Plexus® Launches New Thermomechanical Polyurethane Structural Adhesives to Address Heat, Stress, and Durability Challenges

📰 Press Release:

FOR IMMEDIATE RELEASE

Three new products – DT2325, DT2430, and DT2630LD – enable stronger, more reliable assemblies in thermally demanding applications

[Shannon, Ireland / Danvers, MA] – May 11, 2026 – Plexus®, a global leader in high‑performance structural adhesives, today announced the launch of three new thermomechanical polyurethane structural adhesives designed to help engineers manage the increasing thermal and mechanical stresses found in modern assemblies. The new products (Plexus DT2325, Plexus DT2430, and Plexus DT2630LD) expand the Plexus polyurethane portfolio and provide designers with new ways to integrate structural bonding and thermal performance into a single material solution.

Polyurethane adhesive

“As industries push toward higher power density, lighter designs, and mixed-material assemblies, traditional joining methods are reaching their limits,” said Chintan Patel, Product Manager Specialty Adhesive. “Rigid adhesives can crack under thermal cycling, while conventional thermal interface materials manage heat without providing structural support. Plexus polyurethane adhesives are engineered to bridge that gap, combining thermal management and structural bonding in a single solution to simplify design and improve long-term reliability.”

Engineered to Meet Today’s Assembly Challenges

The new Plexus polyurethane formulations are designed for thermal management, vibration, and impact while maintaining controlled thermal conductivity across wide temperature ranges. By combining mechanical toughness with functional thermal performance, these adhesives become an integral part of the system, not just a joining method.

Key benefits include:

  • Tough, elastomeric structural performance
  • Stress relaxation during thermal cycling
  • Controlled heat dissipation without brittleness
  • Low VOC and low‑odor formulations
  • UL94 V‑0
  • High dielectric strength for electrically sensitive assemblies
  • Compatibility with cartridge and bulk dispensing systems

These capabilities help simplify system design, reduce reliance on mechanical fasteners, and improve long‑term reliability in heat‑generating environments.

Product Overview

  • Plexus® DT2325 – Flexible Structural Adhesive for Thermally Dynamic Assemblies

Plexus DT2325 is designed for assemblies where thermal cycling, vibration, and CTE mismatch drive failure risk. With high elongation and excellent impact resistance, it maintains bond integrity as temperatures rise and materials move.

Ideal applications include:

  • Battery housings and modules
  • Electronics enclosures
  • Transportation side walls and structures
  • Mixed‑material joints requiring stress absorption

Thermal conductivity: ~0.4 W/mK

  • Plexus® DT2430 – Structural Adhesive with Functional Heat Dissipation

Plexus DT2430 offers a balanced solution for assemblies requiring strength, flame resistance, and improved thermal flow. It delivers tough elastomeric performance while helping manage heat without sacrificing durability.

Ideal applications include:

  • Power electronics housings
  • EV and industrial control modules
  • Structural bonding with moderate heat transfer needs

Thermal conductivity: ~1.1 W/mK
Features: UL94 V‑0 rated, strong metal and PET adhesion

  • Plexus® DT2630LD – Structural Thermal Pathway Adhesive

Plexus DT2630LD is engineered for applications where bonded interfaces directly contribute to thermal management. With high thermal conductivity and a low‑modulus, non‑sag formulation, it enables adhesives to become part of the thermal pathway.

Ideal applications include:

  • EV battery systems
  • Data center power distribution units (PDUs)
  • Power electronics and cold plate assemblies
  • Industrial systems with high heat density

Thermal conductivity: ~2.0 W/mK
Features: UL94 V‑0 rated, low modulus, non‑sag properties

Design with Confidence

By combining durability, flexibility, and thermal performance, Plexus polyurethane structural adhesives enable engineers to design smarter, lighter, and more reliable systems and thus reducing failures, extending service life, and simplifying assemblies in thermally active environments.

For more information about Plexus DT2325, DT2430, and DT2630LD, visit Technical Services or contact your Plexus representative.

About Plexus

Plexus structural adhesives are trusted worldwide for their ability to bond dissimilar materials with strength, durability, and performance across demanding industrial environments.

About ITW Performance Polymers

ITW Performance Polymers is a global leader in adhesives, sealants, coatings, and engineered polymer solutions that improve performance, safety, and reliability across industrial environments.