The 7 Steps of Custom Powder Coating: How Creative Solutions Deliver the Best Results

A small flaw in powder coating can compromise your part's aesthetics and durability. This demanding sheet metal finishing technique requires precision at every step, from surface preparation to packaging and shipping. That’s why it’s critical to choose a partner that treats your project with the attention to detail you’d expect from your own team.

At All Powder Coat & Screen, we’ve perfected our process through decades of experience, and our team can spot any subtle details that could prevent exceptional results. In this step-by-step guide to our powder coating, learn how our creativity and problem-solving deliver excellent finishes every time.

A Guide to Our Powder Coating Services

In our facility, powder coating follows a careful plan, with each step refined over years of innovation and thousands of successful projects. Here’s a look at how we transform your parts:

1. Preparation: Each part begins its journey with careful racking. Our technicians strategically position parts on specialized hanging racks, carefully considering factors like part geometry and coating requirements. This critical step enables efficient processing through subsequent stages.
2. Cleaning: We thoroughly clean every part by dipping them into a degreasing unit, a rinse bath, a phosphate tank, and then the rinse bath again. This removes contaminants to create the optimal surface for powder adhesion and long-term durability.
3. Initial Bake: After our cleaning process leaves the surface nearly pristine, our initial bake removes any remaining film, dirt, or grime. 
4. Masking: Critical areas that must remain powder-free require precise protection through masking. At APCS, our inventive technicians evaluate each part's specifications to develop a customized masking strategy with tapes, plugs, caps, and more.
5. Powder Application: Using advanced electrostatic spray equipment, our certified technicians carefully apply your chosen powder coating with precision and consistency.
6. Final Baking: We bake the parts again, allowing the powder to harden and stick to the metal for a smooth, durable finish.
7. Unmasking and Packaging: We remove any masking and carefully package the parts for shipping. If we are assembling any parts, we perform that operation after our unmasking.

The Art of Problem Solving in Powder Coating

At APCS, our core process remains the same for every part, regardless of geometry, color, or material. However, most projects demand unique solutions during multiple steps. Our team’s expertise and creativity allow them to solve new challenges nearly every day.

Parts Without Hanging Points

When parts arrive without pre-designed hanging points (a common oversight from external fabricators), our team employs ultra-fine wire suspension techniques, adjusting wire placement mid-process to ensure complete coverage. 

Oversized Parts

For parts too large to hang traditionally, we determine solutions on a case-by-case basis. We recently developed a specialized pallet system with adjustable metal runners for one such part. This innovation allowed us to move this large piece through our coating process while still ensuring thorough coverage, even on bottom surfaces.

Complex Masking

Beyond standard masking techniques like thread protection, we are always ready to address unique challenges, as well. Recently, we powder coated a large enclosure that required a pristine interior. We assembled it first, masked it, coated it, then disassembled it for final unmasking.

Focused on Quality in Every Aspect

Each step of our process at All Powder Coat & Screen reflects our commitment to excellence. From initial hanging through final packaging, our creativity sets us apart. And that creativity extends to all of our metal finishing solutions, including our pad printing services, metal screen printing, and beyond.

Request a quote today to see how our pride in craftsmanship leads to flawless results.