Low Transfer Efficiency on Complex Geometries
Metal furniture, shelving and cabinets often include slender sections, welds, inside corners and narrow gaps. The Faraday cage effect and unsuitable application settings can leave recesses exposed or undercoated, while the use of reclaim powder may cause deposition to fluctuate.
Formulation Design
- Optimise particle-size distribution and charging characteristics to improve penetration and deposition on complex geometries.
- Subject to flow and mechanical-property requirements, adjust powder flowability and reactivity to reduce sagging on vertical surfaces and pull-away from edges and corners.
Process Control
- Coat inside corners, welds and shadowed areas before large flat surfaces; use a low-voltage pre-coat or touch-up pass where necessary.
- Adjust gun distance, spray angle, reciprocator speed and part grounding to suit the geometry and avoid back ionization at high voltage.
- Fix the reclaim-powder blend ratio and monitor particle-size shifts to prevent fines enrichment from destabilising deposition.
Validation Focus
- Minimum film thickness in recesses
- First-pass transfer efficiency
- Film-thickness uniformity
- Reclaim-loop stability