When it comes to protecting and insulating electronic components, the choice of encapsulant is critical.

In this blog post, we will take a closer look at the fascinating properties of EP-3500. This cutting-edge material is making waves in electronics design and manufacturing. We will explore this material's various applications and how it drives innovation in the industry.

Epoxy Encapsulant EP-3500: Insights and Innovations


CoolTherm® EP-3500 epoxy system is a two-component system designed for encapsulation of motor stators, transformer coils, and devices requiring a rigid, high thermal conductivity material with a low coefficient of thermal expansion. The epoxy system provides high-temperature stability combined with excellent electrical insulation.

Features and Benefits:

Superior Heat Dissipation - typically provides 30-50°C lower motor end winding temperatures during high-power operation.
Low Viscosity - provides low viscosity for a highly-filled material; self-levels to fill voids in motor stators/rotors, transformer coils and other electrical devices.
Durable-cured material resists cracking during multiple thermal cycles from sub-zero temperatures to 200°C.

Shelf Life/Storage:
Shelf life of each component is nine months when stored at 25°C in original, unopened container. CoolTherm EP-3500 resin must be periodically rotated within its container to maintain maximum shelf life. Settling will occur. Product must be mixed as directed before use. To achieve properties and minimize hard-packed settling of fillers during storage, follow the general considerations and storage tips recommended in the Technical Tip - "Mixing of CoolTherm EP- 3500 and EP-2000 Potting Materials".

  • Advanced Formulation for Maximum Protection

    Epoxy Encapsulant EP-3500 stands out in the world of electronics manufacturing due to its advanced formulation, delivering unparalleled protection for electronic components. This encapsulant is engineered to provide maximum defense against various environmental stresses, including moisture, chemicals, and mechanical impact.

    Its superior electrical insulation properties act as a shield against voltage spikes and other electrical hazards, ensuring the long-term integrity and functionality of electronic devices. EP-3500's ability to withstand and mitigate these stressors makes it a top choice for applications where component reliability is paramount.

  • Tailored for Efficiency and Reliability

    EP-3500 is specifically designed to enhance the efficiency and reliability of electronic devices. Beyond its protective qualities, this epoxy encapsulant offers exceptional thermal management properties. By effectively dissipating heat and maintaining optimal operating temperatures, EP-3500 plays a crucial role in preserving the performance and longevity of electronic components.

    Whether in high-power electronics, sensitive semiconductor devices, or other critical applications, EP-3500 ensures that devices can operate consistently and efficiently.

  • Versatility Across Industries

    One of EP-3500's standout features is its versatility. It finds applications across a huge range of industries, including consumer electronics, automotive systems, aerospace components, and industrial machinery.

    EP-3500's adaptability makes it an indispensable tool for engineers and manufacturers who require a reliable encapsulation solution in diverse and demanding environments. Its ability to deliver consistent performance and protection, regardless of the industry, underscores its versatility and effectiveness.

  • Ease of Integration

    Epoxy Encapsulant EP-3500 offers a highly convenient application process that seamlessly integrates into production lines. Its user-friendly nature simplifies the encapsulation procedure, enabling a fast and efficient solution for all electronic encapsulation requirements. Whether applied manually or through automated processes, EP-3500's ease of integration reduces production time and costs, making it a practical choice for both high-volume manufacturing and specialized projects.

Epoxy Encapsulant EP-3500 distinguishes itself with its advanced formulation, which provides maximum protection against environmental stressors and electrical hazards. It contributes to the efficiency and reliability of electronic devices, offers versatility across various industries, and seamlessly integrates into production processes. These qualities position EP-3500 as a game-changing solution for electronic encapsulation needs, ensuring the durability and performance of electronic components across diverse applications, including silver paste.

Technical Specifications of CoolTherm® EP-3500 Epoxy System


  • Dark Gray Paste (resin)
  • Light Gray Paste (hardener)
  • Gray Paste (mixed)

Dynamic Viscosity:

  • Resin: 9200 CP @ 60°C
  • Hardener: 6400 CP @ 60°C
  • Mixed: 8000 CP @ 60°C

Number of Components:

  • Two-Component (2K)

Cure Time:

  • Staged cure: 2 hours
  • Working Time: >3 hours @ 60°C


  • 90 (Shore D)

Thermal Conductivity:

  • 3.3 W/m.K @ 120°C, 150°C, 180°C & 210°C
  • Can be achieved using a slow heating ramp to 210°C

Dielectric Strength:

  • 15.4 kV/mm (390 V/mil)

Application Insights: Where EP-3500 Excels

  • Semiconductor Packaging: EP-3500 is ideal for encapsulating semiconductor chips. It provides a robust protective barrier that shields delicate semiconductor components from physical damage, moisture, and thermal stress. This encapsulation ensures the long-term reliability and performance of semiconductor devices.
  • LED Encapsulation: In LED applications, EP-3500 plays a vital role in maintaining the longevity and performance of sensitive diodes. By encapsulating LEDs, it shields them from environmental exposure, extending their operational life and preserving their luminous output.
  • Power Electronics: EP-3500 finds its niche in high-power electronic applications. Its excellent insulation properties and effective thermal management enable it to handle increased electrical loads. This makes it well-suited for power electronic devices, ensuring their reliability and durability under demanding condition.
  • Industrial Application: Due to its durability and robustness, EP-3500 is a valuable choice for industrial electronics that operates in harsh environments. It offers protection against dust, moisture, and temperature extremes, making it an excellent solution for electronics used in industrial settings.

Innovations Driven by EP-3500

EP-3500 stands at the forefront of encapsulant innovation, thanks to ongoing research and development efforts. Its properties are continuously refined to address the evolving challenges in electronics design. These challenges include the need for miniaturization, accommodating increased power densities, and incorporating greener materials into manufacturing processes. EP-3500's adaptability and innovation make it a reliable choice for the future of electronics manufacturing solder flux and potting compound.

Best Practices for Using EP-3500

  • Surface Preparation: Thoroughly cleaning and removing contaminants from surfaces is crucial to achieving maximum adhesion strength when applying EP-3500. Achieving a secure bond is dependent on proper surface preparation.
  • Curing Process: Achieving the best properties of EP-500 relies on following the recommended curing process. Proper curing ensures optimal performance, including mechanical strength and protection properties. Adhering to the manufacturer's curing scheduling is vital to obtain the desired results.
  • Handling and Storage: EP-3500 should be handled carefully to prevent contamination or damage. Any unused portions should be stored according to the manufacturer's guidelines to maintain efficacy and shelf life. Proper handling and storage practices help ensure the consistency of its performance over time.

The Final Word – Future of Electronics

The future of electronics manufacturing is one where devices are more robust, reliable, and high-performing than ever before. EP-3500 will play a significant role in this future, offering manufacturers and designers an encapsulant that meets the highest protection and performance standards.

Discover the full potential of Epoxy Encapsulant EP-3500 and how it can revolutionize your electronics manufacturing process. With EP-3500, step into an era of innovation and ensure that your products stand the test of time and function.

Now available for your consideration is the Epoxy Encapsulant EP-3500, which can enhance the performance of your electronics. Feel free to explore its benefits Now!