Since the Restriction of Hazardous Substances Directive (RoHS) went into effect on July 1st, 2006, most thick film chip resistors have complied with the directive through exemption 7(c)-I, which allows for "...lead in a glass or ceramic...or in a glass or ceramic matrix compound." 

High voltage applications frequently require high resistance value resistors with the ability to handle high working and overload voltages.

Stackpole's metal alloy current sense chip resistors offer efficiency and accuracy for high-current power supplies.

Stackpole’s HCS raised element SMD high current shunts offer up to 10W power ratings.

Applications for precision resistors are becoming more common. For those applications with high power requirements, this can be challenging as many of these devices require lower power ratings for high precision.

Current sensing for motor control applications often requires robust current handling and the lowest possible PCB temperatures. Unfortunately, high current or overload current handling typically means higher PCB temperatures.

High voltage applications such as HVAC controls, appliance and white goods controls, metering, automation, medical devices, digital storage, and surge protection devices typically require resistors with high working voltage that may be challenging to find. If the applications are low current or low energy, film resistors are an ideal technology.

Precision electronics applications such as instrumentation, medical devices, avionics, and aerospace not only require resistors with tight tolerance and low TCR, but also environmental stability. When these applications also require pulse handling, finding the right resistor can be challenging because precision thin film resistors are not typically known for their pulse handling.

Applications such as industrial and automotive power control require low resistance values, high power ratings, and resistance to sulfur contamination. Stackpole state. Thick film chip resistors are not typically sulfur resistant, especially in higher power ratings, and many high-power resistor series do not offer values below 1ohm.

High power applications requiring resistors with power ratings above 1W can be challenging. For ceramic based chip resistors, this generally requires chip sizes of 2010 or larger which are susceptible to cracking and solder joint failure.

High reliability chip resistors can be more difficult to find and even more so when there are pulse handling requirements.

MELF resistors are known for their thermal characteristics and their environmental and electrical stability.

Current sensing for a wide range of products and applications requires both low and high resistance values with high stability, reliability, and low TCR.

Sulphur contamination for thick film resistors is becoming a more prominent issue for a wide range of end products.

Automotive grade resistors offer increased reliability and improved performance without the high cost and limited availability of components procured to established reliability military specifications.

High efficiency current sensing requires low resistance values. However, lead resistance may cause inaccuracies in sensing measurement for ultra-low resistance values.

Power electronic engineers continue to push for higher power, lower values, and better precision. Most common resistor technologies cannot adequately meet all three requirements, but Stackpole’s CSS/CSSH Series is able meet these demands in a variety of sizes, power ratings and values.

As power electronics evolve, the requirements for high current, low resistance sensing resistors continues to increase. Emerging applications, such as hybrid power systems, may require high power, high accuracy, and low thermal resistance. These are a difficult combination for many traditional sense resistor technologies.

Commercial and industrial power electronics increasingly demand robust power supplies with high stability and low thermal resistance. For these requirements, standard chip resistors may not be the best solution.

Current sensing for high efficiency typically requires very low resistance values. However, sensing accuracy is more challenging for lower resistance values due to lead resistance effects. Four terminal shunt resistors eliminate errors due to lead resistance.