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Modern electrical component design keeps shrinking, and the materials that complete those designs have to keep up. When a conductive epoxy has to wick into extremely small spaces, carry real current, cure to suit the process, and stay affordable enough to scale, off-the-shelf products often fall short on at least one count.
This is the story of how Resin Formulators developed RF 2969, a cost-effective silver-filled epoxy system that met the conductivity, processability, and scalability needs of aerospace and defense electrical component design, in versions tailored to different cure requirements.
The Challenge
Various aerospace and defense customers were looking for a silver-filled epoxy system that would fit new and improved electrical component designs. The specific need was a product that could wick into extremely small spaces to complete an electrical connection, a demand that modern, increasingly miniaturized component designs place on conductive materials.
Beyond simply reaching into tight geometries, the application carried several requirements at once:
- High electrical conductivity to reliably complete the electrical connection.
- A flexible cure profile, with the ability to cure at ambient or elevated temperatures depending on the application.
- Suitability for multiple roles, including electrical circuitry, EMI shielding, and the grounding of composites.
No single existing product brought all of these together in a way that fit the new designs and could scale cost-effectively across multiple programs. The customer needed a purpose-built conductive epoxy rather than a compromise.
Resin Formulators began a design and development process where it was decided that multiple versions were needed, including a heat-cure and a room-temperature curing formula. Rather than forcing every customer into one cure schedule, this approach let the same conductive epoxy system be matched to different production processes and component requirements.
The resulting product, RF 2969, met the technical needs for the new designs and was also recognized as a cost-effective solution for scalability. It delivered the following for these applications:
High Conductivity in a Low-Viscosity System
The silver-filled formulation provided the high electrical conductivity required to complete connections, combined with the low viscosity needed to wick into the extremely small spaces of modern component designs.
Cure Versions to Match the Process
By developing both a heat-cure and a room-temperature curing version, Resin Formulators expanded the range of application requirements the epoxy could support, whether the process called for an ambient cure or an elevated-temperature cure.
Versatility Across Electrical Applications
RF 2969 is suitable for electrical circuitry, EMI shielding, and the grounding of composites, allowing a single qualified conductive epoxy system to address multiple needs across a program rather than requiring a different material for each.
For designs that call for a conductive adhesive in a different viscosity or format, Resin Formulators also offers RF 2869, an electrically conductive epoxy for related circuitry and shielding applications.
This kind of application-specific development is central to how Resin Formulators approaches custom epoxy formulations for electronics manufacturing.
The Outcome
RF 2969 solved the customers' challenge on every front. The RF 2969 silver-filled epoxy provided the high conductivity and low-viscosity wicking that modern electrical component designs demanded, with cure versions that fit real production processes, at a cost that supported scaling across multiple programs.
The result has proven durable. RF 2969 has been a successful aerospace solution for over 20 years and is qualified for use on military aircraft, commercial satellite, rocket, and automotive programs, a track record that speaks to both its technical performance and its value over time.
Several key factors contributed to the success of this project and are worth highlighting for engineers and procurement professionals working on similar challenges.
Conductivity and Processability Can Be Designed Together
A conductive epoxy is only useful if it can be applied where it is needed. Targeting high conductivity and low-viscosity wicking in the same formulation meant the material performed electrically and fit the geometry of modern designs.
Multiple Cure Versions Widen the Application Window
Offering heat-cure and room-temperature versions let one conductive epoxy system serve customers with very different process constraints, rather than excluding those who could not accommodate a single cure schedule.
Cost-Effective Formulation Enables Scale
A material that performs but cannot scale economically has limited reach. Designing RF 2969 as a cost-effective solution is part of why it has supported aerospace and defense programs for two decades. Conductive systems like this often work alongside Resin Formulators' thermal management solutions when a design has to move heat as well as carry current.
For over 60 years, Resin Formulators has developed epoxy and polymer systems for aerospace, defense, and advanced engineering applications. Backed by in-house formulation expertise and Advanced Material Lab Testing, the team delivers both proven material solutions and custom formulations to solve complex engineering challenges while meeting demanding performance, processing, and qualification requirements.
Contact the Resin Formulators team to discuss your electrical component or conductive materials challenge. For more examples of Resin Formulators solving complex materials challenges, download the Resin Formulators success stories brochure.
Frequently Asked Questions About RF 2969
What is RF 2969?
RF 2969 is a cost-effective silver-filled epoxy system developed by Resin Formulators for modern electrical component design. It provides high electrical conductivity and low viscosity for wicking into very small spaces, and is suitable for electrical circuitry, EMI shielding, and the grounding of composites.
What is a silver-filled epoxy used for?
A silver-filled epoxy is an electrically conductive adhesive used to complete electrical connections, provide EMI shielding, and ground components, including composite structures. The silver filler gives the cured epoxy high electrical conductivity while retaining the bonding and protective properties of an epoxy.
Does RF 2969 come in different cure versions?
Yes. RF 2969 was developed in multiple versions, including a heat-cure and a room-temperature curing formula, so the same conductive epoxy system can be matched to different production processes and component requirements.
Is RF 2969 qualified for aerospace and defense programs?
RF 2969 has been a successful aerospace solution for over 20 years and is qualified for use on military aircraft, commercial satellite, rocket, and automotive programs.
How does Resin Formulators develop custom conductive epoxies?
The team works directly with customers to understand both the performance requirements, such as conductivity and cure, and the practical constraints of the application. Development targets both dimensions, with in-house formulation and advanced material lab testing to validate material performance.
