
Moulding and Encapsulation
Protection that lasts under demanding conditions
Electronics operating in harsh environments require protection that remains effective over time. Fosstech has long experience with molding and encapsulation of components used in applications where water exposure, pressure, temperature variation, and corrosion are critical factors.
Molding and encapsulation at Fosstech are used to protect internal components from environmental and mechanical damage, not as a generic coating process. Solutions are developed to match how products are used in practice, and it is not uncommon for Fosstech to take over projects where previous solutions have failed in operation.
What we deliver
Fosstech provides molding and encapsulation solutions for a wide range of components and assemblies.
Typical applications include:
- Transducers, sensors, and electronics
- Mechanical components and assemblies
- Connectors and cable transitions
Material selection is based on the specific application and operating environment. Fosstech works with polyurethane, epoxy, and silicone systems, selected according to protection requirements, mechanical behaviour, and long-term exposure conditions.
Production is carried out with controlled processes to ensure consistent results. Dedicated tooling and customised molding processes are developed when required to meet project-specific needs.
Designed for long service life
Encapsulation failures are rarely caused by the material alone. Leakage and long-term degradation typically originate at interfaces, transitions, or internal voids.
Fosstech designs encapsulation solutions with these risks in mind. Particular attention is given to cable routing, interfaces, primer systems, and curing processes. Air pockets are actively avoided through controlled preparation and vacuum-assisted molding where required.
Solutions are developed to withstand long-term exposure to water, oil, chemicals, and pressure. For subsea and defence-related applications, service life expectations often extend well beyond typical qualification periods.
Material selection and process control
Encapsulation materials are selected based on how the product will be used. Mechanical behaviour under pressure, thermal effects, and compatibility with internal components are evaluated before production.
Process control is critical to achieving reliable results. Curing times, primer application, mold preparation, and handling steps are defined and followed closely. Some processes require extended curing periods that cannot be accelerated without compromising quality.
Modern production equipment and defined procedures are used to ensure repeatability and consistent quality across deliveries.
Integration with development and production
Molding and encapsulation work at Fosstech is closely integrated with development and production. Early collaboration with engineering helps identify risks related to geometry, material behaviour, and interfaces before solutions are finalised.
This integration allows encapsulation solutions to be prototyped, tested, and adjusted early, reducing the likelihood of failures discovered late in the project or after deployment.
When additional expertise is required, Fosstech works with selected local partners while retaining responsibility for the final solution.
When to contact us
Fosstech molding and encapsulation solutions are well suited when components must be protected for long-term operation in demanding environments.
Typical situations include:
- Products exposed to water, pressure, or corrosive conditions
- Assemblies where leakage or mechanical failure is unacceptable
- Applications requiring long service life without access for repair
- Projects where previous encapsulation solutions have failed