How EMI Shielding Coatings Reduce Product Failure Rates?
We are in a tech-driven world with electronic devices and electronics everywhere – homes, factories, vehicles, and even medical devices. And with more electronics, there is a significant challenge – electromagnetic interference (EMI). If left unchecked, EMI can cause unacceptable combinations of frequent malfunctions, decreased device life, and total system failure.
That’s where EMI shielding coatings serve as a viable and affordable option that can prevent EMI by blocking or lessening the impact of electromagnetic interference, technological failure, and impact that might happen. This blog explains how EMI shielding coatings, especially arc spray coating, play a vital role in reducing product failure rates and enhancing device performance.
What is EMI and Why Is It a Problem?
Electromagnetic interference (EMI) is a disruption caused by electromagnetic waves (operations or behaviour) through electronics and electrical devices. EMI can disrupt performance in other devices where signal transmission is disturbed, loss of transmitted data may occur, or damaged circuits may take place, and element performance behaviour cannot be relied on.
Typically, EMI is produced from the following sources;
- Mobile phones
- Wi-Fi routers
- Industrial equipment
- Motors and transformers
Ensuring these devices perform as expected in an EMI-heavy environment is problematic for engineers and manufacturers.
How EMI Shielding Coatings Reduce Product Failures?
1. Increased Device Reliability
EMI shielding coating can prevent interference with sensitive components. In turn, this will prevent unexpected shutdowns, signal errors, or overheating – all common causes of product failures.
2. Improved Circuit Protection
Shielding can prevent unwanted currents or voltage spikes from reaching the internal circuitry. This ultimately helps eliminate the risk of short circuits, burned components, or loss of data.
3. Enhanced Signal Integrity
When it comes to communication devices or sensor performance, clean signal transmission is critical to accuracy and speed. This is especially important in medical devices, aerospace, and automotive electronics, where using dirty signals can have serious repercussions.
4. Fewer Warranty Claims and Recalls
When the ultimate failure of the product is due to EMI shielding, the manufacturer is burdened with costly repairs, returns, or recalls. The potential for reducing post-sale failures is extraordinary by implementing EMI shielding coatings and restoration, improving brand image and customer confidence.
The Role of Arc Spray Coating in EMI Shielding
Arc spray coating is a widely used technique for applying EMI shielding coatings. The process uses metal wires that are melted with an electric arc to create molten particles that are then sprayed onto a surface to form a uniform conductive coating.
The benefits of arc spray coating for EMI shielding include the following:
- High conductivity for excellent shielding from EMI.
- Very strongly adherent to plastics, composites, and metals.
- Coating thickness customized to the EMI protection level required.
- Low thermal impact, which makes it safe for heat-sensitive components.
- Cost-effective for mass production.
Arc spray coating is an excellent facility for consumer electronics, military electronics, automotive controls, etc.
In The End
EMI-related product failures can be costly, risky, and damaging to the brand’s credibility. As such, EMI shielding coatings are no longer optional but a requirement of modern product design.
Whether you’re designing small consumer electronics or complex industrial systems, adding EMI shielding is a good way to enhance product reliability, reduce the chance of failure, and comply with regulations.
Making EMI protection decisions today will lead to fewer problems in the future.