Electronic Potting Compound Market

The electronic potting compound market for EV charger is projected to grow from an estimated USD 0.36 billion in 2025 to USD 0.96 billion by 2032, registering a CAGR of 14.9%. Thermal curing remains dominant in EV charger potting due to its effectiveness in thick encapsulation layers used in high-power DC fast chargers, providing uniform curing, strong electrical insulation, and long-term thermal stability. The increasing adoption of 800 V+ architectures and megawatt charging systems further strengthens demand for thermally cured materials, as they ensure reliable performance under continuous high-load conditions. UV-assisted hybrid curing technologies are being increasingly adopted in automated manufacturing environments, as they enable rapid surface curing for quicker handling while a secondary thermal cure ensures complete material performance. Manufacturers are increasingly optimizing cure profiles to minimize exotherm and internal stress in dense power assemblies. Additionally, curing systems compatible with inline, automated production lines are becoming essential to support high-volume charger manufacturing.

Leading players, such as Henkel Corporation (Germany), Parker Hannifin Corp (US), ELANTAS (Germany), Dow (US), and Momentive (US), are expanding their EV charger-specific potting portfolios, particularly in high-thermal-conductivity, high-dielectric formulations for DC fast chargers. Through product launches and technology upgrades, these companies are strengthening their qualification depth, OEM partnerships, and compliance readiness for high-voltage charger platforms. As the market evolves, potting compound manufacturers are co-developing application-specific materials with charger OEMs, optimizing formulations for automated dispensing, and localizing production to meet regional certification and supply chain requirements.

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In January 2026, Henkel launched Loctite STYCAST US 8000 A/B, a two-component polyurethane potting compound designed for demanding power electronics applications. The material offers high dielectric strength, low ionic content for corrosion resistance, and low-viscosity flow for reliable, void-free encapsulation in EV charger power modules.

In November 2025, Henkel Corporation (Germany) launched thermal potting solutions that are designed for critical EV power conversion components, including on-board chargers and inverters, and provide different levels of thermal conductivity to meet varying design requirements. Loctite SI 5643 and Loctite SI 5637 are two-component, fast-curing, low-viscosity, thermally conductive silicone potting compounds developed for high-performance power electronics.

In September 2025, Dow launched DOWSIL EG-4175 Silicone Gel for high-voltage EV power electronics. The gel resists up to 180°C (356°F) and is designed for next-gen IGBT modules in EV batteries and inverters, enabling higher voltage and greater efficiency.

Henkel Corporation (Germany) is focusing on expanding its portfolio of high-performance silicone potting solutions for power conversion modules by introducing fast-curing, low-viscosity, thermally conductive grades for onboard chargers and inverters. This is supported by automated dispensing validation and early “design in” engineering support through regional battery and power centers, helping OEMs shorten qualification timelines. Henkel also uses its global application laboratories to speed up scale-up activities and support compliance testing for high-voltage platforms.

Parker Hannifin Corp (US) concentrates on thermally conductive potting and encapsulation systems, including the CoolTherm range, supported by validated dispensing equipment and UL qualification to address high-power charger assemblies and battery modules. Its market approach combines material performance, application expertise, and certification support to reduce OEM risk in sealed DC fast charging modules, while also targeting aftermarket and modular replacement opportunities to scale adoption.

ELANTAS (Germany) leverages its background in insulating varnishes and casting and potting resins to support an e-mobility-focused portfolio for charging infrastructure. The company offers customized potting, casting, and thermal interface systems designed to address partial discharge resistance and heat management in 800 V and higher voltage charger designs, supported by strong technical application support and regional manufacturing to meet OEM and regulatory requirements.

Dow (US) is aligning its materials portfolio with EV power systems by promoting formulated encapsulants and DOWSIL electronics products that combine thermal management with compatibility for automated assembly of battery and power electronics modules. The company emphasizes system-level material solutions such as gap fillers, potting gels, and conformal coatings that simplify automated dispensing and meet automotive fire and protection requirements, supported by dedicated account teams working closely with charger and battery OEMs.

Momentive (US) is advancing silicone-based thermal management and potting solutions, such as the SILCOOL and SILTRUST product lines, for high-temperature, long-life performance in EV chargers and battery systems. Its development efforts focus on low-modulus, high-thermal-conductivity silicones with added fire-safety features, combined with application laboratory support and sampling programs to accelerate validation for automated, high-volume manufacturing.

Market Ranking

The electronic potting compound market for EV charger is fragmented, with five main players holding 20% to 25% of the total market. Henkel is expanding its EV-oriented potting portfolio with fast-curing, low-viscosity silicone and polyurethane grades designed for high thermal conductivity and compatibility with automated dispensing systems, supported by global application laboratories that help accelerate OEM qualification. Dow is promoting silicone-based, thermally conductive encapsulants and gel systems for higher-voltage power electronics, supported by mobility-focused account teams that work directly with charger and battery module manufacturers to integrate materials into production lines. Parker Hannifin is emphasizing low-viscosity, thermally conductive potting systems under the CoolTherm range, supported by third-party certifications and validated dispensing solutions to secure adoption in sealed, high-power DC modules and modular aftermarket components. ELANTAS is building on its expertise in insulating resins to provide customized casting, potting, and thermal interface systems for 800 V and higher-voltage designs, while expanding regional manufacturing and technical support to meet OEM certification requirements. Momentive is concentrating on low-modulus, high-thermal-conductivity silicone potting and sealing solutions for chargers and connectors, supported by application laboratories and sustainability initiatives aimed at accelerating adoption in high-temperature DC charging environments.

Related Reports:

"Electronic Potting Compound Market for EV charger, By Charger Type (AC, DC), Setup Type (Wall Mount, Stationary), Material Type (Polyurethane, Silicone, Epoxy), Curing Technology, Application, EV Component, and Region - Global Forecast to 2032" 

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