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Insulcast

Insulcast

Insulcast is a line of two-component epoxy and silicone potting and encapsulation compounds from ITW Performance Polymers. Chemical Concepts stocks the Insulcast range for electronics OEMs, coil and transformer builders, and power electronics assembly, where parts need dielectric insulation, heat dissipation, and protection from moisture, chemicals, and vibration.

The epoxy side covers Insulcast 116 FR, an easy 1:1 general purpose potting and casting compound rated UL 94V-0, Insulcast 116 FR FC for faster set on a production line, Insulcast 140 FR when you need very high thermal conductivity (2.3 W/mK) and service to 155 C, Insulcast LN 1-05 for large non-cracking pours, and Insulgel 70 CC FR NS, a flexible epoxy with low CTE for assemblies that see thermal shock. Insulcure hardeners let you set pot life from 45 to 300 minutes on several of these systems. On the silicone side, RTVS 27 and its FC, LV, and HTC variants give you low viscosity potting from -55 C to 204 C that stays repairable after cure, and RTVS 3-95-1 and RTVS 3-95-2 push thermal conductivity and service temperature to 260 C for EV battery and high voltage work. RTVS 41 and RTVS 44 primers improve silicone adhesion on metal, glass, ceramic, and many plastics.

Insulcast was established in 1972 and is manufactured by ITW Performance Polymers, with North American operations in Danvers, Massachusetts and Montgomeryville, Pennsylvania.

Picking a potting compound comes down to viscosity, pot life, thermal conductivity, and what the compound has to bond to. Our team specs these systems every week and can narrow the list before you order sample quantities.

Browse our potting and encapsulation compounds or call the technical team at (800) 220-1966 or email [email protected] for help matching a grade to your assembly.

  • Features & Applications
  • Resources

Insulcast Features and Applications

Substrates

  • Metals: aluminum, steel, copper, brass
  • Plastics: ABS, polycarbonate, nylon, acrylic
  • Glass, ceramics, and PCB substrates
  • Potting cups, cases, and molded housings

Applications

  • Ignition coils and transformers
  • Printed circuit board potting and encapsulation
  • EV battery modules and power electronics
  • High voltage power supplies
  • Heat sink bonding, surface mount, and die attach
  • Telecom, utility, and power generation equipment
  • Aerospace and defense electronics

Key Features

  • Insulcast 116 FR: 1:1 by weight general purpose epoxy, UL 94V-0, 90 minute pot life, good fit for hand mixing or automatic dispensing.
  • Insulcast 116 FR FC: same 1:1 chemistry with a 30 to 45 minute pot life and 16 hour room temperature cure for faster line turns.
  • Insulcast 140 FR: 2.3 W/mK thermal conductivity and service from -55 C to 155 C for dense assemblies that run hot.
  • Insulcast LN 1-05: non-cracking epoxy built for large pours, 8 to 10 hour pot life, UL 94V-0.
  • Insulgel 70 CC FR NS: flexible epoxy with high elongation and low CTE, an alternative to urethane without isocyanate exposure.
  • RTVS 27 series: low viscosity silicone potting from -55 C to 204 C, easily cut away for component repair. FC (fast cure), LV (gap filling), and HTC (1.0 W/mK) variants available.
  • RTVS 3-95-1 and 3-95-2: high thermal conductivity silicones to 1.44 W/mK with service to 260 C, suited to EV and high voltage applications.
  • RTVS 42 Curtis II: silicone-epoxy copolymer that resists thermal shock cracking and bonds well to most metals and plastics.
  • Insulcure hardeners: Insulcure 9, 11B, 20, 24, and 26 set pot life from 45 to 300 minutes on compatible epoxy systems.
  • RTVS 41 and RTVS 44 primers: improve silicone adhesion on metal, wood, glass, ceramic, and many plastics.

Insulcast Technical Resources

Need a specific TDS, SDS, or a cure schedule check before you commit to a grade? Call (800) 220-1966 or email [email protected] and we will pull the documentation and confirm availability.

Insulcast is a line of two-component epoxy and silicone potting and encapsulation compounds from ITW Performance Polymers. Chemical Concepts stocks the Insulcast range for electronics OEMs, coil and transformer builders, and power electronics assembly, where parts need dielectric insulation, heat dissipation, and protection from moisture, chemicals, and vibration.

The epoxy side covers Insulcast 116 FR, an easy 1:1 general purpose potting and casting compound rated UL 94V-0, Insulcast 116 FR FC for faster set on a production line, Insulcast 140 FR when you need very high thermal conductivity (2.3 W/mK) and service to 155 C, Insulcast LN 1-05 for large non-cracking pours, and Insulgel 70 CC FR NS, a flexible epoxy with low CTE for assemblies that see thermal shock. Insulcure hardeners let you set pot life from 45 to 300 minutes on several of these systems. On the silicone side, RTVS 27 and its FC, LV, and HTC variants give you low viscosity potting from -55 C to 204 C that stays repairable after cure, and RTVS 3-95-1 and RTVS 3-95-2 push thermal conductivity and service temperature to 260 C for EV battery and high voltage work. RTVS 41 and RTVS 44 primers improve silicone adhesion on metal, glass, ceramic, and many plastics.

Insulcast was established in 1972 and is manufactured by ITW Performance Polymers, with North American operations in Danvers, Massachusetts and Montgomeryville, Pennsylvania.

Picking a potting compound comes down to viscosity, pot life, thermal conductivity, and what the compound has to bond to. Our team specs these systems every week and can narrow the list before you order sample quantities.

Browse our potting and encapsulation compounds or call the technical team at (800) 220-1966 or email [email protected] for help matching a grade to your assembly.

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