Securing Electronics Against Corrosion: A Strategic Imperative for EMS Providers

Securing Electronics Against Corrosion: A Strategic Imperative for EMS Providers

In the world of Electronic Manufacturing Services (EMS), maintaining the integrity and reliability of electronic components is critical. As the backbone of modern technology, EMS providers are tasked with assembling and delivering products that must perform flawlessly across diverse industries, from automotive and aerospace to consumer electronics and medical devices. However, one persistent challenge stands in the way of long-term reliability: corrosion damage.

Environmental exposure to humidity, condensation, salt, and pollutants can compromise the functionality of electronics, leading to costly failures, warranty claims, and reputational damage. For EMS providers, the stakes are high, and the need for innovative, effective solutions has never been greater.

The Corrosion Challenge in Electronics

Corrosion is a silent adversary, gradually degrading the performance and lifespan of electronic devices. It can occur at any stage, from production to end-user application, with causes that include:

Humidity and Condensation: Moisture can infiltrate unprotected circuits, leading to short circuits and oxidation.

Saltwater and Pollutants: Common in automotive and industrial environments, salt and pollutants accelerate corrosion, especially in harsh climates.

Temperature Variations: Rapid thermal cycling can lead to condensation, promoting corrosion in vulnerable areas.

Inadequate Coating Methods: Traditional protective coatings often fail to provide consistent coverage, leaving gaps for environmental ingress.

For EMS providers, managing these risks is critical to ensuring the reliability of electronic assemblies in all operating conditions.

Current Approaches and Their Limitations

Traditional methods to protect electronics include liquid-based conformal coatings and mechanical enclosures. While these approaches provide some level of protection, they come with significant drawbacks:

Liquid-Based Coatings

Often require extensive masking to avoid coating-sensitive areas, increasing labor costs and production time.

Can create air pockets during application, leading to incomplete coverage and vulnerabilities.

Act as insulators, hindering the natural dissipation of heat and potentially causing thermal-related failures.

Mechanical Enclosures

Add weight and bulk to assemblies, which is undesirable in compact designs such as automotive and consumer electronics.

Degrade over time, leading to gaps in protection.

Fail to address the need for component-level safeguarding.

These methods often struggle to meet the reliability and scalability demands of EMS providers who operate in highly competitive and quality-sensitive markets.

The Advanced Solution: Pulsed Plasma Nano-coating Technology

To address the limitations of traditional methods, pulsed plasma nano-coating technology from innovators like P2i has emerged as a game-changing solution. This advanced conformal coating approach offers unparalleled protection against corrosion while resolving the pain points of EMS providers.

Key Features of Pulsed Plasma Nano-coating:

Ultra-Thin, Uniform Application: Applied at the molecular level, the coating ensures complete, even coverage of complex geometries, including underfill protection for components.

Thermally Transparent: Unlike traditional coatings, nano-coatings allow for natural heat dissipation, maintaining the optimal performance of electronic components.

Minimal Masking Requirements: Precision application eliminates the need for extensive masking, streamlining the production process.

Enhanced Durability: The coating withstands extreme conditions, including high temperatures, humidity, and salt exposure.

Reworkable: Supports solder-through reworkability, reducing waste and increasing manufacturing efficiency.

Advantages for EMS Providers

For EMS companies, integrating nano-coating technology into production lines delivers measurable benefits:

1. Improved Product Reliability: Electronics are safeguarded against moisture and corrosive damage, significantly extending their lifespan and reducing failure rates.
2. Operational Efficiency: Simplified processes, including reduced masking and rework requirements, lead to faster production cycles and cost savings.
3. Competitive Differentiation: Delivering products with superior corrosion resistance and thermal management capabilities strengthens relationships with OEMs and expands market opportunities.
4. Environmental Compliance: Nano-coatings meet global environmental standards, including being PFAS-free, helping EMS providers align with regulatory and sustainability goals.

Why EMS Providers Should Act Now

The competitive landscape for EMS providers is more demanding than ever. OEMs expect not only high-quality assemblies but also solutions that address long-term reliability challenges like corrosion. Incorporating advanced protective technologies like pulsed plasma nano-coating is no longer a luxury—it’s a necessity to stay ahead.

P2i’s nano-coating technology offers EMS providers a scalable, efficient, and effective solution to corrosion challenges, enabling them to deliver electronics that excel in any environment.

 

A Call to Action for EMS Leaders

Are you ready to revolutionize your approach to electronic protection? Partner with experts who understand your challenges and can provide tailored solutions that enhance your manufacturing processes and product reliability. Contact P2i today to learn how our next-generation nano-coating technology can empower your business to deliver electronics that perform flawlessly—no matter the environment.

📩 Let’s protect the future of your electronics. Together.

In today’s fast-paced tech landscape, the miniaturization of electronic devices has become a defining trend. From smartphones to medical wearables, the demand for smaller, more efficient gadgets is relentless. However, as we shrink technology to fit in our pockets, we must also ensure that these devices can withstand the rigors of everyday life. Enter conformal coatings—a powerful solution for protecting electronics against moisture, dust, and harsh environmental conditions.

 

The Rising Importance of Conformal Coatings

Conformal coatings are thin protective layers applied to circuit boards and electronic components. They serve as a barrier against environmental factors, ensuring that sensitive electronics operate reliably in various conditions. This technology is particularly crucial in sectors like automotive, aerospace, and medical electronics, where failure is not an option.

 

Hot Topics Driving the Industry

1. Miniaturization of Electronics

As devices become smaller, so do the challenges of protecting them. Advanced conformal coatings are designed to fit into the tightest spaces without compromising protection. This trend is especially relevant in the booming market for wearables and IoT devices, where every millimeter counts.

 

2. Environmental Resistance

Today’s electronics must endure a wide range of conditions—from humidity to extreme temperatures. Conformal coatings provide a robust defence, making them indispensable in sectors like automotive, where vehicles are exposed to harsh weather and operational stress.

 

3. Sustainability

Eco-friendliness is no longer just a buzzword; it’s a necessity. Manufacturers are increasingly looking for non-toxic, sustainable materials. Water-based, bio-based and gas phase conformal coatings are leading the charge, aligning with global efforts to reduce environmental impact. You can read more about these advancements at IPC.

 

4. Advanced Materials

Innovations in coating materials, such as nano-coatings, are enhancing durability and performance. These cutting-edge solutions not only offer superior protection but also improve the longevity of electronic components.

 

5. Electric Vehicles (EVs)

The rise of electric vehicles has put a spotlight on the importance of conformal coatings. Protecting the intricate electronics in EVs is crucial for performance and safety, making conformal coatings a vital component of the automotive supply chain.

 

Challenges on the Horizon

While the benefits of conformal coatings are clear, several challenges remain that manufacturers need to address:

 

1. Adhesion Issues

Achieving strong adhesion on various substrates can be difficult, particularly with newer materials. This challenge demands ongoing research and development.

 

2. Regulatory Compliance

Navigating the complex landscape of environmental regulations can be daunting for manufacturers. Staying compliant while still delivering high-performance coatings is a balancing act.

 

3. Application Techniques

The method of application—whether spraying, dipping, brushing or applying through gas phase—can greatly impact the uniformity and effectiveness of the coating. Finding the right technique for specific applications is essential.

 

4. Cost vs. Performance

Manufacturers often face the challenge of balancing cost with performance. Advanced coatings may come with a higher price tag, making it vital to evaluate the long-term benefits they provide.

 

5. Durability and Longevity

Ensuring that coatings maintain their protective qualities over time is critical. In high-stress environments, the durability of conformal coatings can make the difference between success and failure.

 

The P2i Advantage

At P2i, we understand these challenges and have dedicated ourselves to developing cutting-edge conformal coatings that not only protect but also enhance the performance of electronic devices. Our patented technology offers unparalleled moisture and dust resistance, ensuring that your products can thrive in even the most demanding environments.

 

Why Choose P2i?

1. 1. Innovative Solutions: Our state-of-the-art coatings are designed to meet the unique needs of modern electronics, providing superior protection while maintaining the integrity of your designs.

 

2. Sustainability Focus: We prioritize environmentally friendly solutions, offering coatings that are both effective and compliant with current regulations.

 

3. Expertise and Experience: With 20+ years of experience in the industry, our team of experts is well-equipped to help you navigate the complexities of conformal coatings.

 

4. Tailored Approaches: We understand that every project is unique. Our customized solutions ensure that you get the right protection for your specific needs.

 

5. Proven Results: Our coatings have been rigorously tested in real-world conditions, providing you with peace of mind that your products will perform reliably over time.

 

Call to Action

Are you ready to elevate your electronics to the next level? Don’t let environmental challenges compromise your technology. Partner with P2i and experience the transformative power of our conformal coatings.

 

Contact us today to learn more about how we can help protect your devices and ensure their longevity. Together, we can pave the way for a more durable, efficient, and sustainable future in electronics.

 

Get in Touch

Visit our website at P2i.com or reach out to our team directly at info@p2i.com. Let’s work together to safeguard your innovations and create products that stand the test of time.

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In the ever-evolving tech landscape, conformal coatings are not just an option; they are a necessity. Embrace the future of electronics protection with P2i—where innovation meets reliability.

In the fast-evolving world of medical devices, particularly hearing aids, manufacturers face a growing challenge: ensuring devices can withstand elements like sweat, rain, and humidity without sacrificing performance. Historically, PFOA-related chemistries were the go-to choice for water protection, but since the global roll-out of restrictions on their use the role of advanced coating technologies becomes critical. Not only for compliance but for ensuring device reliability and customer satisfaction.

 

The Urgency of Regulatory Compliance

Several hearing aid customers have already transited to the PFOA-free Splashproof coatings.  Those operating with PFOA-related substances under exemptions face rapidly approaching deadlines. For EU 2020/784 the exemption for using PFOA and related substances for invasive and implantable medical devices ends 4 July 2025.

Penalties for non-compliance could be severe, including hefty fines and restrictions on market access. More importantly, manufacturers must ensure that the alternatives they adopt do not compromise the device’s effectiveness or durability.

 

P2i’s Solution: Advanced Molecular Protection

Enter P2i, a pioneer in the next generation of conformal coatings. Our unique, patented technology offers a robust solution tailored specifically to meet the demands of the hearing aid industry. Unlike traditional coatings, P2i’s technology works at the molecular level, providing a thin yet durable barrier against moisture and debris. This technology not only meets but exceeds the protection offered by older, more hazardous chemistries.

 

Our coatings are proven to protect hearing aids from the most common forms of damage: corrosion from sweat and humidity, and mechanical failures caused by exposure to water. These solutions have been in the marketplace since 2010. What sets P2i apart is our ability to deliver this level of protection without the added weight, bulk, or cost associated with mechanical seals and gaskets. Moreover, our approach circumvents the common issue of degraded sealants over time, ensuring long-term reliability and user satisfaction.

 

Collaboration and Rapid Deployment

Understanding the specific needs and challenges of hearing aid manufacturers is central to our strategy. A member of the P2i team is always ready to engage with manufacturers to delve deep into their specific requirements. This collaborative approach allows us to tailor our solutions to meet not only the technical and operational requirements of production but also the commercial needs and timelines crucial for a successful market launch.

 

Our proven track record with consumer electronics—where we’ve already met similar regulatory standards for non-medical devices—positions P2i as a reliable partner in adapting to and exceeding regulatory expectations for medical devices. By choosing P2i’s PFOA-free coatings, manufacturers can avoid the pitfalls of regulatory non-compliance while enhancing their product’s marketability through superior performance and reliability.

 

The Cost-Effective, Sustainable Choice

Choosing P2i’s PFOA-free coating solutions represents a cost-effective strategy for manufacturers. It eliminates the need for more cumbersome, less effective methods while providing superior protection. Furthermore, our coatings align with ongoing global chemical regulations, ensuring that products are future-proof and environmentally friendly, providing both PFAS-free and PFOA-free solutions.

 

In an industry where innovation is key to success, P2i leads with solutions that not only meet the current market demands but also anticipate future challenges and regulations. The urgency for manufacturers to transition to safer, more sustainable technologies like ours is paramount. It’s not just about meeting a regulatory deadline; it’s about leading the way in the industry with products that offer the highest standards of safety, performance, and environmental responsibility.

 

Conclusion

As we move forward, P2i remains committed to innovation in protective coatings, ensuring that our partners in the hearing aid industry—and their customers—can rely on their devices to perform exceptionally, regardless of environmental conditions. With P2i, manufacturers are not just adapting; they are setting new standards in device protection and customer care.

 

For hearing aid manufacturers facing the dual challenges of regulatory pressure and the need for high-performance, durable products, the solution is clear: P2i’s advanced, PFOA-free coatings offer a pathway to compliance, enhanced device performance, and overall market success. Contact us today so we can help you meet your regulatory requirements in a timely manner.

In the ever-evolving landscape of electronic device protection, and the need to meet the right-to-repair requirements, one method stands out as the epitome of technological advancement: Plasma Coating. As a revolutionary approach, plasma coating surpasses traditional methods like physical gaskets, parylene, and liquid-based conformal coatings, offering unparalleled advantages technically, operationally, and commercially.

Technical Advantages:

Uniform and Precise Coverage: Plasma coating ensures a consistent and uniform protective layer on electronic components. The precision of application, achieved through the inherent molecular-based approach, eliminates the risk of uneven coating, providing comprehensive coverage that liquid coatings could never achieve.

Microscopic Protection: With plasma coating, the protective layer reaches microscopic levels, offering superior defence against contaminants, moisture, and corrosive elements. This microscopic protection surpasses the capabilities of traditional methods, enhancing the reliability and longevity of electronic devices.

Enhanced Dielectric Properties: Plasma coating exhibits excellent dielectric properties, ensuring optimal insulation for electronic components. This out-performs the insulation capabilities of physical gaskets and liquid coatings, reducing the risk of electrical failures and improving overall device performance.

Operational Excellence:

Thinness and Lightweight Design: Unlike physical gaskets that add bulk or parylene coatings that can be too thick, plasma coating provides an ultra-thin and lightweight protective layer. This not only preserves the aesthetic design of electronic devices but also contributes to improved portability and ease of integration.

Conformity to Complex Geometries: Plasma coating adapts seamlessly to intricate and complex component geometries. It conquers challenges that physical gaskets and liquid coatings may face in conforming to irregular shapes, ensuring every nook and cranny is effectively shielded and doesn’t suffer from edge effects.

Efficient and Scalable Process: The plasma coating process is efficient and scalable, allowing for high-volume production without compromising quality. This operational efficiency outshines the labour-intensive application of physical gaskets or the time-consuming curing processes associated with liquid coatings. In addition, there is no trapped air during plasma deposition and so coatings remain intact and fully protective throughout temperature and humidity changes experienced during product use.

Commercial Value Proposition:

Cost-Effectiveness: Plasma coating proves to be a cost-effective solution over the long term. In addition to the extended lifespan due to reduced field failure returns, the reduced labour requirements of minimal masking, factory footprint and ability to eliminate scrap due to product re-work and repair; a reduced piece part price is achieved. Making plasma coating a financially sound choice for manufacturers and end-users alike.

Increased Productivity and Reliability: The reliability of plasma coating translates to increased productivity for end-users. Reduced downtime due to electronic failures enhances overall operational efficiency, providing a competitive edge in the market.

Environmental Sustainability: Plasma coating is an environmentally friendly option, with minimal waste and no solvents or volatile organic compounds (VOCs). This aligns with the growing demand for sustainable practices in manufacturing.

In conclusion, plasma coating emerges as the unequivocal leader in electronic device protection, outshining physical gaskets, parylene, and liquid-based conformal coatings in terms of technical prowess, operational adaptability, and commercial viability – whilst delivering to the right to repair requirements. Embracing this cutting-edge technology is not just a choice; it’s a strategic imperative for those seeking optimised and future-proofed electronic protection. Elevate your electronic devices with the superior shield of plasma coating and redefine the standards of reliability and longevity by contacting us today to understand how this can work on your products.

1 In 5 electronic products are disposed of annually and only 20% are formally recycled. Driven by the need to facilitate the development of a circular economy and with the view to save costs for consumers, the ’Right-to-Repair’ offers numerous benefits for electronic products. There is a strong desire today for manufacturers to move away from a traditional linear model of ‘take, make, use and dispose’ and adopt a process which minimises or eliminates the disposal element. This will be further enabled by jurisdictions implementing the ‘right-to-repair’, just as the European Commission has announced.

Additionally, this will drive manufacturers to ensure their water-proof products are repairable to increase product lifecycles; they will need to adopt new eco designs to ensure the high levels of quality and reliability are still achieved and delivered to the consumer. The Ellen MacArthur Foundation estimates that circular economy activities could contribute as much as US$700 million in annual material cost savings to consumer goods production, along with a 48% reduction in carbon dioxide emissions by 2030.

 

Change in mindset.

Ever since electronics have been in existence, methods to prevent them being damaged by corrosion caused by liquid, humidity and condensation have always been at the forefront for product designers. With the connected world, 5G and IoT all gathering pace, more than ever there is a need to reduce the quantity of materials used, deliver lighter and smaller form-factor products whilst maintaining the high levels of protection to the elements.

Methods used historically to protect devices include mechanical seals and gasket o-rings; however, not only can the protection be compromised during shipment, drops, bends and general day-to-day usage, the design and build makes it all but impossible for the consumer to repair and maintain protection.

The lack of recyclability and sustainability, along with the need to improve the life cycles of water-proof electronic devices has led to the formation of the United Electronics Coating Association (UECA). The UECA will develop technical and market solutions to further the environmental and sustainability goals globally for all electronic products. By identifying the relevant regulations covering chemicals, and those covering the circular economy, reusability and recycling of electronic products, the association will guide the membership in the development of the appropriate product solutions.

 

Moving forward

Fortunately, solutions exist today, proven in mass manufacturing on over a billion devices, where printed circuit board arrays (PCBAs) can be fully protected at the molecular level. This ensures maximum reliability & recyclability whilst enabling reuse to increase the product’s lifecycle.

These coatings are created using plasma enhanced chemical vapour deposition (PECVD). The PCBAs to be treated are loaded into a vacuum chamber, evacuated to low pressure, a liquid is vaporised into the chamber which is then ionised and deposited onto the surface to give an ultra-thin barrier coating.

Furthermore, these ultra-thin plasma barrier coatings can lower the total cost of ownership of device level liquid protection by at least 40%. Click here to find out more.

When the Sustainability Revolution began to gain pace in the early noughties, companies initially, and understandably, looked inwards. The first drive in sustainable credentials was to put your own house in order, with directives around energy usage, packaging and materials, employee behaviours and a raft of initiatives that looked to lessen carbon footprint and increase green awareness on all fronts. So far so good.

It’s not just about you
But the requirement for profitability has always meant that commercially, quality at the best price, was the Mother Lode in terms of developing an increasingly global supply chain. While this brought frontline commercial benefits, and globalization has seen economies burgeon the world over, it has also brought companies the burden of scrutiny across the chain: Sustainability an increasing focus in this regard.

A wide-ranging Impact Policy
P2i has been on its own Environmental journey since its inception in 2004. Like other companies, P2i apply non-financial factors in order to analyze processes and identify material risks and growth opportunities. As a global leader in sustainably protecting products, P2i are dependent on collaborating with a complex supply chain of innovative partners. Our needs are not necessarily driven by price, though of course a factor, but in the need to keep developing P2i products to be ever more efficient and exceptional through time.

Working with the industry
Today P2i are developing a robust range of protection solutions that ensures the lowest total cost of ownership for conformally protecting electronics from corrosion damage, whilst ensuring the highest reliability and circularity. As the leader in ultra-thin plasma conformal coating solutions and having commercialised a generation of halogen-free plasma conformal coatings, P2i work with customers who have profound Supply Chain Sustainability programmes that run in parallel with our own efforts and ensure the best-in-class performance for all stakeholders.

Striking carbon emission reductions
Our advances within the industry are considerable. For example, P2i could save 50K tonnes carbon emissions on mobile phones, which is a sizeable amount of OEM’s suppliers’ carbon emissions avoided. This success is the result of our in-house expertise and capabilities as a sector front-runner and also on the high demands of our suppliers, who work with us to establish best-in-class products.

The cost of living across the world is rising and it looks set to increase further as we head towards a global recession. In 37 of 44 countries studied by the Pew Research Center (making use of data from the OECD), the average annual inflation rate in the first quarter of 2022 was at least twice what it was in the first quarter of 2020. In 16 countries, first-quarter inflation was more than four times the level of two years prior.

As a result of these rampant price rises, more people than ever are looking at ways they can save the pennies and be more cost efficient. When we combine this financial prudence with the greater environmental consciousness we are seeing from consumers today, it is not surprising that behaviours around purchasing and owning electronic devices are changing. People increasingly want a device that is durable and long-lasting: both because it is more cost-effective but also because it is more sustainable.
Manufacturers therefore need to be cogniscent of these trends; look at the components of devices and re-evaluate how they can prevent electronic damage and increase product life-cycle to the benefit of their consumer customers and themselves.

Protecting all the constituent parts – waterproof, sustainable electronics

To do that, of course, they will need to sustainably protect devices and materials and given the ever-present risk of corrosion damage, liquid protection is critical to this.

Traditional conformal coatings are simply not sufficient to reduce repairs, carbon footprint and costly device failure. Liquid-based conformal coats protect only certain components, however, do not protect the full board inside the device. This can mean the end for devices that are susceptible to water ingress such as those with multiple moving parts or are open in design. Components that protect the insides of devices such as O-rings and gaskets fall short of resilience as they can be easily dislodged, allowing liquid to seep in and causing irreversible water damage.

Ultra-thin plasma conformal coatings delivering a robust conformal coating will increase product lifecycles and eliminate scrap on the assembly line when the product is being made because they can form a reworkable protective layer.

Consequently, manufacturers won’t need to landfill waste products because the process instead enables them to rework products and replace components. As a result, with product lifecycles increasing, return rates will fall away. When products do get returned when customers have finished using them, there is the potential to then re-use them by simply re-using or recycling the key components and feeding them back into the supply chain.

There are also commercial benefits for the device manufacturer from all this. They get a great return on investment for the extra cost of the nanocoating versus the cost of the logistics of the returns and repairs on their devices.

Yet, as we look to the future, there is no sign of the current economic crosswinds abating anytime soon. In this environment, it is even more important than ever that the customer is king. The good news is that electronic device manufacturers can put consumers first, while also forwarding their own interests. As always, protecting core components from liquid damage by offering the right kind of protection will be key in making this happen.

See how P2i’s unique technology benefits the electronics sector by reading our dedicated page.

In the current economic climate, it feels that there isn’t a week that goes by without reported shortages. Whether it’s the lack of sunflower oil due to 52% of it being sourced from Ukraine, or the well-publicised scarcity of baby formula products in the United States, businesses are facing new challenges in bringing services and products to consumers.
The electronics sector hasn’t been immune from material shortages, with the lack of semiconductor chips affecting industries from automotive to games consoles. Almost every digital electronic device today is now powered by a semiconductor, which reflects their importance in the market. Concerningly, following a continued shortage since the onset of the Covid-19 pandemic, it’s now feared that this situation won’t ease until 2023.
While organisations struggle with limited production capabilities and consumers fight to source electrical products, increasing the product lifecycle with sustainable electronics will help keep stock numbers as high as possible and prevent more chips being needed for repair or replacements. But what can manufacturers do to ensure this type of longevity and waterproof electronics?

Increasing device lifespan
The answer is sustainable conformal coatings. Increasing the product lifecycle for as long as possible will not only ensure value is maintained for the current user, but also for any subsequent users. Preventing electronic damage typically revolves around the need to reduce corrosion to internal elements from liquid ingress. Depending on the type of device, there’s likely to be different requirements, whether it’s simply splash resistance to increase the hydrophobic properties or the ability to be submerged.
Thankfully, P2i’s ultra-thin plasma coatings are the way to sustainably protect devices and materials. These coatings keep devices working for longer and means that scrap is eliminated from the assembly line when the product is manufactured due to being reworkable, while return rates reduce as reliability increases.

Reduce, reuse, recycle
While maintaining product lifespan is beneficial in reducing the number of scarce additional semiconductors needed for replacements, it’s also critical in contributing to the circular economy. It’s been calculated that in 2022, there is over 347 metric tonnes of unrecycled e-waste on earth, with only 17.4% of it being collected and properly recycled.
Building sustainability into IoT devices from the design stage is vital to ensure that they don’t add to the concerning number of e-waste electricals sitting on landfill. Increasing product lifespan is also a necessity as consumers aim to be more sustainable in their purchases. According to Deloitte’s Sustainability & Consumer Behaviour 2021 report, over a third (34%) of consumers said that they opt for brands that have environmentally sustainable practices or values.

Accounting for external factors
There’s little doubt that the shortfall of semiconductor chips has sent shockwaves through the electronics sector. With the issue looking set to remain, manufacturers need to adopt sustainable solutions to keep their products out in the market for longer, allowing them to weather the chip shortage storm. Increasing product lifecycles has an additionally positive effect on the circular economy. Organisations now have a responsibility to keep IoT devices operational and away from landfill, thereby benefitting the planet and meeting consumer demand.
See how P2i’s unique technology benefits the electronics sector by reading our dedicated page.

Longer product lifetimes can help reduce smartphones’ environmental impact. First, however, vendors and carriers may need to find more efficient methods of liquid protection. Deloitte Global predicts that smartphones are likely to generate an astonishing 146 million tons of carbon dioxide (CO2) or equivalent emissions (CO2e) in 2022 alone, placing an urgent need to reshape the sustainability practices of the smartphone industry.

Manufacturers and suppliers must urgently find ways of reducing the carbon footprint generated both by the manufacturing process and across the product lifecycle. They need to be able to extend product life and produce less waste during the manufacturing process whilst also focus on extending the life of devices further by making them more repairable. These aims are critically important in the face of today’s climate emergency. After all, “the single biggest factor that could reduce a smartphone’s carbon footprint is a longer expected lifetime.” But how can manufacturers and suppliers best achieve them and what are the benefits of this?

How liquid protection extends product life

Producing products with a longer lifespan will help reduce the need for repairs and spare parts, and a manufacturer’s environmental footprint. The key to ensuring that level of robustness in production is the utilisation of longer-lasting protection. It is here where liquid protection plays a crucial role.

Of course, manufacturers must largely focus on reducing e-waste, but also on extending the product lifecycle with design-in sustainability. That involves protecting the product from damage, including from liquids, right from the start. The logic is simple – If products are not damaged, they are not thrown away and there’s less need to mine for minerals and increase the environmental footprint. In the electronics manufacturing sector, damaged products represent the fastest growing waste stream, so the urgency in the race to reduce waste is clear. Manufacturers must act now, yet many simply don’t have the right systems in place to prevent liquid damage and reduce e-waste.

Live long and prosper

Making products that live for longer will be the fastest route towards satisfying ESG demands for electronics manufacturers. According to the Global E-Waste Monitor 2020 report, 75% of emissions linked to a smartphone can be attributed to the manufacturing stage. It might come as a surprise but extending the life of these devices by just 4.5 years can cut emissions in half, making the smartphone lifespan extension the single biggest factor that could reduce its carbon footprint. One way to achieve it is by implementing protective technologies that were designed to prolong the product lifetime at its design stage. With the right level of liquid protection incorporated into the devices, manufacturers can not only contribute to saving the planet, but also save on the costs of ‘tear downs’ and repairs later on.

Coatings that fall short

Traditional coatings are simply not sufficient enough to reduce repairs and carbon footprint. Liquid-based conformal coats protect only certain components, however, do not protect the full board inside the device. This can mean the end for devices that are susceptible to water ingress such as those with multiple moving parts or are open in design. Components that protect the insides of devices such as O-rings and gaskets fall short of resilience as they can be easily dislodged, allowing liquid to seep in and causing irreversible water damage.
There’s also the case of device cleaning which presents further danger. Chemical cleaning products can be particularly harmful if they reach the inside of a device. This has become a more significant problem as a result of the pandemic, which has meant devices are likely to be cleaned more often.
Find out more about the impact of Covid-19 and regular cleaning from our whitepaper.

There is a better way

Adding solid protection to devices is crucial to increase their lifespan and help manufacturers become more sustainable. However, traditional coatings are not the solution as they likely to increase the devices’ bulk and weight, making them less desirable to consumers and therefore negatively affecting the manufacturers’ bottom lines. They can also remove the all-important design freedom of engineers who wish to innovate and pioneer new electronic devices.
Manufacturers have always wanted to have greater freedom to design electronics that look instantly appealing and be comfortable for users to handle and operate. The latest ultra-thin plasma coatings from P2i allow electronics manufacturers to embrace that design freedom and have complete confidence in device protection that supports sustainability initiatives. Even when water can easily enter a device, whether by damage or design, P2i’s ultra-thin plasma coatings can eliminate internal corrosion and prolong the devices lifespan, without compromising on their weight, usability and appeal.
As less than 20% of electronic waste is currently collected and recycled, adopting nano-technology liquid protection solutions will also enable manufacturers to fully rework their devices. Reducing e-waste, costs and the use of chemicals by applying nano-coatings is a great way to deliver the sustainable competitive advantage to consumers and protect the environment.
Discover more about P2i’s sustainable liquid protection solutions for consumer electronics here.