Industrial coating is often considered one of the final steps in manufacturing, but decisions made much earlier in the design and fabrication process can have a significant impact on coating quality, efficiency, cost, and production schedules. For OEMs and manufacturers, designing metal components with the finishing process in mind can help reduce masking problems, coating buildup, rework, handling difficulties, and unexpected delays.
Working with an experienced industrial metal coatings partner early in the process can help manufacturers identify potential finishing concerns before a part moves into full production.
Consider the Coating Process During Part Design
The shape and configuration of a metal component can affect how easily it can be cleaned, pretreated, coated, cured, handled, and inspected. Deep recesses, enclosed areas, overlapping surfaces, narrow openings, and complicated geometries may require additional consideration depending on the coating process being specified.
Manufacturers should also consider how parts will be positioned or suspended as they move through a coating line. Rack points, hanging locations, part orientation, drainage, and accessibility can all influence production efficiency and coating coverage.
Account for Coating Thickness and Tolerances
Industrial coatings add measurable thickness to the surface of a component. That added thickness can become important where parts must fit together precisely.
Threads, bearing locations, electrical contacts, mating surfaces, press-fit areas, holes, and other dimensional features may need to remain coating-free. Identifying these areas clearly on drawings or specifications allows the coating provider to plan appropriate industrial masking before production begins.
Considering tolerances in advance can help avoid situations where an otherwise properly coated component becomes difficult or impossible to assemble.
Surface Condition Matters Before Coating Begins
The condition of the incoming metal is another important consideration. Rust, scale, welding residue, oils, fabrication contaminants, previous finishes, and oxidation may interfere with coating adhesion if they are not properly addressed.
Depending on the substrate and coating requirements, professional surface preparation and sandblasting may be necessary before the finishing process begins.
Designers and manufacturers should therefore consider not only what the finished component should look like, but also what condition it will be in when it arrives at the coating facility.
Select the Coating Based on the Part’s End Use
The operating environment should help determine which finishing system is specified. Parts exposed to moisture, chemicals, abrasion, sunlight, impact, temperature changes, or corrosive environments may require different levels of protection.
Industrial powder coating can provide durable protection and attractive finishes for many manufactured products, while e-coating can provide uniform corrosion-resistant coverage for complex metal components and difficult-to-reach areas.
The right choice depends on the substrate, geometry, appearance requirements, performance specifications, environment, and intended use of the finished component.
Provide Clear Drawings and Specifications
Clear communication between the manufacturer and coating provider becomes especially important when a component has critical dimensions, appearance standards, masking requirements, specific coating thicknesses, color requirements, testing standards, packaging needs, or production deadlines.
Drawings should clearly identify critical surfaces and coating exclusions whenever possible. Providing expected quantities and future production volumes can also help the coating provider determine the most efficient process for repeat manufacturing.
Prevent Coating Problems Before Production Starts
Many of the issues discussed in our guide to industrial coating failure and prevention can be reduced by considering finishing requirements earlier in the manufacturing process.
New Finish, Inc. works with manufacturers throughout North Carolina, South Carolina, and Virginia, providing powder coating, e-coating, liquid coating, CARC, masking, sandblasting, surface preparation, and production coating support.
If you are developing a new component, preparing for production, or evaluating coating requirements for an existing product, contact New Finish, Inc. to discuss your industrial coating project. Early communication can help identify potential challenges and develop a finishing process that supports quality, efficiency, and consistent production.