Powder Coating Delivers Tough, Eco-Friendly Finishes for Metal and More
Powder coating is a high-performance dry finishing process that produces uniform, durable, and eco‑friendly finishes on metal—and now even on plastics and composites. At Plastonics, we use advanced powder coating methods to deliver attractive, long-lasting finishes across industries.
What Is Powder Coating?
Powder coating applies a dry powder—typically a mix of resins, pigments, and additives—via electrostatic spray onto a grounded substrate. After application, coated parts enter an oven where the powder melts and either cross-links (in thermosets) or solidifies (in thermoplastics), forming a hard, consistent film.
The Powder Coating Process
Surface preparation is vital: parts are cleaned and pre-treated via washing, degreasing, or abrasive blasting for optimal adhesion. Powder is then sprayed using a charged gun (corona or tribo), which ensures even wrap-around coverage. The final step is curing at ~180–200 °C for 10–15 minutes, depending on the material, ensuring a tough, resilient finish.
Materials: Thermoset vs Thermoplastic
Thermoset powders (e.g., polyester, epoxy, TGIC-based) chemically cross-link during curing and cannot be remelted—ideal for heat- and chemical-resistant final finishes. Thermoplastic powders can be remelted, offering smoother finishes with less energy input, common in dip applications.
Why Powder Coating Excels
Powder coating is preferred for its:
- Exceptional durability: Superior resistance to chips, corrosion, UV, and wear
- Environmental friendliness: No solvents or VOCs; overspray is reusable
- Consistency and finish quality: Even coats (typically 2–8 mils), minimal sagging
- Cost-effectiveness: Faster cycles, lower material waste, low maintenance .
- Versatility: Wide range of colors, textures, metallics, and protective finishes .
Common Applications
Used in automotive (clips, springs, wireforms), appliances, industrial equipment, outdoor furniture, and more—powder coating now extends to plastics, MDF, composites, and wood with UV-curable powders.
Applications include:
- Heavy equipment, agricultural machinery
- Metal fabrication parts like panels, racks, and cabinets
- Architectural and outdoor furniture
Managing Film Thickness
Optimal thickness ranges between 2–8 mils (50–200 µm), depending on application. Too thin compromises protection; too thick leads to defects like orange peel. Accurate control is essential for high-performance results.
Powder Coating Compared to Other Methods
| Feature | Powder Coating | Wet Paint | Thermal Spray |
| VOC Emissions | ✅ Minimal | ❌ High | ✔ Varies |
| Overspray Reusable | ✅ Yes | ❌ No | ❌ No |
| Durability | ⭐⭐⭐⭐⭐ | ⭐⭐ | ⭐⭐⭐⭐ |
| Film Thickness Control | ⭐⭐⭐⭐ | ⭐⭐ | ⭐⭐⭐ |
| Cost Efficiency | ⭐⭐⭐⭐ | ⭐⭐ | ⭐⭐ |
| Material Compatibility | Metals, plastics via UV | Most substrates | Wide, but rough look |
Powder coating is overall stronger, cleaner, and more efficient than wet paint, and more refined than industrial thermal spray.
Plastonics’ Expertise in Powder Coating
Plastonics delivers top-tier powder coating services, with:
- Full surface prep using chemical and blast treatments
- Electrostatic spraying with corona and tribo options
- Precision ovens for accurate curing and film thickness
- Thermoset and thermoplastic powders to match specs
- Sustainable practices with minimal waste and VOCs
- Free sample runs and 5–10 day lead times
Leverage our experience to bring your parts to highest standard.
Final Thoughts
Powder coating stands out as a robust, sustainable, and versatile finishing process, delivering tough, aesthetically pleasing results for a wide range of parts and industries. It offers superior durability, eco-friendly application, and finish consistency unmatched by traditional painting.
At Plastonics, we specialize exclusively in coating small parts, Our process is engineered for precision, efficiency, and total coverage—perfect for high-volume runs where uniformity and protection are critical.
Ready to elevate your small components with premium powder finishes? Reach out today for a free sample run and personalized quote.