Henry Ford once said, “You can have a Model-T in any color
you want. So long as it’s black.” For an industry once
focused primarily on manufacturers’ needs, powder coating is
transforming the automotive industry with faster production times
and lower operating costs, plus irresistible value propositions
for consumers.
For years, conventional liquid coatings were the standard for
the automotive industry. But these coatings can emit dangerous VOCs
at their application stage. Powder coatings do not use solvents;
therefore, little or no harmful emissions are released into the
atmosphere, eliminating the need for costly waste disposal systems.
Oversprayed powder can also be collected and reused, resulting in
additional cost savings. And because powder does not run or drip,
the result is a uniform, superior-quality finish.
Transforming the IndustryClear Topcoats—Conversion
from liquid to powder clearcoats for auto body exteriors is moving
rapidly. Powder topcoats resist acid rain, the sun’s ultraviolet
rays and road and weather damage, helping cars retain their “showroom
look” much longer and improving their resale value.
Body Primers—Powder coating has made substantial
inroads as a primer for car, van and pickup truck bodies in the
United States. Auto body primers in colors will be next.
OEM and Aftermarket Parts—There is huge
market potential for high-heat resistant powder coatings on aftermarket
mufflers, which resist corrosion, protect against nicks and prolong
the life of the muffler. Some companies are already applying heat-resistant
powder to aftermarket mufflers, and the new-car market is thought
to be two or three years away.
Powder coating is also applied to wheels, grilles, bumpers, door
handles, roof racks and exterior and interior trim. “Under
the hood” uses include oil and fuel filters, brake pads, engine
block casings, suspension components and radiators.
Accessories—Pickup truck and SUV owners
can purchase powder coated side steps, bed rails, luggage racks
and toolboxes as dealership add-ons or in aftermarket stores and
catalogs.
Performance Enhancers—Performance car owners
can find powder coated special suspension units, carburetor parts
and valve covers, plus flashy rear-view mirror mounts and other
exterior adornments.
Powder
Coating and the Future of Plastics
Powder coating plastic surfaces represents a major growth area.
In the automotive industry, plastic sheet-molded compounds receive
wet finishes that take more time and are not environmentally friendly.
The challenge for powder coating is getting it to stick, because
the various compositions of a plastic surface make it a moving target.
There is also a concern about the potential impact to the plastic
from high heat exposure during the cure cycle.
The powder industry is optimistic that these challenges can be
met. One custom coater in Michigan who works with the automakers
said, “We’re testing the powder process to see if we can
get coverage adhesion by using ultra-violet curing for powder on
plastic sheet molding compounds, which also keeps the heat levels
under control.”
In coating plastics, manufacturers are concentrating on such items
as wheel covers, rear-view mirrors, door handles, air conditioning
vents and interior clothes-hanger hooks. From top to bottom, from
inside to out, powder coating takes first place at the automotive
finish line.
