Protecting Hearing Aids with Precision – A Solutions-Led Approach
Hearing aids are among the most demanding electronic devices on the market. They operate in a uniquely hostile environment – exposed daily to humidity, perspiration, skin oils and intermittent liquid ingress – all within an ever-shrinking form factor. As product miniaturisation accelerates and sustainability requirements tighten, manufacturers are under increasing pressure to deliver long-term reliability without compromising performance, repairability or cost structure.
At P2i, we take a solutions-led approach to this challenge. Rather than forcing a single technology into every application, we work with our customers’ Qualification Test Plans and CAD/STEP data to determine what level of protection is genuinely required, and which coating technology will deliver the best commercial and technical outcome.
The Corrosion Challenge in Modern Hearing Aids
The electronics within hearing aids – including PCBAs, interconnects, battery contacts and microphones – operate in a harsh, moisture-rich environment where sweat and salts can rapidly drive corrosion. As designs become more compact and geometrically complex, traditional protection methods such as liquid conformal coatings, gaskets, tapes and adhesives begin to show their limitations, adding thickness, constraining tolerances and complicating rework. Even thinner options like parylene can increase scrap and restrict serviceability. At the same time, manufacturers must align corrosion protection strategies with tightening environmental regulations and sustainability goals, including the move towards PFAS- and PFOA-free chemistries.
Splash-Proof Plasma Coating – PFOA-Free, Solvent-Free Protection
Our Splash-Proof plasma coating is PFOA-free – a significant milestone for manufacturers seeking environmentally responsible protection. It is applied using a dry, solvent-free plasma process containing no volatile organic compounds and no harmful wet chemistries.
Because the coating forms at a molecular level, it is ultra-thin – far thinner than gaskets, tapes or traditional liquid coatings. It fits everywhere without adding bulk or affecting tight mechanical tolerances. Critically, there is no change to microphone performance or audio quality, fully differentiating it from other coating technologies.
Splash-Proof technology prevents liquid ingress into the treated device under typical exposure conditions. It is ideally suited to protecting against splashes, light sprays and everyday perspiration while preserving the integrity and acoustic performance of the device.
Barrier Coating – PFAS-Free Corrosion Defence for Higher-Stress Environments
For applications requiring enhanced protection, our Barrier Coating provides PFAS-free corrosion defence – an increasingly important factor as the industry moves away from legacy fluorinated chemistries.
Barrier technology protects electronics even in scenarios that mimic IPx3-8 forces, such as stronger sprays, partial immersion or heavy sweating environments. In events where liquid is forced into the device, the coating prevents corrosion damage to the underlying board.
Like Splash-Proof, Barrier is delivered through a dry plasma process – with no nasty solvents, no volatile organics and no environmentally problematic substances. The result is robust corrosion protection that meets both reliability and regulatory requirements.
Repairability, Rework and Reduced E-Waste
Serviceability is essential in hearing aids, where batteries must be replaced, components repaired and e-waste minimised for both commercial and environmental reasons. Our plasma coatings support full repairability and rework, with precise masking and de-masking to protect selected PCBA areas while leaving connectors, test points and acoustic elements unaffected. Compared to parylene-coated devices, this approach can simplify assembly testing and reduce scrap, enabling durable protection in use without compromising in-market serviceability or sustainable product lifecycles.
A Pragmatic Option – Liquid-Based Coatings Where Appropriate
Many manufacturers already operate dip or spray nozzle systems for liquid-based conformal coatings. In some cases, the most operationally cost-efficient solution may be to optimise the chemistry within an existing setup.
As part of our solutions-led methodology, we can assess whether a revised liquid-based coating meets your performance requirements. This can represent the lowest entry point to protection.
However, where long-term reliability, environmental compliance and product differentiation are key drivers, Splash-Proof and Barrier plasma coatings typically provide superior performance. Their ultra-thin, solvent-free, PFOA-free and PFAS-free characteristics offer a clear technical advantage over traditional wet processes.
Proven Performance – Over 15 Years Supporting the Hearing Aid Industry
For more than a decade and a half, we have partnered with hearing aid manufacturers to engineer reliability into their products from the outset. Our work consistently delivers:
- Over 15 years’ experience delivering protective coating solutions to the hearing aid sector
- A consistent focus on reducing field-failure rates in real-world user environments
- Improved long-term reliability as device designs continue to evolve
- Fewer corrosion-related returns and lower warranty costs
- Reduced service interventions and improved operational efficiency
- Enhanced brand reputation through dependable product performance
- Molecular-level protection that translates into measurable downstream commercial benefits
Choosing the Right Protection for Your Device
There is no one-size-fits-all answer. The right solution depends on your product architecture, qualification criteria, environmental targets and cost structure.
By reviewing your Qualification Test Plan alongside your CAD or STEP files, our engineering team can recommend the coating that genuinely meets your requirements – whether that is Splash-Proof, Barrier or a tailored liquid-based solution within your existing process.
If you are developing the next generation of hearing aids and want to reduce field failures while meeting evolving environmental standards, we would be pleased to explore the right path forward with you. Get in touch to start the conversation.
2025 has been a year of real progress for P2i – a period where long-term relationships came to fruition, new technologies moved from development into deployment, and our global footprint continued to grow. Below is a look back at the key moments that shaped the business this year and the foundations they’ve set for 2026.
Jolt Capital Takes a Controlling Stake in P2i
The most significant milestone this year was Jolt Capital’s decision to take a controlling stake in P2i, supported by an initial €8 million investment. After several years of close collaboration, this formal partnership marks a turning point for the company. For Jolt, P2i is a clear fit with their deeptech investment philosophy – a proven, sustainable technology with global relevance and strong growth potential.
For us, the investment brings both strategic backing and financial strength at a pivotal time. With more than a billion devices already protected using our plasma-enhanced thin film deposition process, the backing of Jolt’s experienced team reinforces our ability to scale, diversify, and accelerate innovation. As Jolt’s first UK investment, it also signals their confidence in the direction we’re heading and the opportunity ahead in protective nanotechnology across electronics, automotive, and medical sectors.
Launching Our Liquid Barrier Coatings Offering
Another major highlight was the launch of our Liquid Barrier Coatings (LBC) – a fully defined, production-ready solution that removes the uncertainty typically associated with coating qualification. By reviewing a customer’s Qualification Test Plan and CAD/STEP files, we can now recommend the best coating first time, rather than relying on trial-and-error testing.
These ultra-thin coatings integrate seamlessly into existing manufacturing lines – spray, dip, jet, no vacuum, no cure cycles – and deliver proven protection from IPX3 through to IPX8. They’re flexible across substrates, fast to apply, and built to keep pace with real-world production demands. For teams looking to strengthen device reliability without slowing down throughput, the LBC range offers a practical, highly optimised route forward. If you’d like to explore what this could look like for your own products, our engineers are always on hand to talk through the details.
Advancing PFOA-Free and PFAS-Free Protection for Hearing Aids
Protection requirements for hearing aids are becoming more complex, driven by tighter global regulation and rising expectations around device reliability. Over the past year, we placed particular focus on supporting manufacturers through this transition with our long-established, PFOA-free and PFAS-free molecular coating solutions. With major regulatory deadlines now in force, including the end of PFOA exemptions for medical devices entering the EU, our coatings offer a fast, compliant, and high-performance alternative to traditional seals and legacy coatings, chosen not just for compliance but for the reliability, reduced returns, and improved consumer confidence they deliver. Learn more.
Expanding Our Presence in India
This year also saw the start of an important new partnership in India. Working closely with our customer, we’ve already helped deliver stronger reliability and lower failure rates by integrating our molecular technology into their production processes. It’s early days, but the results have been very encouraging. India is a strategic growth region for us, and we’re excited to deepen our presence there as we move forward.
Thank you to all of our customers, colleagues, and stakeholders for your support throughout the year. In the year ahead, we look forward to becoming further established in India, entering new territories, and strengthening our position across global markets. We’re proud of what 2025 has delivered – and even more excited for what 2026 will bring.
In automotive electronics, every degree counts. As vehicles become more intelligent and power-dense, the demand for reliable thermal management across Printed Circuit Board Assemblies (PCBAs) has never been greater. Effective heat management is central to electronic reliability, with studies confirming that even small temperature rises can accelerate component failure rates. Automotive PCBA thermal-management coatings are playing a critical role in keeping systems stable under extreme conditions – from the first board layout to final field repair.
P2i’s advanced pulsed-plasma nanocoatings bring a new level of control and efficiency to automotive electronics. They deliver robust environmental protection while maintaining exceptional thermal transparency – a balance that conventional conformal coatings struggle to achieve. This unique capability benefits engineers at every stage of development: design and architecture, new product introduction (NPI), and repair or remanufacture.
Smarter Thermal Management Starts in the Design Phase
For PCB Design Engineers, Hardware Architects, and Electronics Design Engineers, the relationship between board layout and heat dissipation is vital. Component placement, trace routing, and overall density all influence thermal flow.
Research shows that coating thickness and formulation directly influence how well PCBAs manage heat and maintain long-term reliability. This reinforces the importance of choosing protective coatings that support, rather than hinder, thermal performance.
Traditional coatings can add unwanted insulation, limiting flexibility in layout and miniaturisation. P2i’s ultra-thin plasma nanocoatings provide a consistent, thermally transparent barrier that protects without obstructing heat pathways. Designers can confidently position components closer together, supporting higher functionality in smaller spaces while maintaining stable operating temperatures. By integrating automotive PCBA thermal-management coatings early in the design process, architecture teams can create compact, high-performance systems that stay cool even under load.
Supporting NPI Teams Through Production Challenges
New Product Introduction teams face an array of technical challenges, from achieving consistent coverage to balancing performance with manufacturability. Conventional liquid coatings often require extensive masking, longer curing times, and additional inspection steps, all of which add complexity and cost.
P2i’s pulsed-plasma process eliminates many of these constraints. Its precise application coats every surface evenly – even around underfill areas and component edges – without adding bulk or disrupting thermal pathways. For NPI, Manufacturing and Process Engineers, this translates to smoother production runs, fewer rejects, and simpler rework procedures.
By choosing P2i’s thermal-management nanocoatings for automotive electronics, manufacturers can enhance yield and reliability while reducing total cost of ownership.
Extending Product Life with Repairable, Sustainable Coatings
In the repair and remanufacturing stage, coatings often determine whether a component can be safely reused or must be scrapped. Heavy or brittle coatings can make repairs difficult, trapping heat and preventing solder rework.
P2i’s coatings are different. Their molecular-level uniformity ensures excellent adhesion and durability, yet they remain thin enough to support efficient rework and reapplication. This means boards can be repaired, reused, or recycled – aligning with sustainability goals and reducing waste.
For Repair Engineers, Remanufacturing Engineers and Product Sustainability Engineers, automotive PCBA thermal-management coatings enable a more circular approach to electronics – protecting performance while supporting responsible lifecycle management.
Why Choose P2i
Across design, manufacturing, and repair, P2i’s nanocoating solutions provide measurable advantages:
- Superior Thermal Transparency: Allows heat to dissipate freely for improved reliability
- Minimal Masking: Saves labour and reduces production time
- Reworkable Protection: Supports reuse and sustainability targets
- Proven Durability: Resists moisture, salt, and contaminants in automotive environments
- PFAS-Free Chemistry: Ensuring compliance with evolving environmental regulations
Whether you’re developing next-generation ECUs or extending the lifespan of legacy systems, P2i helps you balance protection, performance, and sustainability.
Let’s Talk About Your Next Design
P2i partners with leading automotive electronics teams to solve complex reliability challenges through advanced surface engineering. To discuss how our automotive PCBA thermal-management coatings can improve your designs, streamline production, or extend product life, contact our team today.