Conformal Coating Services for Aerospace & Defense

Products and systems manufactured or processed for aerospace and defense purposes must meet some of the world’s most demanding standards and regulations. The equipment and devices used in these industries often stretch the rules of physics to achieve their goals, and as such, there’s no room for error in any process that goes into creating these products.

At Plasma Ruggedized Solutions (PRS), we specialize in plasma treatments, potting and encapsulation, and conformal coating services for these challenging applications. We focus on aerospace and defense projects that fall into the C4ISR and C5ISR categories for the security forces of the United States and NATO. These applications require the highest-performing materials and engineering solutions. PRS takes pride in our ability to meet or exceed these requirements.

Learn more about our conformal coating services, industries served, and certifications below, or contact PRS to learn more about our capabilities. Contact Us

Conformal Coatings for the Toughest Applications

PRS works with leading aerospace and defense OEMs, including Aerojet, Boeing, Raytheon, Honeywell, GD, Northrup Grumman, GE, and Lockheed-Martin. Line operating devices may experience extreme temperatures and extraordinary shock and vibration, among other challenges. Given the harsh environmental threats our clients face, PRS works to determine the best conformal coating methodology and material choices for the specific application need.

Conformal Coating for Specialized Aerospace & Defense Applications

Conformal Coating for Underwater Vehicles & Systems

Submarines, unmanned underwater vehicles (UUVs), and deep-sea defense sensors are constantly exposed to moisture, saltwater corrosion, and extreme pressure.  PRS's conformal coatings and potting solutions offer long-term protection against water intrusion, salt, and chemical damage.  Our parylene coatings deliver a uniform, pinhole-free barrier that ensures critical underwater electronics maintain functionality in submerged and high-pressure environments.  

Conformal Coating for Spacecraft & Satellite Electronics

Electronics used in space must withstand extreme thermal cycling, radiation exposure, and vacuum conditions.  PRS coatings, including Blue Spark parylene and PRS XY-C, provide proven protection against outgassing, radiation effects, and temperature extremes.  These coatings ensure mission-critical systems-from satellites to launch vehicles-meet stringent NASA, NADCAP, and AS9100 standards for reliability in space applications. 

Conformal Coating for Drones & UAV Systems

Unmanned aerial vehicles (UAVs) and drones must operate in harsh environments where dust, moisture, vibration, and temperature threaten sensitive electronics.  PRS specializes in applying conformal coatings, potting, and encapsulation to protect navigation, communication, and surveillance systems in UAVs. Our solutions extend operational reliability, making drones capable of completing missions under extreme deployment conditions.  

Conformal Coating for Missiles & Guided Munitions

Missiles, rockets, and guided munitions experience intense acceleration, vibration, and heat during launch and flight.  PRS's high-performance coatings and encapsulation materials protect circuit boards and guidance systems from these extreme stresses.  By reducing vibration impact, shielding against thermal shock, and preventing moisture intrusions, PRS ensures that missile and rocketry electronics remain mission-ready.

Conformal Coating for Remotely Piloted Vehicles (RPVs)

Land, sea, and air-based remotely piloted vehicles (RPVs) require electronics protection that resists shock, dust, moisture, and tampering.  PRS's conformal coatings and potting solutions safeguard advanced communications, reconnaissance, and targeting systems, allowing RPVs to perform reliably across diverse mission environments.  With ITAR-compliant and military-grade solutions, we ensure RPVs maintain peak performance in critical defense applications. 

Benefits of PRS’s Conformal Coating Services

Conformal coatings provide a uniform, pinhole-free circuit board coating that allows for complete protection from moisture and impact. Our NADCAP, AS9100, and NASA-certified conformal coating services meet FDA requirements and military specifications. Some advantages of our conformal coating process include:

• Advanced thin film applications (angstrom level) than other coating processes
• Excellent mechanical and thermal-resistant coating materials
• Water, chemical, and corrosion-resistant properties
• Reduces vibration effect for circuit boards

We have the experience and engineering expertise to provide plasma treatments, potting and encapsulation, and conformal coating services to keep systems operating in challenging environments. Our services include conformal coating removal and stripping to rework assemblies and restore failed devices.

Conformal Coatings for Aerospace & Defense

Our capabilities include an arrangement of industry-certified and regulated conformal coating services. We choose an optimal coating method for your application’s requirements to deliver a consistent and smooth conformal coating that protects from moisture and impact. Below are some specific application processes that achieve high-quality conformal coating results:

• Brush coating
• Dip coating
• Spray coating
• Vapor deposition

Aerospace & Defense Plasma Treatments

Plasma desmear and etch-back PCB treatment services remove the residues left behind following circuit board manufacturing drilling processes. These treatments ensure circuit reliability in PCBS by promoting good electrical contact between their interconnects and copper through-plating. Additional benefits of plasma treatments include:

• Safe & environmentally friendly materials
• Does not create hazardous waste
• By-products are 100% safe for disposal

Potting and Encapsulation Solutions for Aerospace & Defense

This process encapsulates an electronic assembly with a compound to protect the components from shock, vibration, corrosion, and contaminants. With potting and encapsulation, electronic assemblies can resist dust, moisture, and chemical contamination, as well as security threats, including tampering and reverse engineering. Added features include:

• Enhanced circuit reliability
• Protection against voltage arcs & short circuits
• Prevents the formation of tin whiskers

Additional Conformal Coating Services for Drones & Smart Munitions

PRS offers a range of coating solutions engineered explicitly for drones and smart munitions. We can perform a number of services to resist moisture and impact damage, protecting these critical defense systems from dust, sand, salt, water, and mold.

Drones are classified as a C4ISR surveillance and reconnaissance device. PRS specializes in conformal coating for drone defense electronics and can provide potting and encapsulation services to your specifications. For guided smart munitions, a C5ISR device, we offer our core services of potting and encapsulation, plasma treatments, and conformal coating. Request a Quote

Conformal Coating Quality Certifications

At Plasma Ruggedized Solutions, we ensure that your conformal coating provider meets industry production and safety standards while offering you the highest quality products available.

PRS complies with NADCAP, NASA, AS9100, ISO 9001:2008, COMSEC, ITAR, RoHS, and FIPS. These certifications indicate that we adhere to strict industry standards in our conformal coating, potting and encapsulation, underfill, and plasma treatment processes.

We use low-VOC count materials and environmentally friendly treatments, cleaning, and disposal processes to make operations as “green” as possible. Through our sustainable processes, we have reduced single-use materials by 20% and rely on 95% recycled metals in our manufacturing processes.

Cleanroom Capabilities

PRS features two Class 10 ISO-2 cleanrooms for all processing. Our facilities are practically cleanrooms themselves, with air filtration to 20,000 ppm. All parts are inspected, cleaned upon arrival, and baked to remove excess moisture. A critical engineering and service feature is our proprietary plasma etch-back or surface treatment to ensure maximum coating material adhesion.

Conformal Coating Formulated Materials

Plasma Ruggedized offers a unique arrangement of RoHS, REACH-compliant, UL-compliant, and ISO 10993-compliant coating solutions based on your industry needs. Our conformal coatings, such as the Blue Spark™ Parylene Dimer, offer a high-performance film visible in UV light for convenient inspection while yielding excellent chemical, electrical, and physical properties. Our Parylene C Dimer, PRS XY-C™ Dimer, presents the same high-performance, high-purity characteristics as Blue Spark™ without the added UV tracer material.

Additionally, we offer our Kryptos-17™ Epoxy Resin Potting Material for operational protection with a better-finished product and greater reliability than other electronic potting materials. Our line of underfill materials, including state-of-the-art Kronos-10™, protects your PCBs from the thermal dissipation of BGA, LGA, and other like componentry that create and emit significant heat signatures.

Contact Plasma Ruggedized Solutions Today for Parylene Coating Services and More

Plasma Ruggedized Solutions can provide engineering expertise as a leader in conformal coating services, as well as potting and encapsulation for aerospace and defense products. You can learn more about the importance of parylene and its relevance to the defense industry in our whitepapers.