Henkel launches next generation polyurethane potting solution for industrial and power electronics reliability

In today’s rapidly evolving industrial and power electronics landscape, manufacturers face increasing pressure to enhance reliability, extend product lifetimes, and ensure stable performance under harsher operating conditions. Systems such as motor controls, power supplies, inverters, battery management units, HVAC control modules, and industrial sensors are exposed to sustained heat, humidity, vibration, and corrosive environments. These conditions increase the risks of corrosion, silver migration, insulation breakdown, and premature failure — driving demand for advanced potting materials capable of delivering robust, long-term protection.

As a global leader in materials innovation for electronics, Henkel is responding to these market challenges with the launch of Loctite STYCAST US 8000 A/B, a next generation two component polyurethane potting compound designed to deliver exceptional electrical insulation, mechanical durability, and long term reliability in demanding environments. This new solution strengthens Henkel’s portfolio of high performance encapsulation materials and supports customers seeking enhanced protection for mission critical industrial and power electronics assemblies.

Loctite STYCAST US 8000 A/B is engineered for reliability from the inside out. Its ultra low ionic content (less than 20 ppm) minimizes corrosion and prevents silver migration in high humidity environments — one of the leading causes of leakage currents and short circuits. With a UL 746 RTI rating of 140°C and UL 94 V 0 flammability certification, the material provides proven thermal endurance and safety. Electrically, its dielectric strength of 24 kV/mm and surface insulation resistance above 10⁸ Ω after 500 hours at 85°C/85% RH ensure long term insulation stability even under extreme environmental stress.

Thanks to its low mixed viscosity (3,800–5,800 mPa·s) and standard 4:1 mixing ratio, Loctite STYCAST US 8000 A/B offers smooth, consistent dispensing and excellent flow into narrow gaps and complex geometries — supporting void free encapsulation and efficient high volume manufacturing. Its ability to cure at room temperature or through accelerated heat schedules enables process flexibility and reduced energy consumption. Mechanically, the material delivers a balanced combination of strength and flexibility, with Shore A hardness of 89, 9 MPa tensile strength, and 87% elongation, allowing it to absorb vibration and thermal expansion without cracking or losing adhesion.

“At Henkel we are committed to enabling the next generation of reliable, energy efficient electronic systems. With the launch of Loctite STYCAST US 8000 A/B, we are expanding our advanced protection portfolio to support customers facing increasingly harsh environmental and compliance requirements,” comments Eric Zhai, Global Senior Market Strategy Manager for Power & Industrial Automation at Henkel Adhesive Technologies.

With a global innovation network, dedicated electronics laboratories, and deep expertise in materials development, Henkel continues to invest strategically in next generation encapsulation and protection technologies. The company’s commitment is reinforced by strong collaboration with OEMs and Tier suppliers to accelerate the adoption of advanced potting materials across critical industrial and power electronics applications.

“Through close partnership with our customers, Henkel is delivering materials that drive reliability, compliance, and long term sustainability,” concludes Eric Zhai. “Loctite STYCAST US 8000 A/B is a powerful example of how innovations can rapidly progress from concept to production — helping manufacturers reduce field failures, extend product lifetimes, and meet the growing demands placed on modern electronic systems.”

To learn more about Loctite Stycast US8000 AB, visit this web resource.