One partner. The right protection for your application.

The right coating depends on your device, your line, and your reliability target. P2i is the only engineering partner offering end-to-end protective coating capability at OEM scale — globally.

Not sure where to start? Talk to an application engineer

The problem

Most devices don't wear out. The environment gets them first.

Liquid and environmental damage are the leading causes of electronics field failures — a significant share of warranty returns, field replacement costs, and recalls across every major sector. For a hearing aid in the rain, a vehicle infotainment unit in a condensation-prone cabin, an industrial sensor in a humid factory — the environment is not exceptional. It is the everyday use case.

Most manufacturers treat protection as a late-stage question. P2i’s engineers are most effective at specification — but they will work with you at any stage of the design process, including late-stage qualification.

Core technology

P2i’s plasma coating is a dry, room-temperature PECVD process that deposits a covalently bonded barrier at the molecular level. The coating penetrates complex 3D structures — connectors, microphone ports, densely packed PCBA — minimising masking requirements across the device. The result is a barrier that doesn’t add to form factor, doesn’t compromise audio performance, and doesn’t require the product to be sealed or re-engineered.

Performance characteristics

Covalent bonding

The coating is chemically attached to the substrate — it doesn’t migrate, delaminate, or degrade over humidity cycling.

Masking significantly reduced

The plasma process minimises masking requirements across complex surfaces, including connectors, ports, and microphone membranes.

100% reworkable

Components can be repaired, soldered, and replaced after coating. Battery changes. Screen replacements. Full right-to-repair compatibility.

No change to audio performance

Unique to P2i across all known coating technologies. Confirmed across 15+ years of hearing aid deployments.

PFAS-free process

Clean-chemistry formulations available. No aqueous waste stream. Room-temperature application. Regulatory-aligned.

Turn-key deployment

P2i equipment is deployed factory-in-factory — FOC equipment placement, per-unit fee model. No capital expenditure. No long installation.

99.995% first-pass yield. Zero scrap. Parylene replaced — at scale.

A large West Coast electronics OEM qualified P2i’s PFAS-free Barrier Coating as Plan of Record across multiple China and Vietnam factories — replacing parylene across all earphone and wireless earphone devices. Masking eliminated. Scrap reduced from a 3% plateau to zero.

Plasma product lines

Barrier

Full protection for the PCBA. Covalent barrier coating — nano-thin, connector-compatible, reworkable.

Best for: Hearing aids · Wireless earphones · Wearables · Any device where PCBA integrity is the primary failure mode.

Splash-Proof

Consumer-grade moisture protection at line speed. Significantly reduces field failure returns. No hardware change required.

Best for: Smartphones · Consumer electronics · Point-of-sale · Devices requiring moisture resistance without full IP rating.

Core technology

P2i’s Liquid Barrier Coating (LBC) is a spray- or dip-applied process that integrates with existing wet-process manufacturing infrastructure — delivering consistent, conformal barrier protection at production scale without capital expenditure on new equipment. LBC is engineered for environments where line speed, process compatibility, and high-volume consistency are the primary requirements.

Performance characteristics

Line integration

Deploys on existing spray or dip infrastructure. No new capital equipment. No production line reconfiguration.

High throughput

Engineered for volume — process parameters matched to target throughput from day one.

Consistent coverage

Conformal coating across complex surface geometries at production speed, without the manual touch-up of traditional spray conformal.

PFAS-free options

PFAS-free process formulations are available. Migration roadmap on request.

Engineering-led qualification

P2i engineers review your reliability requirements and device specifications, qualify the process to your line, and confirm before scale-up.

More than 4 million doorbells protected.

LBC deployed at production scale across smart home and IoT applications — integrating directly into existing spray line infrastructure with zero capital expenditure.

More than 5 million wireless earphones protected.

LBC qualified and deployed at volume for consumer audio — consistent conformal coverage at line speed, without new capital equipment.

Development

Not every protection challenge has a standard solution. Unusual product geometries, mixed-material substrates, complex thermal or chemical exposure profiles, or qualification requirements that existing coating chemistries cannot meet — these are the problems P2i’s development team is built for.

We work with customers to define the performance target, assess the available chemistry options, and develop a process that can be qualified to the specification and the production line. If the right solution exists in our existing portfolio, we will tell you. If it doesn’t, we will tell you that too — and we will work to build it.

Capabilities

Process development

Custom PECVD and liquid coating process development for non-standard geometries, materials, or qualification requirements.

Formulation development

Chemistry development in partnership with P2i’s materials science team — for applications where available formulations fall short.

Qualification support

End-to-end support through the customer’s qualification test plan — from initial specification through production sign-off.

Development partnerships

Long-term engineering partnerships for customers in early device development — embedding protection qualification into the product roadmap from the start.

Process

How the decision is made

Every engagement starts with your reliability requirements and device specifications. We map the failure modes against the performance profile of available technologies. Different processes suit different environments — sometimes more than one is deployed together, sometimes the answer is a process we develop specifically for your device. Our engineers know where those lines are. The output is a recommendation, not a product pitch.

Manufacturing

The protection partner that delivers at scale

Selecting the right coating technology is the first decision. Delivering it at production volume — consistently, across factories and manufacturing regions, on the same line parameters — is the harder one. This is where most coating vendors reach their limit. P2i does not.

Factory-in-factory deployment

P2i coating equipment can be placed directly into your production facility, free of charge. No capital expenditure, no separate installation programme.

Per-unit commercial model

Cost tracks exactly with production volume. No fixed overhead, no idle capacity cost, no minimum volume commitment.

Global manufacturing support

P2i engineering teams operate across established manufacturing hubs worldwide — wherever the factory is.

On-site qualification

P2i engineers are embedded through production ramp — from initial line qualification through volume sign-off.

Consistency across sites

Same process parameters, same qualification standard, same engineering oversight — whether the factory is in East Asia, North America, or Central Europe.

Tell us about your device and your production environment.

We will tell you which protection path is right — and we will deliver it.

Talk to an engineer