Protecting sensitive electronic components from moisture, vibration and thermal stress.
Potting & Encapsulation
Potting and encapsulation surrounds a component - typically electronic - in a cured resin, protecting it from moisture, vibration, thermal cycling and mechanical shock.
The Potting Process
Getting an even, void-free fill matters more here than in most applications, since air pockets or inconsistent mixing can create weak points exactly where protection is needed most.
Potting fills a housing or enclosure around a component with a two-component resin, which then cures to form a solid, protective block around the part. Encapsulation follows the same principle but the cast part is not contained within an enclosure.
- Consistent, void-free fill is critical - trapped air can create weak points or thermal hotspots in the cured resin.
- Many potting resins benefit from on-board de-gassing before dispensing, particularly for optically clear or safety-critical applications.
- Accurate mix ratio matters for cure time and final material properties - too far off ratio and the resin may not cure fully and the mechanical properties of the resin will not be reached.
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Materials Used for Potting
- Epoxy - Very high-physical & mechanical properties for potting and encapsulation, these systems are typically low viscosity to allow the resin to flow well to fill complex enclosures without voids.
- Silicone - Flexible potting, particularly valued where thermal cycling or vibration resistance matters more than rigidity.
- Polyurethane - Most commonly used potting material due to lower cost and good properties. Can be considered a general purpose potting product, but higher grade fire retardant systems are available.
2KM Machines for Potting
Potting spans a wide viscosity range across its three compatible materials, so machine choice depends on your specific resin.
- PGM 100 Compact / PGM 100 Standard - low-viscosity epoxy and polyurethane potting.
- PGM 200 / PGM 320 - mid-to-high viscosity potting resins from pressurised vessels, with the PGM 320 adding on-board de-gassing and ratio traceability for safety-critical applications.
- PGM 400 / PGM 420 - the highest-viscosity potting compounds, dispensed directly from pails or drums.
Industries Relying on Potting
1. Electronics - potting and encapsulation of components for protection against moisture, vibration and thermal stress, including EV battery components.
2. Sub-Sea - encapsulation and protection of components exposed to pressure, moisture and harsh marine conditions.
Potting - FAQs
What is meant by potting and encapsulation?
Potting fills a housing or enclosure around a component with a two-component resin, protecting it from moisture, vibration and thermal stress. Encapsulation applies the same principle to coat the part, but no enclosure or box is used.
What materials are generally used for potting?
Epoxy is used where high strength and rigidity are needed, silicone where flexibility and thermal cycling resistance matter more, and polyurethane across a wide range from lightweight foams to dense, rigid fills.
What industries might be involved in potting and encapsulation?
Electronics is the clearest example - potting and encapsulation protect components from moisture, vibration and thermal stress, including in EV battery applications. Many other industries will encapsulate parts including Sub-sea and Marine who rely on encapsulation to protect components from high pressure and moisture ingress.
Is purchasing resin in bulk containers more cost effective than manually mixing from small tins or kits?
Generally, yes - bulk containers avoid the packaging premium built into small pre-measured kits, and reduce cost per litre for higher-volume production. Small kits suit occasional or very low-volume use, where convenience outweighs the per-unit cost. A 2KM machine dispensing directly from bulk containers combines that cost advantage with metered accuracy you would not get from manually measuring out of a tin.
Would a 2KM machine help to reduce cost and speed up my potting process?
In most cases, yes - automated metering, mixing & dispensing reduces the waste and inconsistency that comes with manually measuring and mixing resin, and dispenses at a consistent, repeatable rate. The option to de-gas the material ‘on-board’ makes a machine delivered solution much faster, cleaner and more reliable.
Get In Touch
Discuss Your Potting Application
Not sure which resin or machine fits your potting process?
Call us today on +44 (0) 1527 834 720 or email us at sales@2km.co.uk
Or complete the form below and a member of our engineering team will be in touch to discuss your specific process requirements.
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With over 50 years of continuous research and development, we stay at the forefront of manufacturing innovation in metering and dispensing technology.
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Our expertise spans extreme material behaviours and complex process requirements across wide range of industries - from wind energy to medical devices to subsea applications.
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Our committed team is at the heart of our success. We design, build, and commission every machine from our UK facility in Bromsgrove, Worcestershire.