Powder’s Advantages and Advancements for Automotive

Q: Most automotive Tier 1 and Tier 2 suppliers use liquid coatings. I understand powder coatings offer advantages over liquid coatings, but I have not heard of many instances where powder is used in this type of application. Is there any powder applicator in the industry that can keep up with automotive Tier 1 or 2 applications and provide advantages over liquid applicators?

A: Powder coating is a popular choice in many manufacturing applications because it provides a durable, high-quality finish that protects parts from corrosion, scratches and wear. In the automotive industry, it is a good choice for components like wheels, frames, chassis parts, engine components and even small parts such as brackets and fasteners. The many advantages include:

• Durability: Powder-coated surfaces resist chipping, scratching and fading.
• Corrosion resistance: The coating acts as a protective barrier against moisture, chemicals and salt.
• Aesthetic appeal: It provides a smooth, even finish with a range of colors and textures.
• Environmentally friendly: Powder coating doesn’t involve volatile organic compounds (VOCs), making it greener than traditional liquid paints.
• Cost efficiency: It reduces waste since oversprayed powder can often be reclaimed or reused.

Many automotive parts are ideal for powder based on powder’s protective properties, such as:

• Wheels and rims: Powder coating adds style and durability to wheels.
• Chassis components: Frames, suspension parts and subframes are often coated to prevent rust.
• Engine parts: Valve covers, intake manifolds and brackets benefit from the heat resistance of powder coating.
• Exhaust components: Special high-temperature powder coatings can be used.
• Interior and exterior trim pieces: Grills, door handles and roof racks are often powder coated for aesthetics and durability.

For years, many manufacturers believed that powder was limited in aesthetic properties. However, that is not the case. Powder coating offers a range of finishes, including gloss, matte, satin, metallic and textured. These finishes can match OEM specifications or achieve unique custom qualities.

Although powder offers optimal finish and durability, it does have limitations. The initial setup of a powder system, for example, can be expensive. Powder also works best on metal parts, which limits applications due to the many resin components used in automotive applications. Another drawback to powder is if there are any defects or coating issues with a finished product, powder coating is not as easily repaired or touched up as liquid coatings. Last, film thickness can be challenging.

Although using powder in automotive applications has some disadvantages, many advancements are being made as well:

• Low-cure powders: New powders that cure at lower temperatures reduce energy costs and enable coating on heat-sensitive materials like plastics.
• Enhanced formulations: New powders have improved UV resistance, anti-corrosion properties and high-temperature tolerances.
• Automation: Robotic powder coating systems increase precision and efficiency in automotive manufacturing.

For powder coating a long series of complex parts, such as chassis or doors, the production line can be enhanced by using an automatic gun or powder bell attached to a multi-axis robot. This system can be programmed to apply powder coating like an experienced operator would. Depending on the capacity and speed of the production line, you can choose the technology that best meets your needs.

Automatic powder bells provide high penetration in faraday cages and improve coverage when mounted on a robot, enabling more precise coating. It is advisable to coat the angles, cages and complex surfaces first, and then finish with the flat surfaces, achieving a uniform finish.

Like any application and material, there are both advantages and disadvantages. If you are seeking new technology to enhance your processes, reduce VOCs or increase production, it’s a good idea to consult with a local distributor or a manufacturer’s representative to determine what best suits your needs. Additionally, scheduling an in-lab demonstration can be an effective way to evaluate the materials and applicators before committing to the equipment.