1) For conformal coating on electronics, what will happen if there is a very thin coating of say only 1-5 micrometers with process point of view?
2) Will this solve the purpose of environmental protection and basic insulation?
3) Will this thin layer be fragile to be handled during processing?
4) Will there be any fouling of this layer during its application?
Without knowing the nature of any proposed coating, it's very difficult to say.
Certainly, Parylene (for example) is applied in thicknesses in that range, and can tolerate modest handling - it's a relatively common coating for assemblies in aerospace applications.
Whether such thin coatings are suitable all depends on what the material is, what it is being applied to, and what conditions it might experience.
Vernier and Micrometer are instruments used to measure thickness with.1&.01 precision of minimum on any scale, though thickness is depending on insulation material you used, lesser would be the thickness needed for good insulating material …
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