Also, use an overbite-style lead cutter. This produces a flat trimmed lead that is not sharp. -----Original Message----- From: TechNet [mailto:[log in to unmask]] On Behalf Of Brooks, Bill Sent: Wednesday, November 03, 2010 4:12 PM To: [log in to unmask] Subject: Re: [TN] SEEKING A VERY THIN INSULATING MATERIALS Trimmed thru hole component leads are typically sharp. Poke right thru most materials under vibration. Nothing will be better than more distance. Trim the leads shorter, increase the distance between the cover and the leads... maybe stiffen the cover... (prevent flexing). As a last resort... Spray/coat the inside of the cover with hard epoxy based coating... wet processes are variable and not as repeatable from part to part... require special handling, masking, etc... not cheap, uses costly touch labor... less than reliable. Could you use a non-conductive cover? Low voltage apps can use 'fish paper'... I never really knew the material well because we didn't decide to use it in any applications I ran into... But I know it was used in the automotive and radio industries for many years. Kapton was preferred in most applications, still is... it is durable and can be applied easily, die-cut with adhesive backing... Will not prevent the leads from poking thru it though for long... Maybe you can etch the cover with indentations or holes to clear the leads? Just a few thoughts based upon what I 'think' you are trying to do... Best regards, Bill Brooks | Datron World Communications, Inc. PCB Designer/Engineer | Office: 760-602-7004| Fax: 760-597-3777 | [log in to unmask] 3055 Enterprise Court, Vista, CA 92081 | www.dtwc.com Performance You Require. Value You ExpectTM ______________________________________________________________________ This email has been scanned by the MessageLabs Email Security System. For more information please contact helpdesk at x2960 or [log in to unmask] ______________________________________________________________________ --------------------------------------------------- Technet Mail List provided as a service by IPC using LISTSERV 15.0 To unsubscribe, send a message to [log in to unmask] with following text in the BODY (NOT the subject field): SIGNOFF Technet To temporarily halt or (re-start) delivery of Technet send e-mail to [log in to unmask]: SET Technet NOMAIL or (MAIL) To receive ONE mailing per day of all the posts: send e-mail to [log in to unmask]: SET Technet Digest Search the archives of previous posts at: http://listserv.ipc.org/archives Please visit IPC web site http://www.ipc.org/contentpage.asp?Pageid=4.3.16 for additional information, or contact Keach Sasamori at [log in to unmask] or 847-615-7100 ext.2815 ----------------------------------------------------- ______________________________________________________________________ This email has been scanned by the MessageLabs Email Security System. For more information please contact helpdesk at x2960 or [log in to unmask] ______________________________________________________________________ --------------------------------------------------- Technet Mail List provided as a service by IPC using LISTSERV 15.0 To unsubscribe, send a message to [log in to unmask] with following text in the BODY (NOT the subject field): SIGNOFF Technet To temporarily halt or (re-start) delivery of Technet send e-mail to [log in to unmask]: SET Technet NOMAIL or (MAIL) To receive ONE mailing per day of all the posts: send e-mail to [log in to unmask]: SET Technet Digest Search the archives of previous posts at: http://listserv.ipc.org/archives Please visit IPC web site http://www.ipc.org/contentpage.asp?Pageid=4.3.16 for additional information, or contact Keach Sasamori at [log in to unmask] or 847-615-7100 ext.2815 -----------------------------------------------------