PCB Hardening Services

Plasma Ruggedized Solutions (PRS) is an industry leader in protecting critical electronics systems by providing advanced material coatings and ruggedization that enable PCBs to operate under challenging conditions. With PCB hardening services, we can provide long-term solutions that mitigate performance and reliability concerns that lead to system failures, ensuring that PCBs in demanding applications can continue to function as intended. While some PCBs may be incompatible with this process, we offer a range of capabilities to meet performance and reliability requirements for compatible systems. 

Why is PCB Hardening Necessary for Critical Electronics?

A variety of today’s critical electronic systems operate in harsh environments, often exposed to shock, vibration, thermal stress, extreme cold, and moisture, and are susceptible to tin whisker formation. Many systems, especially legacy or commercial-off-the-shelf (COTS) printed circuit boards, are not designed for these conditions. Without proper protection, critical PCB assemblies face increased risk of failure, degraded performance, and shortened lifespans, whereas hardening offers a cost-effective alternative to replacing faulty boards.

Environmental Threats and Performance Risks of Non-Hardened PCBs

PCBs must be reliable to ensure the safety of mission-critical systems; they cannot be easily replaced and can cause massive downtime if not properly protected against the operating environment. Potential threats and risks to critical electronics in harsh conditions include:

• Vibration and mechanical shock
• Thermal cycling and extreme temperatures
• Moisture, corrosion, and contamination
• Tin whisker growth and electrical failure
• Long-term exposure leading to system degradation

Benefits of PCB Hardening Services from Plasma Ruggedized Solutions

PCB hardening services offer a range of benefits for applications in demanding environments, providing excellent protection against various environmental factors and performance risks to ensure the reliability of critical electronic systems, such as:

• Sustaining reliable performance in harsh environments
• Extending product lifespan, indefinitely in some cases
• Reduced maintenance, downtime, and failure rates
• Protecting investment in existing or obsolete electronics
• Enabling systems to operate where they are otherwise unable

Our PCB Hardening Process and Protective Capabilities

At Plasma Ruggedized Solutions, we provide comprehensive PCB hardening services to reduce the risk of critical failures and ensure the performance of electronic systems in harsh operating environments. Our process follows these steps to deliver reliable PCBs:

1. Evaluate the PCB condition and component quality, looking for signs of damage and manufacture integrity.
2. Begin with a DI water wash and compatible plasma treatment, then apply masking or demasking for selective protection before wash and bake. If needed, examine for further cleaning.
3. Apply coating solution, either conformal coating, parylene coating, or other materials, depending on the application requirements.
4. Complete final validation and quality checks.

Challenges, Process Methods, and Applications for PCB Hardening

Several challenges may arise during the PCB hardening process, due to the PCB condition or contamination, whether a COTS board can be hardened, and component sensitivity. As a process, hardening relies on predictable, controllable failure mechanisms, which are undermined by contamination, existing defects, or fundamental incompatibility, leaving PCBs susceptible to their environments. In these cases, hardening may worsen PCB performance. However, we can work with compatible PCBs and electronic systems, utilizing the following process methods to protect mission-critical electronics across industries:

• Plasma Surface Treatments
• Advanced Material Coatings
• Cleaning and Compatibility
• Defense and Aerospace
• Industrial
• Medical
• Robotics

PCB Hardening Services for Various Industries

• Defense and Aerospace
• Industrial
• Medical
• Robotics

Contact PRS about Hardening Services for Superior PCB Protection

Since 1990, Plasma Ruggedized Solutions has provided critical electronics support and protection for highly regulated and demanding industries. With the ability to provide engineering, manufacturing, and prototyping, we have worked with OEMs, Tier 1 manufacturers, and government contractors, handling small- to large-scale projects for reliable PCBs across a range of extreme operating environments. Our PCB hardening services complement existing engineering teams by providing compatible materials and expertise to meet your exact requirements for long-term operation and reliable performance. Contact us for more information or request a quote to begin your project today.