While the Conformal Coating department is one of the newest additions to MJS Designs, its impact is significant. To meet growing customer demand for PCB assembly and protective coating under one roof, MJS Designs expanded its capabilities by bringing conformal coating in-house, reducing turnaround times while adding another layer of quality control. Since its inception, the department has not only mastered the technical requirements of conformal coating but has also built the processes, workflows, and standards that support the operation daily. Today, the department is composed of highly skilled, dedicated, and detail-oriented professionals who provide the final layer of protection that helps electronic assemblies perform reliably in even the most demanding applications.
“Everybody on the team is critical to the process,” says Dave Stutenroth, Director of Quality Assurance. “In this department there’s a division of labor, but also a lot of cross training. The goal is that anybody can step into any position.”
Each member of the Conformal Coating team plays an essential role in the process, with Director of Quality Assurance Dave Stutenroth providing leadership and oversight. The technicians specializing in masking, carefully protect the areas of each PCB that should remain free of coating. These team members also assist with post-coating inspections to verify complete coverage and overall quality. Other technicians focus on touch-up work, removing masking materials after coating and ensuring each board was coated where it should be and making any final adjustments as active inspectors. The team’s primary spray technician applies the coating to the boards. Over the past two years, the team has really worked as a collective unit, combining hands-on experience with brainstorming practices to develop standardized processes that ensure consistent coating quality, improve efficiency, and uphold MJS Designs’ rigorous quality standards.
“We are one of the final processes before products ship to the customer,” shares Dave.
Although it is one of the final processes, conformal coating is a critical step for many printed circuit board (PCB) assemblies, providing a protective barrier against harsh environmental conditions. A thin layer of acrylic or urethane resin is carefully applied to the board to protect it from moisture, dust and other potential contaminants, significantly improving its long-term reliability and performance. The process begins with an engineering drawing that clearly identifies which areas of the board should be coated and which must remain free of coating. From there, the team meticulously masks designated components using professional-grade masking materials and gels to cover and protect the designated areas.
“Masking is the most important step of conformal coating,” expresses Nayali, a Conformal Coating Technician. “It is the main, main thing.”
Attention to detail is at the core of every step in the conformal coating process, but nowhere is it more critical than during masking. Widely regarded by the team as the most important step, masking requires exceptional precision to ensure only the intended areas receive protective coating, and since this is the step where most errors can be introduced, it is essential to make sure it’s correct. Using high-grade industrial masking tape, tweezers, scissors and a soft wooden tool known as a spudger, the team carefully masks each board by hand. The process demands not only technical skill, but also patience and focus.
After masking is complete, the boards are moved to the spray booth, where the coating application is manually applied. After the coating has rested, the masking materials are removed and each board undergoes a thorough inspection for any nonconformances or areas requiring touch-up. Once approved, the boards are cured using heat based on the coating material’s specific requirements. Following the curing process, each assembly is inspected once again to verify complete coverage and quality before being packaged and sent to the Quality Assurance team for final inspection.
“Communication is definitely what makes our team successful,” says Jasmine, a Conformal Coating Technician.
“When I mask, and the others are touching up, I go to Judy, Jasmine or Jesus to see if there’s anything I can do better. That’s what has helped us run things smoothly,” adds Nayali.
With multiple customer projects and boards moving through the department simultaneously, communication is essential to maintaining organization, consistency, and efficiency. As one of MJS Designs’ newest departments, the team has prioritized open communication and collaboration from day one. Through regular feedback, clear communication channels, and continually refined processes, they have built a strong foundation that supports consistent quality and has contributed to the team’s success. One of these processes includes established scheduled check-points in which the team stops to inspect, maintain organization and traceability, and ensure work remains aligned with deadlines before moving to the next stage..
“I am most proud of where we started and where we are now, everything has gotten so much better,” shares Jasmine.
“You learn a lot from any mistake you make, and we have learned a lot,” says Judith.
David adds, “This team has accomplished a lot.”
While the Conformal Coating team is known for its hard work and innovative mindset, the members also enjoy working together and make time to celebrate their successes along the way. Their strong camaraderie has helped foster an environment where everyone takes pride not only in their own work, but in what they have accomplished together. As a team, they are especially proud of the techniques they have developed and the improvements they have made since the department’s inception. Their willingness to learn, adapt, and continuously refine their approach has helped shape a department built on precision, collaboration, and exceptional attention to detail.
The trust the team has built in one another has laid a strong foundation for the continued success of the department and the high-quality work they deliver for MJS Designs’ customers. Their reliability, efficiency, and ability to “take care of business” – qualities they identified as some of their greatest strengths – set them apart and contribute to the team’s ongoing success.
“Conformal coating has traditionally been an outsourced process for our company, so bringing this capability in-house has been both challenging and rewarding. Meeting each customer’s unique coating requirements is rarely straightforward, especially when drawings are vague or documentation is limited. Despite these obstacles, our Conformal Coating team has embraced every challenge with determination, continuously refining our processes and driving meaningful improvements. I am incredibly proud of what this team has accomplished in such a short period of time. Their dedication, adaptability, and commitment to excellence have established a strong foundation for the continued growth of this service.” Explains Dawn Northrop, President of MJS Designs.
For over 50 years, MJS Designs has been a trusted leader in PCB engineering, CAD Layout, assembly and test driven by a commitment to delivering exceptional quality and precision. We partner with industry leaders in the
semiconductor, agriculture, medical, commercial, aerospace, and military sectors, providing reliable PCB assembly solutions that bring their projects to life. Learn more about our conformal coating capabilities and how MJS Designs can support your next project by visiting our homepage here.
