Parylene Design Hub
Practical design guidance covering thickness, layout, clearances, masking, materials and manufacturability.
Each article explains why design choices matter, the trade-offs between protection, reliability and cost, and the design-for-coating considerations that help engineers avoid common Parylene coating problems.
Design-for-coating principles that help engineers integrate Parylene reliably from concept through production.
Fast Links – Parylene Design Topics
Parylene Coating Thickness Selection – how thick should the coating be?
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Component & PCB Layout Guidelines for Parylene – spacing, keep-outs and vapour access
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Clearances, Gaps & Encapsulation Rules – how geometry affects coverage and dielectric performance
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Masking Design Requirements for Parylene – keep-out areas, cost drivers and defect risk
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Materials, Adhesion & Surface Preparation – substrate compatibility, cleaning and primers
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Designing for Manufacturability in Parylene Coating – linking design to stable production
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Parylene Coating Thickness Selection – Summary
- Typical thickness ranges for sensors, electronics and harsh environments
- Relationship between thickness, geometry and dielectric performance
- Impact of over- and under-specification on reliability and cost
- Using trials and witness coupons during qualification
Component & PCB Layout Guidelines – Summary
- Component spacing and orientation for vapour access
- Reducing shadowing and trapped volumes
- Designing connector and keep-out locations with masking in mind
- Benefits of early layout review with a Parylene specialist
Clearances, Gaps & Encapsulation Rules – Summary
- How gap size influences vapour penetration
- Designing vented vs sealed cavities intentionally
- Electrical clearances vs coating thickness trade-offs
- Common geometry-related coating failures
Masking Design Requirements – Summary
- Defining keep-out areas early and clearly
- Standardising boots, caps and masking tools
- Reducing labour-driven masking complexity
- Design choices that lower defect risk
Materials, Adhesion & Surface Preparation – Summary
- Compatible, conditional and problematic substrate materials
- Managing silicones, elastomers and low-energy plastics
- Cleaning, activation and adhesion promotion strategies
- Reducing long-term adhesion and contamination risks
Design for Manufacturability – Summary
- Design choices that influence throughput and yield
- Fixturing, handling and inspection access
- Aligning batch size with equipment capability
- Documenting DFM to support scale-up
External Technical References
Disclaimer: This hub provides general design guidance only. Parylene coating performance, suitability and compliance depend on the specific design, materials, geometry and operating environment. SCH Services can review assemblies, drawings and specifications to confirm the most appropriate Parylene coating approach.
