Helpful Hints for Preparing Materials for Powder Coating
Expert guidance to ensure the best possible powder coating results
Why Proper Preparation Matters
Conventional finishes do not produce as good quality coverage as powder coating can. Powder coating produces better coverage over sharp edges and uneven surfaces, but for the best possible results it is a good idea to avoid sharp cut edges - the powder coating will have much greater protection.
As powder coating creates a thicker coating on material, it is important to take this into account when designing a product that will be powder coated. Below we have listed some of the common problems that occur and can be easily avoided.
Porous Materials
Galvanising or casting, for example, can be coated but may require additional processing to achieve a quality powder coat. Porous surfaces can trap air and moisture, which may cause defects in the finished coating. Proper surface preparation and sealing may be necessary for optimal results.
Rough Welds
Make sure all welds are ground smooth to improve the coverage of the powder coating. Rough welds create an uneven surface that can lead to thin spots in the coating and potential weak points. Smooth, well-finished welds ensure consistent coating thickness and superior protection.
Corners
Sharp corners are difficult to powder coat well. Try to make sure the corners have a significant radius. Powder coating tends to be thinner on sharp edges and corners, which can reduce protection against corrosion. Rounded corners allow for more even coating distribution and better long-term durability.
Narrow Gaps
To have the best possible powder coating, make sure there's enough room between gaps. Narrow gaps can restrict powder flow and create thin or uneven coating. Design components with adequate spacing to allow proper powder penetration and ensure complete coverage in hard-to-reach areas.
Joining Tubes
Square tubes intersecting with other square material produces a much better powder coated product than that of a circular tube. Square-to-square connections create cleaner joints with better coating coverage. Circular tubes can create difficult angles and gaps that are challenging to coat evenly.
Sharp Edges
Try to avoid sharp edges as rounded edges will have a much better look when powder coating. Sharp edges tend to attract less powder during application, resulting in thinner coating and potential corrosion points. Chamfering or rounding edges before coating ensures uniform coverage and improved aesthetics.
Masking or Plugging
To make sure parts that are not to be powder coated don't get powder coated, plug them or mask them. Critical areas like threads, mating surfaces, and bearing seats must be protected during the coating process. Use high-temperature masking materials designed for powder coating applications.
Recesses
Avoid creating products with areas that have recesses, as a recess may not be correctly coated and be subject to corrosion. Deep recesses and blind holes can trap air during coating and prevent proper powder penetration. If recesses are unavoidable, consider adding drainage or ventilation holes.
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