February 10, 2023

What is Foreign Object Debris (FOD)?

While it may seem like a slight issue, foreign object debris (FOD) can have a large impact on manufacturing. FOD is any type of material that doesn't belong in the manufacturing process and can cause problems if it's not removed. This can include anything from dust and dirt to tools and small parts.

If FOD is not removed, it can cause complications in the manufacturing process. It can clog machinery, cause quality issues, and even lead to injuries. In some cases, FOD can be hard to spot, so it's important to have a system in place to prevent it from becoming a problem.

How To Spot Foreign Object Debris

When inspecting electronics for FOD, it is important to look for any damage that may have been caused by objects striking the surface of the equipment. This can include dents, scratches, or other marks that could indicate that an object has hit the surface of the device.

It is crucial to check for any fractures or breaks in the housing of the parts, as this can also be an indication of FOD. Additionally, it is important to inspect the electrical connections and wiring for any signs of damage or wear. This can be done by visually inspecting the connections and looking for any loose wires or damaged insulation.

Finally, it is important to test the equipment to ensure that it is still functioning properly. This can be done by testing the power supply, testing the input and output connections, and performing a diagnostic test on the equipment. If any damage is found, it is important to repair or replace the damaged parts before shipping your product.

Does Foam Packaging Create Foreign Object Debris?

Foam can create foreign object debris (FOD) in a variety of ways. One common way is when foam is used as packing material around products. If the foam is not properly secured, it can break off and become loose FOD. 

Another way foam can create FOD is through static discharge. When static electricity builds up on foam, it can discharge and create small holes or tears in the foam. This can cause the foam to break into smaller pieces, which can become FOD. Finally, foam can also break down  over time, which can create small pieces of FOD.

How does Foreign Object Debris Affect Printed Circuit Boards?

Printed circuit boards, also known as PCBs are susceptible to damage from foreign object debris (FOD). This type of debris can cause a variety of problems, including shorts, corrosion, and electrical interference. In some cases, FOD can also damage the solder joints that hold the components in place.

One of the most common ways that FOD can damage a PCB is by causing a short. When debris comes into contact with two or more conductive tracks, it can create a connection between them. This can result in an electrical current flowing through the tracks, which can harm the components or cause the PCB to malfunction

Corrosion is another familiar problem that can be caused by foreign object debris. Debris that contains corrosive materials can cause the tracks on a PCB to corrode over time. This can lead to electrical problems and eventually cause the PCB to fail.

FOD can also cause electrical disturbances. This happens when debris causes signal noise on the PCB, which can make it tricky for the components to communicate with each other. This type of interference can eventually lead to component failure.

That's why it's important to take steps to prevent FOD from coming into contact with your PCBs. You can do this by keeping your work area pristine and free of debris, using protective covers or enclosures for your PCBs, and being careful when handling them. You should also inspect your PCBs regularly for any signs of FOD damage.

What is The Best Way to Eliminate Foreign Object Debris?

Kleanstat Flex (KSF) is the new standard in cushioning materials. The bubbles provide air cushioning without the debris that can be created by foam. It has the cushioning of a traditional bubble but does not suffer from the loss of ESD properties like a typical bubble- nor does it pop! KSF is perfect for a variety of applications where air cushioning is needed, such as packaging electronic components.

KSF is a material introduced by Corstat just in the past few years. KSF is made in either a TPU based material or PVC for a more budget friendly version. Either way it combines flexibility, FOD free cleanliness, permanent dissipative properties and formability.

Kleanstat Flex can be custom ordered in any size or shape to meet the customer's needs. The outside packaging can also be printed using a state of the art printing process. This allows for logos, barcodes or other information to be printed directly onto the material. If you have a need for a flexible, clean and dissipative material, then Kleanstat Flex is the answer.

What Makes Kleanstat Flex Different from Foam?

Kleanstat can be used in a variety of ways to protect your electronics and other sensitive materials. The Kleanstat FlexTote systems are optimal for storing many different sizes of PCBs in one place, while our worker separation curtains and document holders are great for protecting delicate materials from static, dirt, and other potential damage. Whether you need physical protection for your electronics or simply want to organize your workspace, Kleanstat has a answer for you. Contact us today to learn more about our products and how we can help you keep your materials safe.


Kleanstat Flex is an innovative cushioning material that provides air cushioning without the debris created by traditional foam materials. It has the cushioning of bubble wrap but does not suffer from the loss of electrostatic dissipative (ESD) properties, making it much more durable and reliable than typical bubble-wrap.

Kleanstat Flex offers superior protection and cushioning than traditional foam materials, making it an ideal choice for any application where protection is needed. If you are interested in learning more about Kleanstat Flex, don’t hesitate to contact us today! We will be happy to help you find the perfect solution for your needs. Let Kleanstat Flex revolutionize the way you package and transport sensitive materials!