A combustion synthesized AIN powder was studied for its feasibility as a filler for epoxy molding compound (EMC) and effects of various experimental parameters on the thermal conductivity and moisture resistance of the EMC were investigated. The AIN powder was coated with silane both to increase the moisture resistance of the EMC and to enhance the bonding between the filler AIN and the matrix resin. The thermal conductivity could be significantly increased by using AIN powders with large particle sizes and this was considered to be due to a reduction in interface area between the AIN particles and the matrix resin. A thermal conductivity of 14 W/mK was obtained when the EMC was fabricated by a process involving no use of a solvent and a AIN powder with a particle size of 35.3 mu m and a filler content of 67 vol % were used. (c) 2006 Wiley Periodicals, Inc.