The Benefits of Silicone vs Acrylic Conformal Coatings for Electronics

Electronic devices today are more compact, powerful, and sensitive than ever before. As technology continues to advance, protecting printed circuit boards (PCBs) and components from moisture, dust, and environmental stress is no longer optional — it’s essential. One of the most effective protection methods is conformal coating, a thin polymer film applied to electronic assemblies to shield them from environmental damage without affecting performance or size.

Among the many types of conformal coatings available, silicone and acrylic coatings are two of the most widely used options. Both have distinct properties that make them suitable for specific environments and applications. Understanding their benefits, differences, and best uses can help manufacturers make informed decisions — especially in Malaysia’s humid and demanding climate.

In this article, we’ll examine how silicone and acrylic conformal coatings compare in terms of performance, application, and cost — and how Pacific Adhesive Systems (M) Sdn Bhd helps local manufacturers choose the right protection for their electronics.

What Is Conformal Coating and Why It Matters

Conformal coating is a thin protective layer (typically 25–75 microns thick) applied over electronic components and PCB surfaces. It “conforms” to the shape of the circuit, creating a barrier against environmental contaminants such as moisture, corrosion, and dust.

Its primary functions include:

• Preventing corrosion and oxidation on metal contacts

• Improving dielectric strength between conductive traces

• Protecting against condensation, salt spray, and chemical vapors

• Reducing mechanical vibration damage

• Extending the operational life of electronic assemblies

For tropical climates like Malaysia’s — where high humidity and temperature changes are constant — conformal coating is critical for maintaining reliability and preventing premature PCB failures.

Why Silicone and Acrylic Coatings Are Popular Choices

While there are several coating chemistries available (urethane, epoxy, parylene, etc.), silicone and acrylic formulations dominate the market due to their performance balance and versatility.

• Acrylic conformal coatings are known for their ease of application, fast drying time, and strong moisture protection.

• Silicone conformal coatings are prized for their exceptional thermal resistance, flexibility, and durability in harsh conditions.

Each coating type has its strengths, and choosing between them depends on the specific application, environment, and budget.

Overview of Acrylic Conformal Coatings

Key Characteristics

Acrylic coatings are made from acrylic resins dissolved in a solvent base. They are easy to apply using brushing, dipping, or spraying methods, and they dry quickly — either by solvent evaporation or heat acceleration.

Main advantages:

• Excellent moisture and humidity resistance

• Rapid curing, even at room temperature

• Easy rework and removal for repairs

• Good dielectric properties for insulation

• Cost-effective for large-scale production

Because of their simplicity and cost efficiency, acrylic coatings are widely used in consumer electronics, telecommunications equipment, and general-purpose PCBs.

Limitations

However, acrylic coatings have limitations when it comes to extreme environments:

• Moderate temperature resistance (typically -65°C to +125°C)

• Limited chemical resistance against solvents and oils

• Lower flexibility compared to silicone coatings

This means that while acrylic coatings are ideal for indoor or controlled environments, they may not withstand prolonged exposure to harsh industrial or automotive conditions.

Overview of Silicone Conformal Coatings

Key Characteristics

Silicone coatings are formulated from polysiloxane polymers, offering superior flexibility and stability under thermal and mechanical stress. They are typically applied in liquid form and cured at room temperature or with heat.

Main advantages:

• Excellent high-temperature stability (up to +200°C or more)

• Outstanding moisture and salt mist resistance

• Superior flexibility to handle vibration and expansion

• Strong chemical and UV resistance

• Long-term reliability under harsh environmental exposure

These properties make silicone coatings a top choice for high-reliability applications such as automotive electronics, aerospace systems, LED assemblies, and outdoor electrical devices.

Limitations

While silicone coatings provide robust protection, they have some drawbacks:

• More difficult to remove or rework once cured

• Higher cost compared to acrylic coatings

• Longer curing time for some formulations

Despite these factors, many manufacturers consider silicone coatings an excellent long-term investment due to their stability and lifespan.

Head-to-Head Comparison: Silicone vs Acrylic Coatings

This comparison highlights that acrylic coatings are best for low to moderate environmental stress, while silicone coatings excel in high-temperature or high-humidity conditions.

Environmental Factors: The Malaysian Perspective

Malaysia’s tropical environment presents significant challenges for electronic components:

• High humidity accelerates corrosion and dendritic growth on PCBs.

• Temperature fluctuations cause material expansion and contraction.

• Airborne contaminants such as dust and salt from coastal regions further degrade unprotected boards.

For manufacturers operating in these conditions, silicone conformal coatings offer better long-term protection due to their moisture barrier and flexibility. Acrylic coatings, while cost-effective, may require more frequent maintenance or reapplication in such climates.

Applications of Silicone and Acrylic Coatings

When to Choose Acrylic Coating

• Consumer electronics and telecommunications

• Indoor control panels and instrumentation

• Shorter product life cycles or cost-sensitive production

• Applications where easy rework or repair is required

When to Choose Silicone Coating

• Automotive electronics exposed to engine heat and vibration

• Aerospace systems operating under high-altitude or vacuum conditions

• Outdoor LED lighting, solar equipment, and sensors

• Harsh industrial or marine environments

• Long-life, mission-critical devices requiring high durability

In many cases, manufacturers also combine coating types or apply dual-layer systems (acrylic for base protection and silicone for outer resistance) to achieve both cost efficiency and performance.

The Role of UV-Curable and Hybrid Coatings

Recent innovations have introduced UV-curable and hybrid silicone-acrylic coatings, which combine the advantages of both chemistries.

UV-curable coatings cure instantly under ultraviolet light, significantly reducing production time and energy consumption. Hybrid formulations improve adhesion and reduce cracking, offering flexibility with the convenience of fast curing.

Pacific Adhesive Systems (M) Sdn Bhd provides advanced UV-curable and hybrid coatings tailored for electronics manufacturers seeking high-speed, low-emission, and durable protection systems.

Application Techniques for Conformal Coatings

The method of application can impact coating uniformity, performance, and cost-efficiency. Common techniques include:

• Spraying: Ensures even coverage, ideal for high-volume production.

• Brushing: Suitable for touch-ups or small areas, but may lack consistency.

• Dipping: Provides complete coverage for simple geometries, but masking is required.

• Selective Coating: Automated robotic systems apply coatings precisely on designated areas — ideal for complex PCBs.

After application, coatings may undergo heat or UV curing, followed by inspection using UV light or thickness measurement tools to verify proper coverage.

Working with the Right Adhesive and Coating Partner

Selecting the right conformal coating is only part of the solution — successful implementation also depends on proper material handling, application techniques, and quality control. This is where having a knowledgeable supplier makes a difference.

Pacific Adhesive Systems (M) Sdn Bhd offers complete support for electronic manufacturers across Malaysia, providing:

• Silicone and acrylic conformal coatings suited for local environmental conditions

• UV-curable and hybrid coating solutions for high-speed production lines

• Low outgassing epoxy systems for optical and aerospace applications

• Technical guidance on surface preparation, coating thickness, and curing optimization

With years of expertise and access to global-grade materials, Pacific Adhesive Systems ensures Malaysian manufacturers achieve reliable, cost-effective, and compliant coating solutions.

The Future of Conformal Coating Technology

The next generation of conformal coatings is focused on combining performance with sustainability and automation. Emerging trends include:

• Eco-friendly, solvent-free formulations that reduce VOC emissions

• Smart coatings with self-healing or sensing capabilities

• Plasma-enhanced coating adhesion for better substrate compatibility

• Automated selective coating systems integrated into Industry 4.0 production lines

As Malaysia continues to grow as a regional electronics manufacturing hub, adopting these advanced coating technologies will be crucial for maintaining competitiveness and product quality.

Conclusion

Both silicone and acrylic conformal coatings offer valuable benefits for protecting electronic assemblies. The best choice depends on environmental conditions, performance requirements, and budget considerations.

• Acrylic coatings are cost-effective, easy to apply, and ideal for standard environments.

• Silicone coatings provide superior flexibility, moisture resistance, and high-temperature durability for harsh or outdoor applications.

For electronics manufacturers in Malaysia, where humidity and heat are constant challenges, selecting the right coating partner is key. Pacific Adhesive Systems (M) Sdn Bhd delivers expert consultation and world-class materials, ensuring your products achieve long-lasting reliability and performance in any condition.

Whether you need fast-curing acrylics for consumer devices or durable silicone coatings for automotive and industrial systems, Pacific Adhesive Systems provides the protection your electronics deserve — built to withstand Malaysia’s demanding climate and beyond.