Preventing Field Failures: Best Practices for Epoxy and Polyurethane Applications

Field failures in applications that rely on epoxy and polyurethane materials can result in costly downtime, customer dissatisfaction, and potential safety concerns. Whether used for potting, encapsulation or adhesion, these materials must be carefully selected, handled, and applied to ensure peak performance. These critical best practices will help you avoid failures and achieve optimal results.

1. Ensure Proper Mix & Ratio Control

One of the most common causes of failure in epoxy and polyurethane applications is improper mixing and ratio control. These materials rely on precise chemical reactions to achieve their fully cured properties. Off-ratio or improper mixing can lead to:

• Incomplete curing, resulting in a sticky or soft final product
• Brittle or weak areas that compromise durability
• Increased shrinkage, leading to cracks or separation

Best Practices:

• Use precision metering and mixing equipment to ensure consistent ratios.
• Verify the mix ratio by weight and volume.
• Perform quality checks such as gel time and hardness testing to verify proper cure.

2. Controlling Moisture & Surface Contamination

Polyurethanes are moisture-sensitive, which can cause foaming, poor adhesion and affect mechanical properties. Epoxies are generally more moisture-tolerant but can also suffer from adhesion failures and reduced strength when applied to contaminated surfaces.

Best Practices:

• Store materials in dry conditions and nitrogen or argon purging when necessary.
• Preheat components or substrates to drive off surface moisture before application.
• Ensure all surfaces are free of dust, oils, and other contaminants using proper cleaning and surface treatment methods.

3. Optimizing Cure Conditions

Temperature and humidity variations can significantly impact the curing process of epoxies and polyurethanes. Improper curing can lead to underperformance, including lower bond strength, reduced flexibility, or stress-related cracking.

Best Practices:

• Follow the recommended cure schedule, including temperature and humidity.
• Conduct in-process checks such as hardness and cross-sectioning to confirm full cure.
• Design production environments with consistent temperature control to avoid variations in material processing.

The Importance of High-Quality, Application-Specific Materials

Not all epoxies and polyurethanes are created equal. Standard, off-the-shelf materials may not provide the properties that your application specifications require. Factors such as thermal properties, environmental conditions, material properties and process and handling must be carefully considered to ensure long-term reliability.

Epic Resins formulates high-performance epoxy and polyurethane materials tailored to specific application needs. Our materials are formulated to meet precise mechanical, electrical, and environmental requirements.

Epic Resins: Your Partner in Material Success

At Epic Resins, we go beyond manufacturing epoxies and polyurethanes—our chemists collaborate with your engineering team to ensure proper material selection or formulation for your product design, specifications and processing needs. Our support includes:

• Expert Technical Sales Team: Helps you identify the best resin for your application.
• Dedicated Chemists: Working alongside your engineering team to guarantee optimized product performance.
• On-Site and Remote Support: Assisting with process optimization and troubleshooting.

By partnering with Epic Resins, your engineers gain access to decades of expertise in epoxy and polyurethane chemistry, ensuring your products perform reliably in the field.

Conclusion

Preventing field failures requires more than just selecting an epoxy or polyurethane—it requires careful material selection, proper processing, and controlled environmental conditions. By adhering to best practices and leveraging Epic Resins’ expert support, engineers can avoid common pitfalls and achieve durable, high-performance results in their applications.

For more information on how Epic Resins can support your material needs, contact our technical sales team today.