For decades, industries have relied on carbon-filled paints, metal-loaded coatings and moulded ESD plastics to manage electrostatic discharge (ESD). These legacy approaches depend on conductive fillersβsuch as carbon black, graphite or metal powdersβto create a discharge path. At first glance they appear effective, but in real use they often create inconsistency, wear-related drift and contamination risk. Thatβs why the ProShieldESD filler-free ESD coating platform is changing how static control is specified.
Modern electronics, medical devices and aerospace systems need ESD protection that stays stable over time, across humidity swings, and under cleaning and abrasion. Traditional filler-based coatings and moulded carbon boxes struggle to deliver truly uniform performance at scale.
The problem with carbon and metal fillers and moulded ESD plastics
1) Inconsistent conductivity
Fillers rarely disperse perfectly in a coating, and moulded parts can show variation through the material. The result is patchy resistivity and βweak spotsβ where charge can build and discharge unpredictably.
2) Performance degradation over time
In coatings, fillers can migrate, clump or wear away at the surface. In moulded parts, conductivity can reduce as surfaces abrade and contamination builds. What starts as protection often becomes unreliableβdriving recoating, replacement and revalidation.
3) Risk of contamination
Carbon and metal particulates can shed from surfaces or transfer during handling. In sensitive environmentsβelectronics, clean manufacturing, medicalβthis creates a genuine quality and compliance concern.
4) Poor substrate flexibility
Many filler-based paints struggle on plastics, foams and packaging, while moulded solutions are limited to fixed shapes and specific polymers. That reduces flexibility and increases the number of special parts you need to buy and control.
5) High lifecycle cost
When you include rework, downtime, inspection checks, replacement parts and repeat purchases, βlow-costβ legacy solutions often become expensive to maintain.
The smarter alternative: ProShieldESD filler-free ESD coating
ProShieldESD filler-free ESD coating achieves stable, homogeneous ESD performance without carbon or metal fillers. Itβs designed to deliver consistent conductivity or dissipation across a wide range of substrates.
- βοΈ Permanent protection β reduced dependency on reapplication and replacement cycles
- βοΈ Uniform performance β minimises weak spots caused by filler clustering
- βοΈ Cleaner process β avoids loose conductive particulates that can contaminate sensitive areas
- βοΈ Broad compatibility β suitable for plastics, foams, packaging, fixtures and floors
- βοΈ Lower lifecycle cost β fewer replacements, less downtime and simpler control
The future of static control
As industries demand higher reliability, flexibility and sustainability, filler-based paints and moulded ESD products increasingly show their limits. A platform approachβbuilt for repeatability and long-term stabilityβoffers a cleaner, more scalable path.
Learn more: Explore the ProShieldESD coating platform or visit proshieldesd.com.
