How to Choose the Right Custom Epoxy Formula for Your Target Market

December 12, 2025

Choosing the right epoxy means matching performance to the user’s needs. A food-processing facility may prioritize chemical resistance and cleanability, while an automotive shop needs impact, heat, and solvent tolerance. The difference between a satisfied repeat customer and a callback often comes down to how well the formula aligns with the market’s environment, regulations, and expectations.

This article will discuss selecting the appropriate epoxy formula for your target market. We’ll also discuss kinds of compounds used for creating custom epoxy products, and the various industries that need specific types of epoxy products.

Practical Tips in Choosing Your Desired Epoxy Formula

Choosing the right epoxy is easier when you focus on the realities of your job, including the service environment, cure speed, compliance, and the finish your market expects. Use the tips below to translate those needs into the right resin chemistry and complete system, from primer through UV-stable topcoat:

Define the Service Environment and Performance Targets

List the chemicals, temperatures, traffic or abrasion, and cleaning regime the epoxy will face, then choose chemistry to match: novolac epoxies for strong acids or solvents and high heat, Bis-A or Bis-F blends for general duty, or cycloaliphatic blends where weatherability and color retention matter. Aim for a glass transition temperature (Tg) at least 20–30°C above your highest continuous service temperature.

Match Cure Schedule, Pot Life, and Downtime

Decide how fast you need to return-to-service and how much working time your crew or process requires. Select hardeners accordingly: fast aliphatic amines for quick ambient cures, cycloaliphatic amines for better color and higher Tg, or latent or heat-cure systems when you can oven-cure; use accelerators only if you can manage reduced pot life and higher exotherm.

Plan for Thickness and Exotherm

For thick castings or deep pours, choose low-exotherm, long-pot-life systems or anhydride-cured epoxies, and pour in lifts to prevent cracking or yellowing. For thin films and recoats, a standard amine-cured 100% solids epoxy with controlled viscosity will wet out well and level without excessive heat.

Verify Substrate Condition and Adhesion Strategy

Check moisture levels (for example, in-slab RH or CM tests), surface profile, contamination, and porosity, then select the appropriate primer or moisture-mitigation layer as needed. Use proper surface prep (shot-blast or diamond grind to the specified CSP), add adhesion promoters for challenging substrates, and seal highly porous concrete to prevent pinholes.

Consider UV and Color Stability Needs

Most epoxies will be amber under UV exposure; if color retention is a concern, consider using cycloaliphatic-amine-cured epoxies with UV stabilizers or topcoating with a UV-stable aliphatic polyaspartic or urethane. For outdoor exposure or light-colored floors, a protective aliphatic topcoat is usually the safest route.

Pick Viscosity and Rheology for Your Application Method

Rolling and squeegeeing benefit from medium-viscosity systems that self-level. Vertical joints require thixotropic pastes that will not sag, while infusion or casting favors low-viscosity formulas with defoamers. Remember, fillers (silica, ceramics) raise viscosity and can affect pumpability and air release.

Align With Regulatory, Safety, and Sustainability Requirements

Confirm VOC limits, odors, and labeling for your jobsite, and specify nonylphenol-free, BPA-reduced or BPA-free, or low-VOC or waterborne options as needed. For specialized uses (such as food contact, clean rooms, and electronics), ensure the epoxy meets the relevant standards and ionic cleanliness or outgassing specifications.

Validate With a Mock-Up and Follow the Data Sheet

Conduct a small test to confirm adhesion, cure, appearance, and chemical resistance under real-world conditions, then lock in the mix ratio, induction time, recoat window, and environmental limits from the product’s TDS or SDS. Record batch numbers, measure substrate temperature and humidity, and use adhesion or solvent rub tests to mitigate risks associated with the full installation.

Different Types of Compounds for Creating Epoxy Formulas

To create the perfect custom epoxy formula, it’s essential to understand the key components that make up the system. Each ingredient plays a vital role in achieving the desired performance, appearance, and durability for your specific project.

Below are the various ingredients you need to know about:

Epoxy Base Resins. These are the backbone of the system and define viscosity, reactivity, and baseline performance. Common choices include Bisphenol-A and Bisphenol-F for general purpose, epoxy novolac for high chemical and heat resistance, cycloaliphatic epoxies for better weathering and electrical properties, and multifunctional epoxies for high glass transition temperature and strength.
Curing Agents or Hardeners. Hardeners react with the epoxy to form a crosslinked network, controlling pot life, cure speed, and final properties. Options include aliphatic and cycloaliphatic amines for ambient cure, amidoamines and polyamides for toughness and moisture tolerance, anhydrides for low exotherm and thick sections with heat cure, and thiols or polymercaptans for very fast or low temperature cure.
Reactive Diluents. These are low-viscosity glycidyl ethers or similar epoxies that reduce mix viscosity without adding VOCs, thereby improving wetting and penetration. Monofunctional diluents increase flexibility but can lower heat resistance, while difunctional and trifunctional diluents maintain higher crosslink density with less sacrifice in performance.
Accelerators and Catalysts. Tertiary amines, imidazoles, and metal complexes accelerate the epoxy-amine or anhydride reaction, thereby shortening cure times or enabling lower-temperature cures. They are powerful tools for a fast return to service, but they also shorten pot life and can increase exotherm, so dosing and thermal management require careful consideration.
Toughening Agents and Flexibilizers. Rubber modifiers, such as CTBN, core-shell particles, and toughening thermoplastics, enhance impact strength, peel strength, and crack resistance. Flexible epoxies or plasticizers can further reduce brittleness, though there is often a trade-off with stiffness, hardness, and high-temperature performance.
Rheology Modifiers and Thixotropes. Fumed silica, organoclays, and urea adducts control sag, bead shape, and anti-settling behavior so materials stay where applied and fillers remain suspended. These additives are essential for vertical applications, joint fillers, and high-build coatings, and they influence leveling and air release.
Fillers and Extenders. Mineral fillers, such as silica flour, calcium carbonate, talc, and wollastonite, reduce shrinkage and exotherm, improve dimensional stability, and can lower the cost. They also affect viscosity, abrasion resistance, and machinability, making them useful in repair mortars, grouts, and tooling compounds.
Functional Thermal and Electrical Fillers. Aluminum oxide, boron nitride, and aluminum nitride boost thermal conductivity for electronics potting or heat-dissipating castings. Carbon black, graphite, and metallic powders add electrical conductivity or static-dissipative behavior, while carefully balancing viscosity and dispersion.
Flame Retardants and Smoke Suppressants. Halogen-free systems based on phosphorus chemistry, such as DOPO, nitrogen synergists, and mineral fillers like aluminum trihydrate or magnesium hydroxide, help meet fire performance targets. Selection and loading impact viscosity, mechanical properties, and cure behavior, so they must be tuned to the application and standard.
Adhesion Promoters and Coupling Agents. Silanes, such as APTES or GPTMS, and specialty phosphate or titanate treatments enhance bonding to concrete, metals, glass, and composites. They create chemical bridges at the interface, raising adhesion strength, moisture resistance, and long-term durability, especially on challenging or dense substrates.
Surface Additives for Flow and Appearance. Wetting and leveling agents, slip modifiers, and anti-crater additives help coatings lay down smoothly and avoid defects such as fisheyes or orange peel. Deaerators and defoamers release entrapped air to minimize pinholes and bubbles, which is critical for high-gloss floors and clear castings.
Pigments, Color Packs, and Decorative Aggregates. Inorganic pigments, such as titanium dioxide and carbon black, provide color and opacity, while metallics and universal color packs deliver consistent tinting across batches. Decorative flakes and quartz blends add aesthetics and texture, and their size and loading can be adjusted to tune slip resistance and coverage.
UV and Light Stabilizers. UV absorbers and hindered amine light stabilizers slow yellowing and chalking in light-exposed areas, extending the visual life of the system. They are often paired with aliphatic polyaspartic or polyurethane topcoats when long-term color retention is critical.
Moisture Scavengers and Surface Tolerance Aids. Additives such as epoxysilanes, molecular sieves, and hydrophobic agents can reduce sensitivity to residual moisture and improve cure under marginal conditions. They are not a substitute for proper moisture mitigation, but they can widen the application window and reduce blush or amine carbonation.
Solvents and Carriers. In solvent-borne or waterborne systems, carriers like xylene, PMA, or water control viscosity, film formation, and open time. They aid application in specific environments, yet must meet VOC regulations, flash point requirements, and site safety considerations.

Different Industries and Their Standard Epoxy Formulas

Now that you understand the key ingredients in epoxy formulas, let’s explore how different industries tailor these formulations to meet their unique needs. From food processing to automotive service, each sector demands specific properties to ensure durability, safety, and performance:

Warehousing and Logistics

A proven build is a 100% solids Bis-A or Bis-F epoxy base cured with a cycloaliphatic amine for hardness and abrasion resistance, installed over a moisture barrier primer when RH or MVER is high. Add a light to medium quartz broadcast for slip resistance, then finish with an aliphatic polyaspartic topcoat for faster return to service and better UV and tire-stain resistance.

Food and Beverage Processing

Use a chemical-resistant epoxy novolac or a BPA-reduced epoxy with cycloaliphatic amine hardener to handle acids, caustics, oils, and hot washdowns. Pair with a moisture mitigation primer on green or damp concrete and apply a quartz broadcast for texture, then seal with a high-build, easy-to-sanitize topcoat that is compatible with your cleaning regimen and supports applicable food contact or hygiene requirements.

Pharmaceutical and Cleanrooms

Select a low-odor, 100% solids, low-emission epoxy cured with a cycloaliphatic amine for smooth, seamless, decontaminable surfaces. Include an appropriate primer for adhesion and moisture control, and finish with a UV-stable aliphatic polyaspartic topcoat for color retention and chemical wipe resistance, with optional conductive or static dissipative variants where needed.

Electronics and ESD Manufacturing

Specify a static dissipative epoxy system using a pigmented epoxy base with conductive carbon or fiber additives, tuned to achieve a surface resistivity of 1×10^6 to 1×10^9 ohms. Install over a moisture-tolerant primer to stabilize readings and complete with an ESD-rated aliphatic topcoat that balances conductivity, cleanability, and abrasion resistance.

Chemical Processing and Secondary Containment

Select a high-functionality epoxy novolac or multifunctional epoxy for maximum crosslink density and resistance to strong acids, solvents, and elevated temperature exposures. Build thickness with multiple coats or a filled slurry, detail cracks and joints, and finish with a novolac epoxy glaze or an aliphatic topcoat if UV exposure is expected outside the containment area.

Parking Structures and Decks

Use a moisture-tolerant primer, followed by a flexible intermediate membrane where crack bridging is required, and a pigmented epoxy wear coat for added durability. Top with an aliphatic polyaspartic or polyurethane for enhanced UV stability, tire wear resistance, and rapid return to service. Additionally, add aggregate for improved traction on ramps and turns.

Automotive Service and Aviation Hangars

A cycloaliphatic amine-cured Bis-F or novolac epoxy provides resistance to fuels, oils, brake fluids, and Skydrol. Apply over a moisture barrier primer, use a slip-resistant broadcast as needed, and finish with an aliphatic polyaspartic for gloss retention, chemical wipe resistance, and fast turnaround in service bays and hangars.

Water and Wastewater Facilities

For immersion and splash zones, use a 100% solids, amine-cured epoxy designed for wet service, or an epoxy novolac for use with aggressive chemicals. Prime with a moisture-tolerant or surface-tolerant epoxy, build film to the manufacturer’s recommended thickness, and consider a UV-stable topcoat in exterior, non-immersed areas for color hold.

Retail and Commercial Interiors

A decorative flake or quartz system built on a pigmented Bis-A or Bis-F epoxy base offers aesthetics with durability. Start with a moisture mitigation primer if testing requires it. Broadcast flakes or quartz to achieve the desired texture and coverage, then seal with a clear aliphatic polyaspartic topcoat for clarity, scratch resistance, and quick reopen times.

Cold Storage and Freezers

Use low-temperature cure epoxies or hybrid epoxy systems that can cure near or below freezing, often paired with fast-setting polyaspartic topcoats to minimize downtime. Include a moisture barrier primer during warm phase preparation, add aggregate for traction, and verify the glass transition temperature is comfortably above the highest expected service temperature after defrost cycles.

Looking for Quality Custom Epoxy Resin? Talk to ASTC Polymers Today!

Choosing the right epoxy formula for your market is easier with ASTC Polymers. With 35+ years of polymer expertise, we translate your environment, chemical exposure, moisture, downtime, and aesthetic goals into a clear, compliant system. Expect fast support, same-day shipping, and local pick-up in Santa Ana. We have served numerous clients with diverse target markets, giving us the expertise to guide you in selecting the ideal epoxy formula.