This month Texcel has officially opened its new dedicated conformal coating room at our Crayford facility, marking another step forward in our manufacturing capability and process control.
Conformal coating is often the quiet protector of complex electronics. It safeguards PCBs against moisture, dust, chemicals and temperature extremes, extending product life and improving field reliability. For many of the sectors we serve, from HV power systems to industrial instrumentation, it is not optional, it is critical.
A Purpose-Built Environment
The new coating room is a fully contained, bright and spacious area located directly off the main production floor. Designed specifically for higher volume and longer production runs, it allows Texcel to operate with greater consistency, better environmental control and significantly improved throughput.
A key part of that control is environmental stability. The room is temperature regulated and humidity monitored to ensure optimal coating conditions at all times. Managing both temperature and moisture levels is critical in conformal coating, as fluctuations can affect viscosity, atomisation, adhesion and curing performance. By maintaining stable conditions, we reduce the risk of defects such as bubbling, poor levelling or incomplete coverage, ensuring a more reliable finish.
The room is fitted with an ATEX-rated extraction system, designed to safely manage combustible fumes. Air is drawn through three stages of filtration.
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A primary filter captures the majority of overspray
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A secondary filter further refines the airflow
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A final filter removes fine particles before air is discharged externally via a compliant three-metre chimney system
The result is a clean, controlled and regulation-compliant environment that protects both product and operator.
From Aerosols to Engineered Application
Previously, coating was applied using aerosols. While effective for low volumes, this approach limited both consistency and production time. For health and safety reasons, spraying could only take place after shift hours, restricting coating to around one hour per day.
As Senior Production Engineer, Mike Keens explains:
“When you first use a can it rushes out, then towards the end it slows right down. You have to be extremely careful with coverage.”
This variability can affect coating thickness and uniformity. The new system eliminates that inconsistency.
Texcel has installed a professional HVLP spray gun within the booth, allowing precise control over material flow, air pressure and fan pattern. Operators can select different nozzles and adjust the spray width from narrow to wide, ensuring even coverage across varying board geometries.
This new controlled application process significantly reduces the risk of uneven layers, excessive build-up or trapped air, helping to avoid issues such as bubbles and inconsistent coating thickness. The result is a smoother, more uniform protective layer with improved long-term reliability.
Temperature control within the room is another critical improvement. Stable environmental conditions reduce defects, minimise overspray and improve drying performance, leading to faster turnaround times and more predictable results.
Commercial and Operational Benefits
The investment delivers clear commercial advantages. By purchasing coating material in bulk rather than in aerosol form, Texcel can secure material at up to four times lower cost. For customers with commercial volumes, this represents a meaningful cost saving without compromising quality.
More importantly, the dedicated space enables longer run times, repeatable processes and scalable capacity. Staff are fully trained, equipped with appropriate PPE and operating within a controlled and documented process framework.
This development also aligns with Texcel’s ongoing strategy to expand automation and enhance internal capability, as outlined in recent operational updates
Designed for the Next Stage
The new conformal coating room is part of Texcels planned infrastructure for future growth. It allows Texcel to support larger volumes, more complex assemblies and customers operating in demanding environments where protection and reliability are paramount.
Looking ahead, we intend to further develop the room with robotic application technology. Introducing automated conformal coating will deliver even greater repeatability, tighter process control and increased throughput, supporting both higher volumes and more complex selective coating requirements.
For customers requiring controlled, repeatable and commercially efficient conformal coating as part of their build, this capability is now fully embedded within Texcel’s production offering.
If you would like to discuss how this enhanced process can support your next project, our team would be pleased to help.
