Controlling powder coating thickness is a balancing act. Too thin, and coatings fail prematurely. Too thick, and manufacturers waste material, risk defects, and increase costs. Achieving consistent film build is less about luck and more about process control.
Why Thickness Matters
Most industrial specifications call for a defined mil range to ensure corrosion resistance, appearance, and mechanical durability. Over-application doesn’t improve performance—it often causes orange peel, poor edge definition, and reduced adhesion.
Key Factors That Affect Film Build
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Gun settings: Voltage, amperage, and flow rate directly influence deposition.
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Part grounding: Poor grounding leads to uneven thickness and overspray.
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Gun-to-part distance: Too close causes heavy build; too far reduces transfer efficiency.
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Powder formulation: Different chemistries and particle sizes build differently.
Reducing Overuse Without Sacrificing Quality
Consistent thickness comes from standardizing parameters, regularly measuring film build, and training operators to recognize early warning signs of over-application. Using magnetic or ultrasonic thickness gauges during production—not just after cure—can prevent costly rework.
The Cost Advantage
Reducing excess thickness by even a fraction of a mil across high-volume parts can save thousands annually in powder consumption while improving finish consistency.
