In industries where precision, reliability, and environmental stability are critical, material selection can make or break performance. One key property engineers and designers must evaluate is low outgassing especially in aerospace, electronics, and automotive applications.
But what exactly is outgassing, and why does it matter?
What Is Outgassing?
Outgassing refers to the release of trapped gases or volatile compounds from a material when exposed to heat, vacuum, or other environmental conditions. While this may seem minor, in sensitive environments such as spacecraft or sealed electronic systems even small amounts of outgassing can lead to:
- Contamination of optical surfaces
- Electrical interference or signal degradation
- Reduced adhesion or bonding performance
- Long-term reliability issues
This is why industries governed by strict standards, such as NASA, require materials that meet specific low outgassing criteria like ASTM E595.
Why Low Outgassing Is Critical
Low outgassing materials are engineered to minimize the release of volatile compounds.
This is especially important in:
Aerospace Applications
In vacuum environments, outgassed molecules can deposit onto sensitive components like lenses, sensors, and solar panels. Materials that meet NASA low outgassing specifications help ensure mission-critical reliability.
Electronics Manufacturing
Modern electronics—especially compact and high-density assemblies require clean, stable materials. Outgassing can lead to corrosion or interfere with delicate circuitry, particularly in flexible printed circuits (FPCs) and sensors.
Automotive Systems
As vehicles incorporate more advanced electronics and sensors, low outgassing materials help maintain performance in enclosed or high-temperature environments.
The Role of Acrylic Adhesives in Low Outgassing
Not all adhesives are created equal. High-performance acrylic adhesives, like 3M™ 966, are specifically formulated to provide:
- Low outgassing and low leachable chloride content
- High temperature resistance (up to 450°F short-term)
- Excellent chemical and UV resistance
- Low Fogging
- Strong peel and shear strength in demanding conditions
These properties make this tape ideal for applications where both mechanical strength and environmental stability are required.
Kapton® Tape with 3M™ 966 Adhesive: A Compatible Solution
This specialized tape combines Kapton® HN polyimide film with a high-performance acrylic adhesive system to deliver a unique balance of electrical, thermal, and mechanical properties.
3M 966 is also laminated to Kapton® XC to produce an electrically conductive tape benefiting from a carbon loaded film substrate utilized in numerous satellite applications providing both thermal and anti-static control.
Key Features
- Meets NASA low outgassing specifications (ASTM E595)
- Available in multiple film thicknesses (1 mil, 2 mil, 3 mil)
- High dielectric strength and electrical insulation
- Excellent resistance to solvents, UV exposure, and extreme temperatures
- Available in single- or double-sided configurations
Common Applications
- Flexible printed circuit (FPC) attachment
- Aerospace bonding and insulation
- LED and sensor assembly
- High-performance electronic devices
Custom Solutions for Specialized Applications
One of the advantages of working with CS Hyde is the ability to custom laminate 3M™ 966 adhesive to a variety of substrates, including:
This flexibility allows engineers to tailor materials to specific requirements—whether for thermal management, electrical insulation, or structural bonding.
Final Thoughts
As industries continue to push the limits of performance and miniaturization (the process of designing, manufacturing, and scaling down components, devices, and systems to become smaller, more portable, and often more powerful), the importance of low outgassing materials will only grow. Selecting the right adhesive-backed film like Kapton® tape with 3M™ 966 adhesive can significantly improve reliability, reduce contamination risks, and ensure long-term success in demanding environments.
If your application requires high temperature resistance, strong adhesion, and low outgassing performance, it is worth exploring engineered solutions designed to meet the highest standards.
Have a challenging application? Partner with CS Hyde to identify the right low-outgassing material solution for your next project.