Technical Component Protection via Polymer Potting and Hotmelt Processes
Werner Wirth offers development services and series production for electronic assembly protection.
wernerwirth.com
The increasing integration of electronic assemblies into decentralized and mechanically stressed application areas—such as smart cities, smart farming, renewable energies, medical technology, and defense technology—requires specific protection concepts against environmental influences. Under the designation VergussPlus, system supplier Werner Wirth provides a combined service consisting of product engineering and manufacturing processes. This technical approach aims to physically and chemically isolate electronic components using polymeric materials, structuring the production process from the prototyping phase through to series production.
Material Selection and Prototype Development
When designing component protection, polymeric materials and the corresponding potting processes are analyzed with regard to their chemical resistance, thermal conductivity, and mechanical strength. Initial prototypes are manufactured and subjected to physical stress tests in a development center in Hamburg equipped with specific manufacturing and testing facilities. This evaluation phase serves to qualify the protection concept with regard to the operational requirements of the electronic assemblies in their later deployment scenario.
Processing Technologies and Production Integration
Methods such as conformal coating, dispensing and metering technology, and hotmelt moulding are used for industrial electronics protection. Werner Wirth handles the physical manufacturing of the component protection and scales capacities according to the required quantities. The manufacturing service ranges from the production of small batches for the ramp-up phase to full series production. To ensure traceability and process stability, product data, machine calibrations, and process parameters are documented via Product Lifecycle Management (PLM) and Product Data Management (PDM). This structured data acquisition enables a standardized transfer of processes to the internal manufacturing area of the plant operator or end user.
Plant Engineering and Material Specifications
The process engineering implementation takes place on the company's own potting and injection molding platforms of the TM series. The machinery also includes specific dosing systems and valves for spraying, coating, jetting, and dispensing. For precise shaping in hotmelt moulding, the required tools are designed and machined in the internal toolmaking shop. The material supply for the protection processes includes casting resins, protective lacquers, and industrial adhesives, whose physical properties are matched to the respective dosing and potting systems. For components exported to the North American market, potting materials certified according to Underwriters Laboratories (UL) standards are available. The company's operational processes are subject to the DIN EN ISO 9001:2015 standards for quality management and DIN EN ISO 14001:2015 for environmental management.
Edited by an industrial journalist, Lekshman Ramdas, with AI assistance.
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