The Real Roadblocks: How to Solve Unexpected Thermal Failures

A Hands-On Guide to Diagnosing and Overcoming Thermal Surprises in Electronics

Unexpected overheating in electronic systems often appears in places engineers least expect, making reliable design a real challenge. In this episode, we explore why thermal problems don't always follow theory and why standard calculations sometimes miss the true source of heat build-up. You'll learn about the main factors that create hidden thermal resistance, such as air gaps, imperfect interfaces, and material thickness. We explain why the "highest conductivity" materials aren't automatically the best solution and how practical strategies like gap fillers, spreaders, and thermally conductive adhesives can prevent and solve thermal failures. Our experts share real-world design tips to manage hotspots, improve reliability, and select the right thermal interface materials for your specific application. RELATED COMPONENTS: Gap Filling Solutions: https://www.we-online.com/en/components/products/tm/gap_filling_solutions Thermal Gap Filler Pad: https://www.we-online.com/en/components/products/THERMAL_WE-TGF Thermal Transfer Tape: https://www.we-online.com/en/components/products/THERMAL_WE-TTT Conductive Insulator Pad: https://www.we-online.com/en/components/products/THERMAL_WE-TINS Graphite Sheet (Heat Spreading Solutions): https://www.we-online.com/en/components/products/THERMAL_WE-TGS Graphite Foam Gasket (hybrid Solutions): https://www.we-online.com/en/components/products/THERMAL_WE-TGFG To view the datasheets or order samples, visit Würth Elektronik online or the MyWE customer portal. Listen to our PODCAST🎙️: https://www.we-online.com/en/news-center/podcast Follow us on LinkedIn: https://www.linkedin.com/company/wurth-elektronik (Americas) Follow us on LinkedIn: https://www.linkedin.com/company/wuerth-elektronik-group (Europe) Like us on Facebook: https://www.facebook.com/WurthElectronics/ (Americas) Like us on Facebook: https://www.facebook.com/Wuerth.Elektronik.Group/ (Europe) Follow us on X: https://x.com/WurthElectronic/ (Americas) Follow us on X: https://x.com/we_online (Europe) Follow us on Instagram: https://www.instagram.com/wurthelectronics (Americas) Würth Elektronik online: https://www.we-online.com/