What are the Key Challenges of Metal Fabrication Painting and Powder Coating?

Metals and Mining Review | Friday, October 27, 2023

Some of the key challenges of metal fabrication painting and powder coating are thick surfaces that add up to longer drying, which increases costs for painting and powder coating. Appearance is also another factor posing challenge, as few of the enamel paints don't dry quickly and require more supervision.

FREMONT, CA: Typically, when people discuss custom metal fabrication, they focus on engineering and design, material selection, or welding processes. Metal fabrication finishes, however, can have a significant impact on a finished product's durability, functionality, and appearance. 

Metal fabrication painting and powder coating are applied onto a surface, unlike anodizing or metal plating, which alter the surface of the material. In addition to providing a greater choice in appearance, the techniques come with varying degrees of durability.

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Powder Coating vs. Painting: Pros and Cons

The appearance of painting and powder coating can sometimes be similar. In contrast, painting is a wet application - typically epoxy or enamel that is applied to a surface and allowed to dry. Epoxies and polyester powders are applied to a surface and melted. When selecting a finish, it is important to consider that not all objects should be subjected to the high temperatures required for powder coating.

In some applications, either of these metal finishing types may be used. Metal fabrication projects can benefit from understanding the following benefits and drawbacks of each. 

The cost of painting vs. powder coating:

Powder coating equipment typically requires a higher up-front investment than painting equipment but requires less technical knowledge. The overall cost of powder coating equipment can vary depending on the number of steps in the conveyor system. Painting is typically less expensive for small-batch jobs. Powder coating will, however, likely cost less per part for components produced in mass. 

The challenges: The number of items being finished can drive up costs for either. In most cases, set-up charges are amortized across the total number of components being finished, whether it is two or twenty. There will be a technical data sheet for each product outlining how it should be applied (air pressure, viscosity, etc.). Customers can add costs if they exceed supplier specifications.

The appearance: Paint comes in a wide range of colors and finishes, from matte to a high gloss. Powder coating offers more options for textured finishes. Both finishes will be even without drips or uneven sections if applied properly.

The challenges: Larger components with varying material thickness can present powder coating challenges. The heat treatment tends to cure faster or slower depending on the thickness of the metal, and in some cases, it can actually burn. Due to inconsistent cure times, it can create a checkerboard appearance or uneven shading. There are also some paints that present challenges. Enamel paint dries slowly and requires more handling. Epoxy paints, such as MIL-DTL-24441 and MIL-DTL-22750, are more user-friendly.

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