Four Forms of Thermal Interface Material: How to Choose Between Grease, Pads, Gel and Potting Compound
2026-10-28 14:10:47
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This paper compares four thermal‑interface materials: grease, pad, gel and potting compound. Gap conditions rather than thermal conductivity govern material selection. It outlines their strengths, limitations and practical criteria for quick application‑oriented material matching.
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Four Forms of Thermal Interface Material: How to Choose Between Grease, Pads, Gel and Potting Compound
There is always a gap between the heat-generating component and the heat sink, and air is a very poor conductor (about 0.026 W/m·K), so the gap has to be filled with a material. A thermal interface is not a component in its own right — it is the sum of the tolerances accumulated across every surrounding part. That is why selection starts with the gap, and only then with the material.
Key point: the gap comes before the material — clamped thin gaps take grease, flat and even gaps take pads, uneven gaps or anything that must be reworked take gel, and open cavities that need protection take potting. Thermal conductivity follows coverage.
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