Short answer: Yes, definitely.
Long answer: Like any other manufacturing process, powder coating automatically presents challenges. You can mitigate those challenges by designing your part with powder coating services in mind.
Note: Each manufacturer will have slightly different handling methods, processes, and automation in place. The following tips can guide your design process, but you will want your manufacturer to confirm their own capabilities.
Here are the major considerations for optimizing your part for powder coating.
Designing for Powder Coating Services
Dimensions
The dimensions of your manufacturer's coating booth will vary. Some booths cannot handle large parts. Although some industrial ovens are 20 feet deep, length and width may be less than 10 feet each. While your manufacturer can jigsaw your parts to fit depth-wise (inefficient but doable), multiple large dimensions can be difficult.
When designing your part, consider how it will fit. If it's too big, can you design the part into sections so it can be assembled after coating? Your manufacturer can give specific insight about the most efficient way to load and coat your parts.
Note: An optimal design will fit inside the booth without being angled. Angling means fewer parts will fit in the booth during a run. For efficient powder coating, leave enough room in each dimension for your part to hang without touching the surfaces of the booth.
Tolerances
Coating adds thickness to your part. Although generally a miniscule change, this can have a big impact on parts with tight tolerances or very small parts.
If this is a concern, be sure to specify a max coating thickness or rethink the thickness of your material. There are ways to decrease wall thickness while maintaining part strength for situations like these.
Uncoated sections & line of sight
Powder coating is applied by spray gun. This means any internal or covered sections may not receive an even coat (or any coat at all).
You will need to design your part to maximize powder coating exposure. That may mean designing it into segments for disassembly (like with dimensions above), or rethinking
Masking
On the other hand, you may want to leave sections uncoated for a variety of reasons. Your manufacturer can assist with masking. Designing your part for masking accessibility can greatly speed up operations and decrease costs.
material & coating chemistry
Some materials withstand the powder coating process better than others. Some metals become brittle during baking, and some will deform under the heat. Some metals react poorly to the cleaning chemicals used to prep for powder coating. Additionally, if there is a weak bond between your coating and your material, the coating will not last long.
Getting Specific
Like any other manufacturing process, the best advice will depend on your specific project. These tips can give you a place to start, but you will need to consider your part's application and intent for a truly optimized design. You'll also need information from your manufacturer on their specific booth and processes.
If you don't have a manufacturer or you're still not sure where to start, we're happy to offer guidance. Simply contact us, or you can schedule a free design consultation.
