About Insulcast
Insulcast Electronics Potting & EncapsulationITW
Insulcast is a line of two-component epoxy and silicone potting and encapsulation compounds from ITW Performance Polymers, established in 1972 with manufacturing in Danvers, Massachusetts and Montgomeryville, Pennsylvania. Insulcast specializes in thermally conductive, low-viscosity, UL 94V-0 certified formulations for critical electronics protection.
Epoxy products provide superior mechanical strength, excellent moisture resistance, high chemical resistance, and good adhesion for PCBs, coils, transformers, and power electronics. Silicone products exhibit high flexibility, are easily repairable, and deliver superior performance across broad temperature ranges with minimal shrinkage during cure.
Applications span aerospace, automotive, electronics, power generation, telecommunications, and utilities. Insulcast protects ignition coils, printed circuit boards, EV batteries, high-voltage power supplies, transformers, and mission-critical industrial controls from moisture, vibration, and thermal cycling.
Key silicone formulations include RTVS 27 (low-viscosity room-temperature vulcanizing for flexible protection) and RTVS 42 (silicone-epoxy co-polymer for severe thermal shock resistance). Epoxy lines include I-Cure 20 and flame-retardant 116 FR for high-temperature dielectric applications.
Find the Insulcast formulation matching your potting requirements (epoxy vs. silicone, thermal conductivity, cure method), then connect with authorized distributors and coil/component builders for volume pricing and technical support.
Prefer a quick quote?
Get Insulcast Pricing in Your Inbox
Skip the search — tell us the part type, size, or spec and we'll come back with pricing.
Frequently asked questions
When should I use Insulcast epoxy vs. silicone potting compounds?
Use epoxy for highest mechanical strength, excellent adhesion, and moisture resistance in high-vibration applications; use silicone for high flexibility, repairability, and broad temperature range (-60 to 200°C), especially where component rework or thermal cycling is critical.
What does UL 94V-0 certification mean for my electronics?
UL 94V-0 is a flame-retardant rating ensuring the potting compound won't propagate burning, limiting smoke generation during electrical faults. It's required for safety-critical electronics in aerospace, automotive, and industrial power systems.
Are Insulcast compounds thermally conductive?
Yes, Insulcast offers both standard and thermally conductive formulations. Thermal versions dissipate heat from high-power components (ICs, transistors) to the encapsulation or mounting substrate, preventing thermal runaway and extending component life.
What's the difference between RTVS 27 and RTVS 42 silicone compounds?
RTVS 27 is low-viscosity for easy potting of delicate components with minimal air entrapment; RTVS 42 is a silicone-epoxy blend handling severe thermal shock (-60 to +200°C) in aerospace and automotive applications with high flexibility.
How do I select the right pot size and cure time for my production volume?
Available in 1-quart to 5-gallon containers; cure times range from 2-24 hours depending on formulation and temperature. Provide your production rate (parts/week) and assembly time budget, and ChatMRO finds the matching package and formulation.