Even well-run powder coating operations encounter defects. The key is understanding why they happen so they don’t recur.
Orange Peel
Characterized by a textured, uneven surface, orange peel is often caused by:
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Excessive film thickness
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Improper cure schedule
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Incorrect powder formulation
While sometimes cosmetic, it can signal deeper process issues.
Pinholing
Pinholes form when gases escape from the substrate during curing. Common contributors include:
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Oil or moisture contamination
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Porous castings
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Inadequate pretreatment
Addressing pinholing requires both surface prep and cure optimization.
Fish Eyes and Craters
These defects indicate surface contamination—often silicone, oils, or airborne contaminants. Even small amounts can disrupt powder flow.
The Importance of Root Cause Analysis
Fixing defects at the application stage without addressing upstream causes leads to repeated failures and unnecessary rework.
