What Are Low Outgassing Adhesives and Why Do They Matter

Low outgassing adhesives play a critical role in electronics, aerospace, optical, and precision manufacturing industries. As components become smaller and more sensitive, even minimal contamination from adhesive materials can affect performance, reliability, and product lifespan. This is why low outgassing epoxy and UV adhesives are increasingly specified in high-reliability applications.

This article explains what low outgassing adhesives are, why they matter, where they are used, and what manufacturers should consider when selecting them.

What Is Outgassing and Why Is It a Problem?

Outgassing occurs when volatile substances trapped inside a material are released over time. In adhesives, this typically happens during curing, exposure to heat, or operation in sealed or vacuum environments. While outgassing may not be noticeable in general industrial use, it becomes a serious issue in precision electronics and optical assemblies.

When gases are released, they can condense on nearby components such as PCBs, connectors, lenses, or sensors. This contamination can cause electrical leakage, signal interference, corrosion, or optical fogging. Over time, even small amounts of outgassing can lead to performance degradation or complete system failure.

What Are Low Outgassing Adhesives?

Low outgassing adhesives are specially formulated to release extremely low levels of volatile organic compounds during curing and throughout their service life. These adhesives are engineered using controlled resin systems and curing agents to ensure material stability under demanding conditions.

Common types of low outgassing adhesives include:

• Low outgassing epoxy adhesives for structural bonding and encapsulation

• UV-curable adhesives designed for clean and fast bonding

• Specialty formulations for vacuum, cleanroom, and aerospace applications

These adhesives are commonly specified where long-term cleanliness, reliability, and compliance with strict standards are required.

Why Low Outgassing Adhesives Matter in Electronics and Aerospace

Low outgassing adhesives are essential because they directly protect sensitive components and ensure consistent performance over time.

Key reasons they matter include:

• Prevent contamination of optical and electronic components

• Maintain electrical insulation and signal integrity

• Reduce risk of corrosion and material degradation

• Support reliable operation in vacuum or sealed environments

• Help manufacturers meet international quality and safety standards

In aerospace and satellite systems, where repairs are impossible, low outgassing materials are mandatory. In electronics manufacturing, they help prevent hidden failures that may only appear months or years after production.

Typical Applications of Low Outgassing Adhesives

Low outgassing adhesives are used across a wide range of high-precision applications, including:

• PCB bonding, encapsulation, and potting

• Optical bonding for lenses, sensors, and displays

• Semiconductor and chip packaging

• Aerospace electronics and satellite components

• Medical and scientific instrumentation

In many cases, low outgassing adhesives are used together with conformal coatings to provide both mechanical stability and environmental protection.

Low Outgassing Adhesives vs Standard Adhesives

The table below highlights the key differences between low outgassing adhesives and conventional adhesive materials.

How Low Outgassing Performance Is Tested

Low outgassing adhesives are typically evaluated using standardized testing methods. These tests measure how much material is released when the adhesive is exposed to heat or vacuum conditions.

Common evaluation criteria include:

• Total mass loss during testing

• Amount of condensable vapor produced

• Material stability after thermal exposure

These tests ensure the adhesive meets the requirements for electronics, aerospace, and optical applications.

Key Factors to Consider When Selecting Low Outgassing Adhesives

Choosing the right low outgassing adhesive requires more than checking a datasheet. Manufacturers should consider:

• Curing method, such as UV, heat, or room temperature

• Operating temperature and environmental exposure

• Substrate compatibility with metals, plastics, or ceramics

• Electrical insulation and mechanical strength requirements

• Compliance with industry and customer specifications

Working with an experienced adhesive supplier helps reduce risk and ensures the selected product performs as intended.

Supporting High-Reliability Manufacturing in Malaysia

Malaysia’s electronics and precision manufacturing sectors continue to grow, increasing demand for advanced adhesive solutions. High humidity, strict export requirements, and global quality standards make low outgassing adhesives especially important for local manufacturers.

Pacific Adhesive Systems (M) Sdn Bhd supplies high-performance adhesive solutions, including low outgassing epoxy and UV adhesive systems, to support reliable electronics production in Malaysia. With technical expertise and application support, the company helps manufacturers improve product quality and long-term performance.

Conclusion

Low outgassing adhesives are essential materials for modern electronics, aerospace, and optical applications. By minimizing volatile emissions, they protect sensitive components, maintain performance, and reduce the risk of long-term failures. For manufacturers focused on reliability and quality, selecting the right low outgassing adhesive is a critical part of the production process.