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August 9, 2025 21 mins

Welcome back to Adhesion Matters. Adhesives have quietly evolved from simple bonders into indispensable, high-performance materials in PCB manufacturing—critical for thermal management, electrical performance, and environmental resilience.  In this episode, we explore how adhesives empower modern electronics: enabling miniaturization, supporting flexible and high-density circuits (think HDI and flex PCBs), and meeting rising demands in consumer tech and electric vehicles.

You’ll discover how specialized adhesive families—epoxies, acrylics, silicones, polyamides, polyurethanes—each offer unique strengths, from rigidity and heat-resistance to flexibility, reworkability, and flame protection. Hear how engineers tailor selections based on criteria like thermal conductivity, environmental durability, and the ability to withstand mechanical or thermal stress over time.

Learn about real-world applications across the PCB manufacturing spectrum: surface mount adhesive placement, underfills, die attaches, conformal coatings, potting compounds, encapsulants, and even thermal interface materials that control heat in EV power systems.

Finally, we look ahead at the future of adhesive innovation: extreme miniaturization, advanced thermal management for EVs, and a push for eco-friendlier, halogen-free, low-toxicity formulations.

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Transcript

Episode Transcript

Available transcripts are automatically generated. Complete accuracy is not guaranteed.
Elena Bondwell (00:00):
What holds our advanced electronics together?
You know, when you think aboutyour smartphone or maybe the
complex systems in an electriccar, you probably picture
intricate wiring, precisesoldering.
But here's the surprising,often unseen answer.
It's not just solder.
It's a whole world of highlysophisticated adhesives.

(00:20):
These are the true unsungheroes working quietly behind
the scenes.
Today, we're taking a deep diveinto that world.
Specifically, we're focusing onadvanced adhesive solutions in
printed circuit boardmanufacturing.

Lucas Adheron (00:32):
That's right.
And our mission today really isto uncover how these adhesives
have fundamentally transformed.
They've gone way beyond justbeing simple bonding agents.
They've become trulyindispensable high-performance
materials.
You should think of them ascritical enablers for, well, for
the miniaturization, theincreased functionality, and the
enhanced reliability thatmodern electronics demand.
We're talking everything fromthe tiniest wearables right up

(00:54):
to the really robust systems inelectric vehicles.

Elena Bondwell (00:57):
Okay.
And to guide us through thispretty fascinating topic, we've
pulled from some comprehensivesources.
We've got a detailed analysisof leading manufacturers Dow,
DuPont, Henkel, and Huntsman.
And we also have someadditional material from
Bodo Möller Chemie.
They're a key distributor formany of these specialized
adhesives.
Okay.
Let's unpack this.

(01:17):
So you're saying it's more thanjust sticking things together.
What exactly are theseadhesives enabling in PCBs?
What's their critical functionbeyond just holding things in
place?

Lucas Adheron (01:28):
Well, their roles are incredibly multifaceted.
They act as crucial enablersfor the entire system's
performance and its longevity.
First off, there's thermalmanagement.
With components getting morepowerful, they generate more
heat.
Right.

Elena Bondwell (01:40):
A big issue.

Lucas Adheron (01:41):
Exactly.
So these adhesives areessential for dissipating that
heat effectively.
It's absolutely vital toprevent device failure and
ensure, well, a long lifespan.
Then you have their electricalproperties.
Adhesives can be formulated toprovide precise insulation for
sensitive areas.

Elena Bondwell (01:57):
Okay, so stopping short circuits.

Lucas Adheron (01:58):
Precisely.
Or, conversely, they can evenoffer precise electrical
conductivity where needed.
This gives you a flexible,often more space-efficient
alternative to traditionalsoldered joints in certain
applications.

Elena Bondwell (02:11):
Interesting.
So they can insulate orconduct?

Lucas Adheron (02:13):
Depending on the formulation, yes.
And finally, they providerobust environmental protection.
These materials shield delicatecomponents from moisture,
corrosive elements, extremetemperature changes, mechanical
shock, vibration, You name it.

Elena Bondwell (02:28):
So without this protection, our devices just
wouldn't survive daily life.

Lucas Adheron (02:32):
Honestly, no, they simply wouldn't hold up to
the everyday abuses theyencounter.

Elena Bondwell (02:36):
It's really easy to overlook these unseen
components.
So when we talk aboutbreakthroughs like in device
miniaturization or say extremetemperature tolerance, are these
adhesives truly the primaryenabler or just one piece of the
puzzle?

Lucas Adheron (02:49):
Oh, they are absolutely a primary enabler.
particularly for how far we'vepushed the boundaries.
This shift is directly drivenby that relentless push towards
miniaturization in consumerelectronics, the need for
high-density interconnects, youknow, HDI boards, and the
increasing use of flexible andrigid flex circuits.

Elena Bondwell (03:09):
HDI boards.

Lucas Adheron (03:10):
Yeah, high-density interconnect.
They pack more components intosmaller spaces using features
like blind vias and microvias.
Think of them as tiny, buriedconnections that allow for
incredible density.
Adhesives are critical Now,this is where it gets

Elena Bondwell (03:30):
really interesting.
We're not talking about someone-size-fits-all glue here, are
we?

Lucas Adheron (03:34):
Not at all.

Elena Bondwell (03:34):
There's a whole palette of chemical families,
each with unique strengths.
Let's dive into some of themain types.

Lucas Adheron (03:39):
Absolutely.
Each chemical family offersdistinct advantages for specific
use cases.
First up, epoxy adhesives.
Think of them as the tough guysof the adhesive world.
They're key in sight.
unmatched rigidity andresistance.
If you need a bond thatabsolutely won't flex and can
stand up to incredible heat orharsh chemicals, epoxy is your

(04:01):
go-to.
They're literally the backboneof many devices, ensuring
structural integrity whereflexibility would actually be a
weakness.

Elena Bondwell (04:08):
Got it.
Tough and rigid.
What's next?

Lucas Adheron (04:10):
Next, acrylic adhesives.
These are more of the versatileperformers.
They offer a great balance offlexibility and strength.
They're less rigid thanepoxies, which makes them
superior for things likeflexible circuits that need
dynamic bending Imagine afoldable phone's hinge
mechanism.

Elena Bondwell (04:26):
Ah, okay.

Lucas Adheron (04:27):
And they're also often fast curing when exposed
to UV light, which really speedsup manufacturing.

Elena Bondwell (04:31):
UV curing, right.
Makes sense for speed.

Lucas Adheron (04:33):
Then we have silicone adhesives.
Yeah.
These are characterized byextreme flexibility and high
heat resistance.
They're ideal for delicatecomponents and for sealing
things up.
They offer exceptionalstability across a remarkably
broad temperature range,typically from, say, minus 45
degrees Celsius all the way upto 275 C in in some specialized
cases.

Elena Bondwell (04:53):
Wow, that's a huge range.

Lucas Adheron (04:55):
It is.
Silicones provide superiorprotection against shock and
vibration.
They're robust under mechanicalstress from thermal cycling.
And crucially, many arereworkable.

Elena Bondwell (05:06):
Reworkable, meaning you can remove them.

Lucas Adheron (05:08):
Exactly.
Which significantly facilitatesrepairs and upgrades.
A big deal these days.

Elena Bondwell (05:13):
Okay, silicones for flexibility and heat range.
What else?

Lucas Adheron (05:16):
Polyamide adhesives.
These are valued for their veryhigh thermal stability.
They can withstand temperaturesup to 300 degrees Celsius.

Elena Bondwell (05:23):
Even higher.

Lucas Adheron (05:24):
Yep.
So they're often found in thehighest reliability flexible
circuit constructions whereextreme heat is just a constant
challenge.
I think aerospace, maybe somedemanding automotive uses.

Elena Bondwell (05:34):
Okay.
And the last main type.

Lucas Adheron (05:35):
And finally, polyurethane adhesives.
These are incredibly adaptable.
They can be formulated foralmost anything high
flexibility, crack resistance,flame retardancy, even thermal
conductivity.
This makes them excellent forencapsulation and insulation
where you need a toughprotective shell that It can
maybe also manage heat orprevent fire spread.

Elena Bondwell (05:54):
So that's the core palette of chemical
families.
But are there other morespecialized adhesive types,
maybe ones used for very nicheapplications or I don't know,
even something common like superglue?
Where does that fit in ordoesn't it fit?

Lucas Adheron (06:08):
That's a great question, because, yes, the
specialized world is vast.
Beyond those main families, youhave things like UV adhesives,
which we touched on for theirincredibly fast curing, perfect
for high speed assembly lines.
Then there are pressuresensitive adhesives, think,
High-tech tapes, basically.
But they typically can't handlethe high-processing heat

(06:29):
involved in making a PCB.
Right.

Elena Bondwell (06:30):
They'd melt.

Lucas Adheron (06:31):
Exactly.

Elena Bondwell (06:32):
Yeah.

Lucas Adheron (06:32):
But their heat-resistant cousins, often
called assembly-resistantadhesives, can handle that heat.
And yes, even cyanoacrylates,what most people know as
superglue, they exist for veryquick, maybe minor fixes during
prototyping or something.
But they're generallyunsuitable for actual PCB
applications involving high heator vibration.
So definitely don't try tosuperglue your graphics card
back together.

Elena Bondwell (06:53):
Uh-huh.
Okay.
Noted.
So how do engineers choose?
What are the critical thingsthey look for?

Lucas Adheron (06:58):
Well, the selection process is highly
nuanced.
It really hinges on severalcritical performance criteria.
This includes mechanicalstrength, obviously.
You need strong, durable bondsthat won't fail.
Sure.
Then thermal stability.
The adhesive can't degradeunder high temperatures, both
during manufacturing and whenthe device is actually running.
And reworkability, which wementioned with silicones.

(07:20):
The ability to remove a curedadhesive for repairs or
component replacement.
That's increasingly valued,both for serviceability and
sustainability.

Elena Bondwell (07:30):
Ah, so no more game over if one tiny component
fails.
That seems like a huge leap,both for the consumer's wallet
and maybe the planet's recyclingefforts, right?

Lucas Adheron (07:40):
Absolutely.
It makes a Massive difference.
Another key aspect is CTEmanagement.

Elena Bondwell (07:45):
CTE.

Lucas Adheron (07:45):
Coefficient of thermal expansion.
It's about how adhesivesminimize stress caused by
different materials expandingand contracting at different
rates when the temperaturechanges.
Think of the adhesive acting asa kind of stress reliever,
preventing components frombasically tearing themselves
apart as temperatures fluctuate.

Elena Bondwell (08:01):
That's fascinating, like a tiny shock
absorber between materials.
What's one common pitfall,though, or maybe a misconception
engineers face when choosing?
What's the biggest gotcha Thesedifferent types are designed to
overcome.
A

Lucas Adheron (08:14):
big gotcha is probably underestimating the
long-term environmental stress.
An adhesive might lookfantastic in initial lab tests,
right?
Strong bond looks good.
But if it can't withstandrepeated thermal cycles, heating
up, cooling down day after day,or humidity or vibration over
years of use, then it'sultimately a failure.
The distinct types we talkedabout are designed to overcome

(08:37):
exactly that, to create a bondthat is not just strong
initially, but predictablystrong for the entire expected
lifespan of the device under thespecific, often harsh
conditions it will actuallyface.

Elena Bondwell (08:48):
Right, reliability over the long haul.
Okay, now that we know whatthese adhesives are made of,
let's see them in action.
Where are they actually usedacross the PCB manufacturing
process day to day?

Lucas Adheron (08:58):
Okay, yeah, they're integral at numerous
stages.
Let's start with componentattachment.
In surface mount technology, orSMT bonding, adhesives are
frequently used to attach chips,SMDs, surface mounted devices,
to the PCB before the solderingstep.

Elena Bondwell (09:13):
Before soldering?
Why?
To

Lucas Adheron (09:15):
hold them in place, especially for
double-sided boards goingthrough reflow ovens.
UV curing adhesives are oftenpreferred here because they cure
so quickly, which is crucialfor high volume production
lines.
Then, a truly criticalapplication is flip chip
underfill.
This is absolutely vital formechanically stabilizing
delicate flip chips and also forcompensating for material

(09:36):
stresses.

Elena Bondwell (09:37):
Underfill.
So it flows underneath thechip.

Lucas Adheron (09:39):
Exactly.
The underfill literally flowsinto those minute gaps beneath
the chip.
It reinforces the tiny solderjoints and minimizes stress from
thermal mismatches between thechip and the board.
And importantly, some underfillformulations are designed to be
reworkable.
That allows for repair orreplacing a faulty chip, which
is a massive benefit forcomplex, expensive components.

Elena Bondwell (09:59):
Okay, that makes sense.
What other attachments?

Lucas Adheron (10:01):
You also have die attach adhesives, used
specifically for bonding thesemiconductor die itself.
These often require very lowwarpage, you don't want the chip
bending, and sometimes preciseelectrical conductivity.
And for applications wheremaybe a full underfill isn't
needed or is too costly, there'sedge bonding and corner
bonding.
Here, adhesives are justapplied to the outer sections of

(10:24):
a package, offering a morecost-effective solution for
targeted mechanical stability.

Elena Bondwell (10:30):
So different levels of securing components.
What about protection?

Lucas Adheron (10:33):
Right.
Beyond attachment, adhesivesprovide crucial protective
layers.
Things like glob top sealingcompounds and potting materials.
These are used to fullyencapsulate electronic
components.

Elena Bondwell (10:44):
Like burying them in protective

Lucas Adheron (10:46):
goo.
Kind of, yeah.
It provides robustenvironmental protection and
mechanical stabilization.
Then you have conformalcoatings.
These are applied as thinprotective layers to shield
entire PCBs from moisture,corrosion, and temperature
fluctuations.
It really extends theiroperational life.
And for high-power electronics,think inverters.
Batteries in EVs, encapsulationresin systems, are specifically

(11:09):
engineered.
They provide extreme mechanicaland electrical protection.
They help improve thermalmanagement by dissipating heat.
And crucially, they helpprevent flame propagation if
there's a short circuit.
That's paramount for safety,obviously.

Elena Bondwell (11:22):
Absolutely critical in things like cars.

Lucas Adheron (11:24):
Definitely.
Adhesives are also fundamentalto the structural integration of
multilayer PCBs.
They're critical for bondingflexible interlayers together or
bonding rigid cap layers inthese complex constructions.
And solder masks, those greenor sometimes other colored
layers you see on PCBs, thoseare essentially permanent
adhesive inks.
They provide long-termprotection, ensure high

(11:46):
reliability, and preciselydefine the areas where solder
connections are made.

Elena Bondwell (11:50):
I I never thought of solder mask as an
adhesive, but it makes sense.

Lucas Adheron (11:53):
It functions like one providing that permanent
protective layer.
Finally, their functional rolein thermal and electrical
management is rapidly expanding.
We have thermally conductiveadhesives, essential for
efficiently dissipating heatfrom power electronics.
And of course, thermalinterface materials, or TIMs.

Elena Bondwell (12:10):
TIMs, right.

Lucas Adheron (12:10):
Like Henkel's well-known Burkwistie brand
products, for instance.
These are essential.
They're designed todramatically improve heat
transfer between heat sources,like a powerful CPU or battery
cells, and their coolingsystems, like a heat sink.
Think of them as everythingfrom soft, compliant pads that
fill So filling every tiny

Elena Bondwell (12:39):
gap for better cooling.

Lucas Adheron (12:40):
Exactly.
And naturally, electricallyconductive adhesives offer a
solution for creating electricalcontacts or maybe performing
repairs without traditionalsoldering.
This is particularly valuablefor temperature-sensitive
components or substrates, wherethe heat from soldering could
cause damage.

Elena Bondwell (12:55):
Okay, wow, they really are everywhere in the
process.
Now let's look at the majorplayers, the companies pushing
the boundaries here.
You mentioned four big ones.
It's not quite head-to-headcompetition, you said, but more
an ecosystem of specialization.

Lucas Adheron (13:07):
That's a great way to put it.
It's like an ecosystem.
Let's call them the fourhorsemen of adhesion for our
deep dive.

Elena Bondwell (13:13):
I like it.
Let's go.

Lucas Adheron (13:14):
Okay, first up, Dow.
They are really the siliconespecialists, known for their
high-performance siliconesolutions under the Dow's old
brand.
Their key insight, or strength,is superior stability across
extraordinarily wide temperatureranges.
Remember that negative 45degrees C to 275 degrees C range
we mentioned?

Elena Bondwell (13:34):
Yeah, that was impressive.

Lucas Adheron (13:35):
That's Dow's territory.
This means robust protectionagainst mechanical and
environmental stress, and theyoffer flexible, often reworkable
options.
Dow focuses on diverse curingmechanisms, too, like Okay, Dow,
silicones, and temperaturerange.

Elena Bondwell (14:03):
Who's next?

Lucas Adheron (14:06):
Then there's DuPont, often seen as the
integrated innovators,especially strong in materials
for flexible circuits.
They offer a reallycomprehensive portfolio,
particularly excelling in andadhesive solutions for flexible
and high-speed circuits.
Their materials enable complex,multi-layer designs, like their
well-known Pyralux brandproducts.

Elena Bondwell (14:25):
The Pyralux.
Right.

Lucas Adheron (14:27):
Heard of that.
Their expertise spansacrylic-based solutions for
dynamic bending, epoxy-based forhigh peel strengths and
chemical resistance, and evenfluoropolymer solutions, which
are crucial for high-speed andhigh-frequency performance.
Think Pyralux HP, which youfind in demanding military,
automotive, and medicalapplications.

Elena Bondwell (14:45):
So do DuPont integrated solutions, especially
for flex and high speed.
Got it.
Number three.

Lucas Adheron (14:51):
Next, we have Henkel.
They are a real powerhouse inassembly protection.
They are recognized globally asa leader in qualified materials
for semiconductor packaging andPCB assembly.
Think brands like Loctite.
Echobaud Technobelty Multicore.
Henkel holds a dominantposition in things like
underfills and encapsulants thatare crucial for today's

(15:11):
miniaturized, high-densitypackages.
Their underfills are engineeredto enhance mechanical strength,
meet tough shock and bendingrequirements, and extend product
lifespan.
And again, they offer valuableoptions for reworkability.

Elena Bondwell (15:25):
Reworkability keeps coming up.
Seems important.

Lucas Adheron (15:27):
It really is.
Henkel also providescomprehensive conformal
coatings, SMT adhesives wetalked about earlier, and a very
wide range of thermal interfacematerials under their
Bergquistie brand.

Elena Bondwell (15:37):
Ah, Bergquistie.
That's the Tim brand youmentioned.

Lucas Adheron (15:39):
That's the one.
And it's worth noting here thatconnection to distributors like
Bodo Möller Chemie.
They are a key channel for manyof these specialized adhesives,
including Henkel's BergquistieTims.

Elena Bondwell (15:50):
That's a fascinating point.
about the distributors playingsuch a crucial role, it really
highlights how these industrygiants, the four horsemen we're
discussing, interact, maybe notjust competing directly.
But let's introduce Huntsmanfirst, and then maybe circle
back to that ecosystem dynamic.

Lucas Adheron (16:05):
Absolutely.
Good point.
And finally, Huntsman.
Think of them as thehigh-performance system
engineers.
They contribute robust epoxyand polyurethane systems under
their eraldite and erathanebrands.
These are vital for reallydemanding applications like
power electronics andencapsulation.
Their products, like Araldite2014-2, which is known for high

(16:26):
chemical and temperatureresistance, feature robust
thermal conductivity, excellentelectrical insulation, and
critical flame retardancy.
This is absolutely crucial forsafety and reliability,
especially in things likeelectric vehicles.

Elena Bondwell (16:38):
Right.
EV safety is

Lucas Adheron (16:40):
huge.
Yeah, exactly.
Huntsman also provides highlyreliable solder masks, like
their Probimer brand.
They actually have over 40years of experience just in
solder mask development alone.

Elena Bondwell (16:49):
40 years just on solder masks.
OK.
So Huntsman, high performancesystems, encapsulation, safety,
and solder masks.
So now that we've met all four,you hinted earlier at this
complementary ecosystem.
How exactly do thesespecialized companies
collaborate or maybedifferentiate themselves to

(17:09):
serve the whole PCB industry?
Because it sounds like amanufacturer might pick and
choose across these players forone board.

Lucas Adheron (17:16):
Exactly right.
What's really fascinating hereis that these companies don't
necessarily compete head-to-headacross the board.
Instead, they genuinely createa complementary ecosystem.
A manufacturer, for instance,might choose DuPont specifically
for their flexible circuits,where DuPont's expertise really
shines.
Then They might turn toHuntsman for the
high-performance encapsulationneeded for their power

(17:38):
electronics section, and thenmaybe rely on Henkel for the
critical underfills required forcomplex chip packages on that
same

Elena Bondwell (17:45):
board.

Lucas Adheron (17:46):
It suggests that no single company offers a
universally best solution forevery single adhesive
application.
Instead, each providesoptimized, specialized solutions
for particular segments andchallenges within the huge PCB
industry.
It's really about finding theright tool for the specific job
at hand.

Elena Bondwell (18:04):
So Specialization is key.
Okay, what does this all meanfor the future then?
How are adhesives continuing toevolve?
What are the big demandsdriving innovation now?

Lucas Adheron (18:14):
Well, adhesives are actively addressing several
major challenges, and they aredefinitely at the forefront of
innovation.
There's the continuedrelentless drive for even
greater miniaturization.

Elena Bondwell (18:23):
Smaller and smaller.

Lucas Adheron (18:24):
Enabling higher component density, finer pitches
between connections than everbefore.
And with increased powerdensity comes heat.
So thermal management isparamount.
Adhesives are becoming evenmore sophisticated for heat
dissipation and cruciallypreventing catastrophic thermal
runaways, especially inbatteries.
There's also a constant pushfor enhanced reliability and

(18:47):
durability.
Adhesives are being formulatedto withstand ever more extreme
conditions, repeated thermalcycling, severe mechanical
shock, harsh chemical exposure,ensuring products last longer in
tougher environments.

Elena Bondwell (18:58):
Makes sense.
What about greener solutions?

Lucas Adheron (19:00):
Yes, absolutely.
A significant and growing trenddriven by both regulation and
consumer demand issustainability and regulatory
compliance.
We're seeing a strong shifttowards halogen-free and
low-toxicity formulations.
We saw examples from Henkel andHuntsman focusing on this.
It reflects an industry-wideemphasis on Good to hear.

(19:23):
And finally, the automotiveelectronics sector, especially
electric vehicles, EVs, is acritical bellwether for adhesive
innovation.
It's really driving thingsforward.
How so?
Well, adhesives and EVs faceunique, really demanding
environments.
You've got high operatingtemperatures from batteries and
power electronics, substantialvibration from the road, diverse

(19:47):
materials needing to be bonded,bonded reliably, and extremely
stringent safety requirements.
Think about preventing thermalrunaways in battery packs.
Adhesives play a role there,too.
This drives intense innovationin thermal management, those
advanced gap pads, liquidfillers we talked about, and
also in developing ultra-fastcuring mechanisms to keep up

(20:07):
with rapid automotive productiondemands.

Elena Bondwell (20:09):
Wow.
So EVs are really pushing theenvelope.
Looking ahead, it sounds likeadhesives are becoming even more
multifunctional.
You could almost imaginematerials that sense and respond
to their environment or cureinstantly.
It almost sounds like sciencefiction becoming engineering
reality, doesn't it?

Lucas Adheron (20:24):
It really does.
The potential is huge foradhesives to do even more than
just bond and protect.

Elena Bondwell (20:29):
So we've taken a deep dive today into the
incredible, often unseen rolethat adhesives play in our
electronics.
It's amazing, really.
From the smallest wearabledevice you might have on right
now to the complex, criticalsystems in an electric vehicle,
these materials are absolutelyfundamental enablers.
They enable performance,reliability, and

(20:49):
miniaturization.
They are truly the invisiblestrength holding our

Lucas Adheron (20:57):
digital world together.

Elena Bondwell (21:20):
Just take a second to consider how much of
our daily technological marvelsrely on these invisible, yet
utterly indispensable bonds.
It makes you wonder what otherhidden heroes might be out
there, quietly enabling the nextbig leap in technology, just
waiting for us to shine a lighton them.
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