Range of Technology Readiness Levels	Description
2	TRL: 1 to 4	Levels involving research
6	TRL: 5 to 7	Levels involving development
9	TRL: 8 to 9	Levels involving deployment

Table 2. Conformal Coatings Potential Solutions

TECHNOLOGY ISSUE		EXPECTED TRL LEVEL*
Conformal Coatings	POTENTIAL SOLUTIONS	TODAY (2024)	3 YEARS (2027)	5 YEARS (2029)	10 YEARS (2034)
CONFORMAL COATING: ISSUE #1 Need more development and application of nano-coatings to account for miniaturization trends (environmentally friendly, sustainable coatings) (Need Sustainable nano-coating)	Development of novel chemistries and processes	4	6	7	8
CONFORMAL COATING: ISSUE #2 Need non-fluorinated high temperature conformal coatings (PFAS)	Development of novel chemistries’	4	5	6	8
CONFORMAL COATING: ISSUE #3 Coverage of conformal coating (low coating thicknesses) (application and material related issue	Development of novel chemistries and processes	4	5	6	8
CONFORMAL COATING: ISSUE #4 Ability to test after conformal coating application	Development of novel processes and testing using hand-held and spectrometry-based tools	5	6	7	9
CONFORMAL COATING: ISSUE #5 Non-silicone CC (new type of CC or hybrid CC (2 layers of CC)- maybe a new category of CC) that can withstand 150C to 175C	Development of novel chemistries	5	5	8	9
CONFORMAL COATING: ISSUE #6 Need more development and application of nano-coatings to account for miniaturization trends (recyclable coatings)	Development of novel chemistries and processes	3	4	5	8

Conclusions

Need more development and application of nano-coatings to account for miniaturization trends (environmentally friendly, sustainable coatings)
Need non-fluorinated high temperature conformal coatings (PFAS)
Need better coverage of conformal coating (for low coating thicknesses) (application and material related issues)

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