The development of electric vehicles has led to new and more stringent requirements for conformal coatings. Traditionally, these coatings were used to protect electronic components from moisture, dust, and chemicals in internal combustion vehicles. However, with electric vehicles, new challenges have emerged:

Extreme temperatures: Batteries, electric motors, and energy management systems generate significant heat. Coatings must therefore withstand higher temperatures and more demanding thermal cycles without losing their protective properties.

High voltage: Electric vehicle systems operate at much higher voltages. Coatings must provide improved dielectric insulation to prevent electrical arcing and failures.

Increased vibrations and shocks: Electric vehicles are often subject to greater vibrations and mechanical stress. Coatings must maintain their structural integrity and adhesion under these conditions.

Specific materials: The use of new materials in electric vehicles, particularly in batteries, may require coatings with specific chemical compatibility.

In response to these challenges, the conformal coating industry has developed more advanced solutions, such as:

High-temperature resistant coatings: While the automotive industry was historically satisfied with resistance up to 130°C, it is now common to see requirements of 150°C continuous, or even up to 160°C. This requires the development of new formulations capable of withstanding these extreme conditions.

At the same time, the evolution toward autonomous driving and enhanced driving comfort means that modern vehicles are increasingly packed with electronics—representing around 50% of the total vehicle cost. This creates a strong financial incentive for manufacturers and subcontractors to optimize production costs and keep vehicles affordable.

Two main solutions are emerging on the market:

• Silicone coatings (up to 200°C resistance), which are still viewed cautiously by manufacturers due to the risk of contamination in production environments caused by volatile components
• UV coatings, which eliminate VOCs and enable ultra-fast curing (in just a few seconds), offering both space and energy savings—making them a future-ready solution

ABchimie has been a pioneer in this field, offering low-viscosity coatings that cure using UV light generated by LED lamps, making the solution even more environmentally friendly.

These advancements ensure that critical electronic systems in electric vehicles remain reliable and high-performing, supporting the growth of this technology.

A similar approach can be used to address capillary effects, where both applications are carried out simultaneously using a dispensing valve for the dam and a film coater or spray system for the coating. The entire process is then cured in a single pass.

With its integrated R&D laboratory, ABchimie continuously supports industrial players by developing reliable, tailored solutions to protect all types of PCBA.