From EVs to IoT: The Explosion of Electromagnetic Interference Risks

As devices become smaller, faster, and more wirelessly connected, one issue continues to grow: electromagnetic interference (EMI). Whether you're designing the next generation of electric vehicles, developing precision medical equipment, or expanding industrial IoT networks, EMI remains a threat to product performance, safety, and regulatory compliance. EMI is more than just a technical inconvenience; it costs manufacturers billions each year in rework, downtime, and lost customer trust. Often, the root cause of EMI problems isn't identified until late-stage prototypes fail testing. 

Why EMI is Becoming a Bigger Problem 

Electromagnetic Interference (EMI) is becoming an increasingly urgent issue in product development for several reasons. As electronic systems are packed more tightly, there is less physical space to isolate signals. Components are being squeezed into smaller footprints, and designers continuously aim for smaller, lighter, and more integrated builds. At the same time, we are adding more sources of interference, including 5G radios, wireless chargers, onboard antennas, and high-speed processors, which create a noisier electromagnetic environment. 

Additionally, the faster switching speeds in modern electronics cause sharper signal transitions, which can generate higher-frequency noise. Wireless systems like Bluetooth, Wi-Fi, and NFC are now more susceptible than ever to degradation and dropouts when exposed to unmanaged EMI. Furthermore, the regulatory environment is continually becoming stricter, increasing the challenge. 

Where EMI is a Dealbreaker 

Certain industries cannot afford inaccuracies. For instance, electric vehicles rely on high-voltage powertrains equipped with sensitive electronics, autonomous systems, and high-speed communication networks. Without proper shielding, the risk of signal disruption becomes high. In medical fields, electromagnetic interference (EMI) is not just a nuisance; it can pose serious dangers. Interference might cause false readings, equipment failures, or communication issues between devices. The defense and aerospace sectors demand exceptional reliability, often in harsh environments. Even minor EMI exposure can threaten mission-critical systems in these industries. Likewise, telecommunications and networking are highly sensitive, where signal integrity is crucial, as even small noise levels can drastically reduce performance. Across all these sectors, the ability to predict and manage EMI is key to product success. 

Solutions That Work 

Effectively addressing electromagnetic interference (EMI) begins with selecting the right materials, as not all shielding options are equal. Each application requires a tailored solution. For example, conductive foams are highly flexible and compressible, making them ideal for gaskets around electronic enclosures or access panels. Fabric-over-foam materials combine shielding effectiveness with mechanical strength, making them suitable for dynamic seals or wipe interfaces. In more demanding situations, oriented wire gaskets deliver excellent conductivity and are frequently used in aerospace and military-grade systems. When bonding is preferred over mechanical fastening, conductive tapes and adhesives provide easy-to-apply shielding options. These solutions ensure electrical continuity across seams and work effectively with both automated and manual assembly processes.  

What Sets PGC Apart 

At PGC, we recognize that shielding isn't a one-size-fits-all solution. Our process begins with engineering collaboration, where we evaluate your specific use case, identify potential vulnerabilities to electromagnetic interference (EMI), and assist you in selecting materials that not only address the issue but also align with your product constraints. We offer custom-cut shielding components designed for complex shapes, and our team has extensive experience recommending materials based on real-world conditions, including temperature, vibration, and regulatory standards. When you're ready to scale up, our manufacturing capabilities allow us to deliver high-volume, precise parts quickly and reliably. We have supported EMI shielding for various applications, such as autonomous drones and medical electronics. No matter the device, we follow a proven process to prevent interference issues before they lead to product failures. 

As our world becomes more connected, the risks of electromagnetic interference (EMI) are increasing. The good news is that with early planning and the right material partner, you can prevent interference in your system before it causes problems. Whether you're facing regulatory requirements, dealing with signal degradation, or simply wanting to make your product more durable, effective shielding is not just an option; it's essential.  

PGC is here to help. Let's work together to ensure your next product is not only functional and efficient but also free from interference.