Material development around your assembly
Custom Formulation for Electronic and Thermal Materials
When a standard material misses a critical requirement, develop a better fit. Haktak reviews chemistry, flow, cure and functional targets together with your parts, production equipment and service conditions.
+ Process
+ ProofDefine success in the finished assembly—not in one data-sheet value.
Start with the part and the problem
Rank measurable must-have targets
Match placement, handling and cure
Agree how the material will qualify
Choose the shortest practical route
When Do You Need Custom Material Formulation?
Custom formulation means developing or modifying a material around an application. It is useful when a critical combination of properties cannot be met by an available grade.
A standard grade already fits
Use a proven product when it meets the complete requirement. Selection and process adjustment may solve the problem without changing chemistry.
Explore material selection & testing →A proven platform is close
Review a targeted adjustment to flow, cure or another limiting property. Retest related functions: changing one variable can affect several others.
Review customization services →The requirement needs a new balance
Evaluate a different chemistry or filler system when existing platforms cannot meet essential constraints. Begin with feasibility and agreed qualification criteria.
Explore Haktak material solutions →Match function before chemistry
Custom Thermal and Electronic Material Formulation Options
Select a starting family, then define the properties that must work together. Material availability and development feasibility are reviewed for each project.
A balanced formulation, not six maxima
What Can Be Adjusted in a Custom Formulation?
Specify acceptable windows, not just higher or lower values. Every adjustment must preserve the properties that make the material usable.
Thermal performance
Adjust the heat-transfer system while checking contact, thickness, density and assembly stress.
Verify: installed thermal resultFlow and dispensing
Target viscosity, recovery and settling for the actual nozzle, temperature and line interruptions.
Verify: repeatable placementCure and working time
Match open life and cure to takt time, part temperature, depth and access to heat or light.
Verify: functional cure stateMechanical behavior
Balance softness, adhesion and strength with movement, load and repair requirements.
Verify: stress and retentionElectrical properties
Define insulation or conduction at the finished thickness and relevant operating conditions.
Verify: grade-specific evidenceCleanliness and compatibility
State restricted substances, nearby sensitive surfaces and limits for bleed or volatile deposits.
Verify: application-specific limitsA development path with decision gates
Custom Formulation Development: From Brief to Pilot Batch
Each stage reduces uncertainty before the next investment. Iterations and timing depend on technical complexity, available raw materials and customer testing.
- 01
Define the brief
Review parts, current failures, mandatory targets and process constraints.
Output / prioritized requirements - 02
Assess feasibility
Choose a baseline and identify competing targets or missing evidence.
Output / development and test plan - 03
Screen formulations
Prepare candidates and remove those that fail critical lab criteria.
Output / candidate shortlist - 04
Trial real assemblies
Use representative parts and equipment; return process feedback for refinement.
Output / application trial results - 05
Qualify the candidate
Check retained function after relevant exposure and agree acceptance limits.
Output / qualified specification - 06
Review pilot production
Check scale-up, packaging and controls before approving routine supply.
Output / production release plan
Need trial quantities first? Discuss prototype samples for your development stage. A successful laboratory sample is not yet proof of production readiness.
Turn the problem into a usable brief
Define Your Custom Material Formulation Requirements
You do not need a finished specification to begin. Share what is known, separate hard limits from preferences, and explain how success will be measured.
- Parts & surfaces
- Drawings, gap range, footprint, substrates and surface treatments.
- Current problem
- Existing material, failure evidence and what must improve.
- Hard limits
- Thermal, electrical, mechanical and chemistry restrictions with units.
- Production conditions
- Equipment, placement, mixing, cure, cycle time and stoppages.
- Qualification
- Service exposure, test conditions and pass/fail criteria.
- Supply needs
- Sample quantity, packaging, forecast and intended launch timing.
Measure the result where it matters
Validate Custom Formulations in the Finished Assembly
Compare candidates under matched conditions. Check both the intended improvement and the functions that must not deteriorate.
Make data comparable
Record specimen preparation, method, temperature and material state. Link each measured property to a defined requirement.
Use the intended equipment
Test dispensing, closure, cure and inspection on real parts. Include tolerance extremes, idle periods and package changes.
Confirm retained function
Retest after relevant cycling, humidity or vibration. Inspect contact, cracking, deposits and any required removal or repair.
Plan repeatability before release
Agree critical raw-material controls, manufacturing instructions, release tests and traceability. Packaging and process changes should be reviewed for their effect on the qualified material.
From an unresolved issue to a development plan
Start a Custom Formulation Review
Tell us what the current material cannot do. Haktak can review whether selection, a focused modification or a new formulation is the practical next step.
Practical development questions
Custom Formulation FAQ
When should we request a custom material formulation?
Consider development when available grades repeatedly miss a critical combination of functional, reliability or production requirements. First check whether material selection or a process correction can solve the issue without changing the formulation.
How does modifying a grade differ from developing a new formulation?
A modification starts with a proven platform and targets a limited change. New development may require a different base chemistry or filler system. Both routes need validation because a change can affect cure, stability, handling or other essential properties.
Which electronic materials can be considered for customization?
Projects may involve thermal interface materials, gels, putties, greases, electronic adhesives, sealants, potting compounds or coatings. The practical scope depends on the application, required chemistry, development feasibility and agreed supply conditions.
What information is needed to start?
Share drawings, substrates, the current material and failure evidence. Add mandatory performance limits, production conditions, service exposure, qualification methods and sample or forecast needs. Identify unknowns so they can be addressed during feasibility review.
Can every material property be improved at the same time?
No. More filler can change viscosity, density and mechanical behavior; faster cure may reduce working time. Rank requirements and define acceptable windows. The goal is a useful balance in the assembly, not the maximum of every data-sheet value.
Can a silicone-free or low-outgassing formulation be evaluated?
These directions can be reviewed for feasibility. Define prohibited substances, declaration scope, test methods and limits. Silicone-free does not automatically mean zero bleed or vacuum suitability; sensitive surfaces and operating conditions require separate assessment.
Should engineering samples be tested on our production line?
Yes, representative equipment trials are important. Lab measurements cannot fully reproduce nozzle geometry, pressure, idle time, material conditioning and assembly delays. Use agreed trial conditions and return both functional measurements and process observations.
How long does custom formulation development take?
There is no universal lead time. Chemistry, raw-material availability, iteration count and customer reliability testing affect the schedule. A realistic development sequence and milestones should be proposed after reviewing the brief.
Are minimum order quantities and packaging fixed?
They are project-dependent. Batch process, raw materials, package format, consumption and forecast volume influence commercial feasibility. Review these needs early so the developed material can be supplied and used practically.
Who owns the custom formulation and development results?
Ownership, confidentiality, exclusivity and access to results should be agreed in the project terms before work begins. Do not assume that a custom development request automatically grants exclusive rights to the underlying formulation.