Fluid Bed Powder Coating Delivers Thick, Durable Finishes with Full Coverage
Fluid bed powder coating is a specialized method where heated parts are immersed in a suspended bed of thermoplastic powder, allowing a thick, uniform coating ideal for heavy-duty and corrosion-resistant metal parts. Plastonics leverages this technique for applications requiring robust, all-over protection.
How Fluid Bed Powder Coating Works
This process begins by fluidizing finely ground powder through air agitation, creating a ‘quicksand-like’ bed. A preheated metal part—is dipped into this bed, causing the powder to melt and adhere to its surface. After dipping, the part undergoes a post-heat cycle to smooth and fuse the coating before cooling
Key stages include:
- Preheat: Metal heated to powder melt temp (350–450 °F)
- Fluidized bath dipping: Powder suspension provides even film build (8–125 mils)
- Post-fuse: Additional heat ensures full melt and tough finish
Advantages of Fluid Bed Over Other Coating Methods
Fluid bed coating offers unique benefits:
- Consistent, thick film: Achieves coatings from ~7–15 mils up to 125 mils
- Uniform coverage on all surfaces and edges, even complex geometries and wire goods
- High material efficiency: Nearly 100% transfer of powder
- Durability: Thick coatings provide corrosion, abrasion, chemical, UV, and impact resistance
- Cost-effective: Minimal waste, low VOCs, and fewer cleanup demands
Ideal Applications & Materials
Fluid bed coating is best suited to:
- Metal parts like steel, aluminum, copper—anything that withstands preheat
- Components requiring thick, durable film: bus bars, wire racks, metal furniture, valves, baskets, industrial tooling
- Avoids hiding critical details, making it less ideal for parts with fine serial numbers or delicate features .
Fluid Bed vs. Other Coating Processes
Here’s how fluid bed stacks up:
| Feature | Fluid Bed Coating | Electrostatic Spray | Wet Paint |
| Film thickness achievable | ⭐⭐⭐⭐⭐ (7–125 mils) | ⭐⭐ (0.8–10 mils) | ⭐ (variable, sag risk) |
| Coverage uniformity | ⭐⭐⭐⭐⭐ fully wraps parts | ⭐⭐⭐ depends on geometry | ⭐⭐ at best |
| Powder use efficiency | ⭐⭐⭐⭐⭐ (≈100%) | ⭐⭐ (overspray) | ❌ (solvent waste) |
| Durability & protection | ⭐⭐⭐⭐⭐ | ⭐⭐⭐ | ⭐⭐ |
| Ideal for complex shapes | ⭐⭐⭐⭐ | ⭐⭐⭐ | ⭐⭐ |
| Environmental friendliness | ⭐⭐⭐⭐ (no VOCs) | ⭐⭐ | ❌ (VOCs present) |
Fluid bed excels at thick, uniform, protective coatings—electrostatic spray offers flexibility and finer finish; wet paint has limited durability and environmental drawbacks.
Why Choose Plastonics’ Fluid Bed Powder Coating
At Plastonics, our fluid bed experts provide:
- Precision-controlled preheat and immersion systems for consistent results.
- Varied polymer options like nylon, polyethylene, epoxy—selected for best performance.
- Quality assurance with process sensors to ensure melt, thickness, and adhesion integrity.
- Eco-conscious operations, recycling unused powder and minimizing emissions.
- A free sample run and fast turnaround, so you can test before full production.
Explore our full fluid bed powder coating capabilities on the Fluid Bed Powder Coating service page for detailed specs and project examples.
Use Cases: Where It Excels
Commonly coated parts include:
- Wire racks and baskets: Full coating protects against moisture and corrosion
- Electrical components: Bus bars need high-thickness insulation
- Industrial hardware: Valves, trays, fixtures benefit from abrasion resistance
- Outdoor and safety equipment: Metal furniture, playground gear, fencing
Considerations & Limitations
While powerful, fluid bed has constraints:
- Requires substantial preheat ovens and part handling systems.
- Not suitable for parts with very thin walls or delicate details—they may overheat or lose resolution.
- Thick coatings may obscure markings—avoid for serial-numbered items.
Final Thoughts
Fluid bed powder coating is an ideal choice when you need a robust, uniform, and highly protective finish on metal components. Its ability to deliver thick coatings with full surface coverage makes it especially valuable for industrial and high-wear applications.
At Plastonics, we specialize in fluid bed coatings—using carefully controlled fluid bed systems that ensure consistency, quality, and long-term performance. Whether you’re coating wire forms, fixtures, or custom hardware, our process is designed for precision and efficiency at scale.
Contact us today to request a free sample run or get a quote for your next project involving small metal components.