The Technology Behind Filler-Free ESD Coating

Why intrinsically conductive polymer technology offers a more stable approach to static control

Filler-free ESD coating changes how static control is achieved. Most conventional ESD paints and conductive plastics rely on carbon or metal fillers to create conductive paths. This can work, but performance depends on filler network continuity, dispersion and environmental conditions.

ProShieldESD takes a different approach. Conductivity is built into an intrinsically conductive polymer backbone rather than suspended particles. This delivers a more uniform, predictable electrical response and reduces dependence on percolation-driven filler networks.

This technology can be used across a wide range of static-control applications, including anti-static coatings for plastic, upgrades to industrial equipment surfaces and solutions for hazardous environments where insulating materials can allow charge to accumulate.

ProShieldESD technology demonstrating advanced ESD protection systems for industrial flooring, hazardous environments and static control applications
ProShieldESD technology can be applied across industrial flooring, equipment, packaging and other surfaces where controlled static performance is required.

Why Filler-Based ESD Paints Fall Short

Traditional ESD paints are typically epoxy or polyurethane systems loaded with conductive fillers such as carbon black or metal powders. These systems rely on filler networks rather than intrinsic conductivity.

  • Fillers can clump, segregate or settle during mixing and application.
  • Conductivity can vary across the surface if dispersion is inconsistent.
  • Resistance can drift over time, particularly with humidity changes.
  • Thin or worn coatings can lose conductivity as networks break down.
  • Maintenance, rework and inconsistency add hidden cost.
Key point: Filler-based systems depend on conductive particle networks. If that network is disrupted, electrical performance changes.

Percolation vs Intrinsic Conductivity

The difference between filler-based and intrinsically conductive coatings is shown below:

Filler-free ESD coating using intrinsically conductive polymer compared to carbon-filled ESD coating showing percolation-dependent conductivity and environmental sensitivity
Comparison of carbon-filled ESD coatings and filler-free intrinsically conductive polymer (ICP) coatings, illustrating percolation-dependent behaviour and sensitivity to humidity, wear and coating thickness.

Carbon-filled systems rely on particles forming a continuous pathway through the coating. Intrinsically conductive polymer systems conduct through the polymer backbone itself, making performance less dependent on dispersion and particle contact.

Moulded Conductive Plastics vs Filler-Free Coating

Moulded conductive plastics are widely used for trays, housings and fixtures, but they also rely on conductive fillers within the material.

  • Only moulded parts benefit from conductivity.
  • Material and tooling costs are higher than standard plastics.
  • Machining, wear or variation can affect performance.
  • Existing assets such as floors, benches and packaging cannot be easily upgraded.

Coating solutions provide a more flexible route by allowing standard materials and installed assets to be converted into static-controlled surfaces.

What ProShieldESD Changes

Filler-Free, Percolation-Free Conductivity

ProShieldESD does not rely on carbon or metal fillers. Conductivity is engineered into the polymer backbone, removing dependence on unstable filler networks.

Tunable Electrical Performance

The system can be tuned to achieve static-dissipative or conductive performance depending on application requirements.

Multiple Chemistries, One Platform

Available in PU, epoxy, water-based and solvent-based systems, allowing selection based on substrate and environment.

Upgrade Existing Assets

Standard materials including plastics, metals, wood, foams and cartons can be converted into controlled ESD surfaces without redesign.

Why This Matters Commercially

The value is not just conductivity, but the ability to engineer predictable static performance into existing materials without redesign.

  • Reduce reliance on expensive conductive plastics.
  • Upgrade installed assets rather than replace them.
  • Create consistent static-control surfaces across mixed materials.
  • Support a wider range of industrial and packaging applications.

Why Choose SCH Services?

SCH Services supports selection, application and implementation of ProShieldESD coating solutions across a wide range of materials and environments.

  • Guidance on where filler-free conductive polymer technology is appropriate.
  • Support across substrates, environments and applications.
  • Access to multiple coating chemistries and delivery routes.
  • Technical and commercial support for new and existing projects.

Call: +44 (0)1226 249019 | Email: sales@schservices.com | Contact Us

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This page provides general technical guidance on filler-free ESD coating technology. Final performance and suitability should be validated against application requirements and relevant standards.