Thick Film High Voltage Resistors vs Wirewound - A Comparison

Two of the most common resistor technologies are thick film and wirewound. In this post we compare thick film high voltage resistors with their wirewound competitors discussing the advantages and disadvantages of each.

Thick film high voltage resistors are manufactured by depositing a resistance film pattern onto a flat substrate (usually Alumina). The assembly is then fired at high temperature. The resistor elements are often applied in spiral patterns and consist of metal alloy or oxide particles, functional elements and a glass particle binder.

Network Resistor Design Considerations

To achieve maximum system performance, in a range of applications, resistor networks or arrays with low TCR, close ratio tolerances and long term in circuit stability are required. In this post, we consider the key network resistor design and manufacturing issues the system designer should consider.

Application Specific Power Resistor Manufacturing Limitations

When considering a custom resistor for any demanding application it is important to recognise resistor manufacturing limitations that may force design compromises.

Snubber Resistor Design For Motor Control Applications

The purpose of snubber circuits is the suppression of voltage spikes that otherwise may damage sensitive electronic components.

Thick Film Resistor In Radar Applications

RADAR systems may be complex but their operation relies on a range of relatively simple resistor components. Resistors are used in pulse forming, sensing, switching, current limiting and RF termination applications, among others.

In the late 1800’s Heinrick Hertz proved that radio waves travel in a straight line and are reflected by a metal object. In RADAR equipment a pulse of high frequency radiation is emitted, based on the time and direction of the returning pulse the distance and direction of a metallic object may be calculated.

High Power Resistor Design and Manufacture

To deliver a high power resistor that continues to operate with minimal performance degradation over it's in service life requires both a detailed knowledge of potential failure modes and thick film resistor manufacturing techniques.

Typical causes of high power resistor failure include:
Thermal stresses.
Surge & ESD.
Mechanical stresses and environmental factors.


The Resistor Network Manufacturing Process

Resistor networks are found in many applications including resistor divider (precision amplifier) circuits, measurement systems, test equipment and industrial automation. The most common application is relatively simple pull up / pull down resistor arrays but for more complex circuits including matched resistors or specialist, application specific, devices a high degree of resistor network manufacturing and design expertise is required.

Thick Film Resistors Vs Thin Film – A Comparison

What are the advantages of thick film resistors over their thin film cousins? In this post, we consider the ideal resistor and discuss how both thin film and thick film resistors compare with that ideal.

The Ideal Resistor

The perfect resistor has zero capacitance and inductance. Its resistance value is precisely known and does not vary over its entire in service life regardless of any external environmental factors such as moisture or temperature.

Thick Film Resistor Design Considerations

When designing any electronic system there are compromises to be made in component selection. This extends to what may be perceived as the simplest components including resistors and capacitors. In this post, we consider typical thick film resistor design and application issues the system designer needs to consider.

The Perfect Resistor

Power Resistors In Current Sensing Applications

Power resistors are used in a variety of power electronic applications as load resistors, braking resistors and pulse management devices but one of the main applications is current sensing elements in power supplies and electric motor control.

When designing power supplies one of the key design challenges is minimising overcurrent and short circuit conditions that may damage sensitive electronic components used in the motor control circuitry. These overcurrent conditions can be caused by a number of factors including motor start-up conditions and high power switching.