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Electronics potting – invisible, but indispensable

5 minute(s) to read June 03, 2025

 

 

Part of our daily lives: Where is electronics dispensing technology used?

 

Dispensing technology is very much part of our everyday lives – and yet it largely remains hidden. Invisible bonding, sealing and potting processes ensure that electronic components are reliable, durable and protected. Sensitive electronics are bonded, potted and sealed. And their heat is dissipated if they need to stay cool.

 

Innovative dispensing systems and materials such as epoxy resins, polyurethanes and silicones not only ensure that components are held firmly in place, they also provide protection and extend the service life – whether in vehicles, household electronics or agricultural machinery. As the complexity of applications increases so too do the demands placed on dispensing technology – especially when electronics need to be mobile, compact and absolutely reliable. 

 

Where is dispensing technology holding our world together?
Dispensing technology used in our daily lives
Where is dispensing technology holding our world together?
1 - E-scooters & e-bikes
1 - E-scooters & e-bikes
Batteries & stators are potted to protect them from water, heat and shocks.
 
Batteries & stators are potted to protect them from water, heat and shocks.
2 - Road and off-road vehicles
2 - Road and off-road vehicles
TIM prevent overheating; potting & sealing guard against dust and stress.
 
TIM prevent overheating; potting & sealing guard against dust and stress.
3 - Space Shuttles
3 - Space Shuttles
Sealing & potting prevent overheating and ensure vibration protection.
 
Sealing & potting prevent overheating and ensure vibration protection.
4 - Air taxis
4 - Air taxis
Bubble-free potting with low-viscosity materials boosts sensor and ECU durability.
 
Bubble-free potting with low-viscosity materials boosts sensor and ECU durability.
5 - Wind turbines
5 - Wind turbines
Vacuum potting ensures IGBT performance in wind turbines under high loads.
 
Vacuum potting ensures IGBT performance in wind turbines under high loads.
6 - Agricultural machinery
6 - Agricultural machinery
Potting shields control units, lighting, and sensors in tough environments.
 
Potting shields control units, lighting, and sensors in tough environments.
7 - Medical devices
7 - Medical devices
CPU chips e.g. in glucose monitors are safeguarded from the environment.
 
CPU chips e.g. in glucose monitors are safeguarded from the environment.
8 - Laptops, chargers & power supplies
8 - Laptops, chargers & power supplies
Potting cools and protects sensors, converters, and fieldbus connectors.
 
Potting cools and protects sensors, converters, and fieldbus connectors.
9 - Locomotives
9 - Locomotives
Stator windings in train drives are fully potted for cooling and insulation.
 
Stator windings in train drives are fully potted for cooling and insulation.
10 - Camera systems
10 - Camera systems
Industrial camera lenses are sealed to withstand harsh conditions.
 
Industrial camera lenses are sealed to withstand harsh conditions.
11 - Heating & HVAC systems
11 - Heating & HVAC systems
Vacuum potting shields controllers & pumps from moisture & temperature shifts.
 
Vacuum potting shields controllers & pumps from moisture & temperature shifts.
12 - Household appliances
12 - Household appliances
Potting protects drive electronics from vibration and moisture.
 
Potting protects drive electronics from vibration and moisture.
Johannes Blaser

“Potting materials perform structural and functional tasks – everything from protecting the electronics from moisture and vibration to dissipating heat. The quality of the dispensing process often determines the operational reliability of entire systems, especially in high-end applications. Invisible from the outside, the reason for such reliability is a highly sensitive and precisely coordinated dispensing process.”

Johannes Blaser Business Line Manager Electronics Dispensing

Protecting sensitive components

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Dispensing low-viscosity potting materials

Dispensing low-viscosity potting materials

Electronics potting in batteries, motors or sensors provides the necessary resistance to vibrations, moisture, dust and fluctuations in temperature for a wide variety of equipment, from e-scooters and air taxis to electric toothbrushes and blood glucose monitors. This means that that their systems remain operational and durable – even under extreme conditions.
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Potting of coils with thermally conductive material in a DC/DC converter

Potting of coils with thermally conductive material in a DC/DC converter

Potting material, which protects against water and vibrations, ensures that you can drive safely in an electric car even in harsh conditions. But it’s not only the battery that would be impossible without dispensing solutions. Cars now have numerous assistance systems, each designed to make driving safer and more comfortable. The radio and cassette player have now given way to a touchscreen infotainment system – in which the electronics are efficiently cooled thanks to thermal interface materials.

Many machines have to operate reliably outdoors in any weather, particularly those in the agriculture industry. The fact that they can operate reliably in extremely high and extremely low temperatures is thanks to modern dispensing and potting technology protecting their sensitive components.

Dispensing technology saves lives

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Glucose sensor: PCB with globe tops for protection against environmental stress

Glucose sensor: PCB with glob tops

Protecting sensitive components in medical devices is just as important, if not more so. The reliability of a blood glucose monitor can mean the difference between life and death. The tiny PCBs, which are tightly packed with smart sensors, have to be particularly well protected. The semiconductor chips on the glucose sensor’s PCB are reliably protected against environmental influences and mechanical stresses by what are known as glob tops without affecting the signal quality.

Bubble-free potting

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Depending on requirements, the electronic components are potted either by means of an atmosphere or vacuum potting process. Maximum reliability is essential, especially in safety-critical areas such as aviation, autonomous driving systems and power electronics.

Bubble-free and homogeneous potting of components in a vacuum chamber using Scheugenpflug equipment

Homogeneous and bubble-free potting of components in a vacuum chamber of the productline Scheugenpflug

When transformers, motors and ignition coils are potted there is a chance that tiny pockets of air can remain in the windings. IGBTs, which play a central role in converting electrical energy and feeding it to the grid, are another critical area.
Dispensing low-viscosity potting materials

Dispensing low-viscosity potting materials

Air bubbles, however small, can impair normal operation, which is why they must not be allowed to form at any point in the entire process – from material preparation and feeding to actual component potting. In such cases, vacuum potting is often the only way to ensure high-quality results that can be replicated time and again, along with long-term insulation, thermal conductivity and mechanical stability.

Dispensing is “lightweight”

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Two people discussing the quality of applied potting and dispensing materials
Safety is an essential aspect – weight is another, especially in the automotive industry. Dispensing technology replaces heavy mechanical fasteners, provides structural reinforcement with minimal use of materials and ensures good bonding between relatively light materials. And thanks to dispensing technology, materials can be used to perform multiple functions at the same time. All in one: bonding, sealing and heat dissipation in a single step. That too saves weight.

Dispensing makes connections …

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… in so many different applications: modern dispensing technology ensures that electronic devices operate reliably and achieve peak performance. It is very much part of our everyday lives – in the automotive and aviation industries, in medical equipment and in wind turbines. Dispensing technology combines structure with function. It protects sensitive components and optimizes industrial manufacturing processes. Electronics potting is therefore a central element of technological innovation – invisible but indispensable.

Precise application of sealing contours using dispensing technology from the Atlas Copco product line Scheugenplfug

Precise application of sealing contours using dispensing technology from Atlas Copco

Dispensing technology is holding our world together. It protects and optimizes. It makes our lives safer and more comfortable – the invisible backbone of so many innovations.

Learn more about our dispensing solutions
Learn more about our dispensing solutions
Discover our diverse dispensing, potting and adhesive bonding portfolio. Our product lines Scheugenpflug and SCA provide a perfect match for nearly all adhesive bonding, dispensing, sealing or potting challenges that might occur in modern manufacturing environments.
 
Discover our diverse dispensing, potting and adhesive bonding portfolio. Our product lines Scheugenpflug and SCA provide a perfect match for nearly all adhesive bonding, dispensing, sealing or potting challenges that might occur in modern manufacturing environments.
Service and support for industrial tools and assembly solutions
Service and support for industrial tools and assembly solutions
We support you all the way, from installation to maintenance and optimization of your tools and processes.
 
We support you all the way, from installation to maintenance and optimization of your tools and processes.
Contact our industrial joining experts
Contact our industrial joining experts
We'll be happy to tell you more on our Joining Solutions. Please let us know how we may assist you!
 
We'll be happy to tell you more on our Joining Solutions. Please let us know how we may assist you!
Our integrated vision portfolio
Our integrated vision portfolio
Our integrated vision solutions ensure process reliability, support quality control, and guide you towards production excellence.
 
Our integrated vision solutions ensure process reliability, support quality control, and guide you towards production excellence.

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