Spraying Coating / Printing

Q: Can KingStar Mold customize spray coatings for specific applications?

Absolutely. KingStar Mold specializes in customizing spray coatings to match the exact needs of each application. We work closely with clients to understand their performance goals—whether it’s wear resistance, thermal insulation, corrosion protection, or electrical conductivity. Based on those requirements, we select the ideal coating material, spraying method, and process parameters. Our in-house engineering team ensures that every customized solution meets both functional demands and dimensional tolerances, even for complex geometries or high-precision parts.

Q: What’s the typical thickness range of spray coatings?

Spray coatings typically range from 50 microns to several millimeters thick, depending on the application. Thinner coatings are used for surface enhancement or anti-corrosion layers, while thicker coatings may be applied for wear protection or dimensional restoration. At KingStar Mold, we tailor coating thickness to meet exact functional and tolerance requirements for each project.

Q: Is thermal spraying suitable for repairing worn or damaged parts?

Yes, thermal spraying is an effective method for restoring worn components. It can rebuild surface dimensions, improve durability, and extend the service life of parts such as shafts, rollers, pistons, and turbine blades. KingStar Mold often uses spraying techniques as part of its precision refurbishment services to reduce downtime and replacement costs for clients.

Q: How does KingStar Mold ensure high-quality spray coatings?

KingStar Mold ensures high-quality spray coatings through a combination of advanced equipment, strict process control, and expert engineering. We begin by carefully selecting the appropriate spraying method—whether it’s plasma spray, HVOF, arc spray, or cold spray—based on the specific material, part geometry, and performance requirements. Our technicians monitor critical parameters such as particle velocity, temperature, spray distance, and feed rate in real time to maintain consistency and coating integrity. In addition, all coatings undergo thorough inspection, including adhesion testing, thickness measurement, and surface quality evaluation, to ensure they meet customer specifications and industry standards.

We provide expert spraying services for coatings, finishes, and protection across various materials.

Surface Preparation: Clean and smooth the surface for optimal adhesion.
Coating Selection: Choose the right paint or coating for durability and aesthetics.
Drying & Curing: Ensure proper drying and curing for a long-lasting finish.

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What is Spray Coating?

Spray coating is a surface treatment process where a liquid or powder coating material is applied to a substrate using a spray gun or similar spraying equipment. This technique involves atomizing the coating material into fine droplets, which are then directed onto the surface to create a uniform, durable layer. Sprayed coatings are commonly used to enhance the appearance, corrosion resistance, and durability of materials, and are widely used in industries such as automotive, aerospace, furniture, and construction.

Thermal spraying and non-thermal spraying are two main categories of coating technologies, classified based on energy source and operating principle:

Thermal Spraying: This method melts the coating material using a heat source and propels it at high speed onto the substrate, forming a coating primarily through mechanical interlocking. Subtypes include arc spraying, flame spraying, plasma spraying, detonation spraying, and cold gas dynamic spraying. These are widely used for corrosion protection, wear resistance, high-temperature components, and precision part repair.
Non-Thermal Spraying: Unlike thermal methods, non-thermal spraying does not involve melting the material. Instead, it relies on mechanical pressure or electrostatic forces to apply coatings. Common types include air spraying, airless spraying, and electrostatic spraying. These are suitable for applications in construction, furniture, automotive, and appliance industries due to their high efficiency and broad adaptability.

Another classification method is to categorize by material type: paint spraying, powder coating and abrasive blasting.

As shown below:

By Material Form:

Paint Spraying

Powder Coating

Abrasive Blasting

By Energy Type:

Thermal Spraying

Arc Spraying

CGDS

Plasma Spraying

Flame Spraying

Non-thermal Spraying

Air Spraying

Airless Spraying

Electrostatic Spraying

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Properties of Various Sealants for Thermally Sprayed Coatings

Sealant	Base Polymer	Curing Conditions	Wetting Angle on γ-Alumina (°)	Viscosity η (mPa·s)	Curing Shrinkage (Weight %)	Curing Shrinkage (Volume %)
A	Inorganic aluminum phosphate	200 °C for 7 h	97	505	48	–
B	Methacrylate¹	60 °C for 1 h	15	6.5	3.8	17.6
C	Methacrylate¹	60 °C for 1 h	15	8.6	2.6	5.3
D	Phenol¹	Room temperature	10	1.5	79.6	8
E	Epoxy	80 °C for 2 h	39	162	0.1	0.2
F	Methacrylate¹	UV curing	26	28	0.5	<2
G	Epoxy	60 °C for 2 h	42	179	1	0.1
H	Furan	60 °C for 1 h → RT	67	626	2	2
I	Vinyl ester	60 °C for 1 h → RT	83	319	0.6	2.4

*Adapted from the work of Knuuttila, J., Sorsa, P., and Mäntylä, T., originally published in Journal of Thermal Spray Technology, 1999, Volume 8, Page 249.
*Online Source: sciencedirect.com

Comparative Analysis of Key Metrics

Spraying Technology	Most Prominent Characteristics	Advantages	Disadvantages	Cost	Applicable Scenarios	Duration
Paint Spraying	Liquid paint application using compressed air or high-pressure systems	- Low cost - Easy to apply - Wide color range	- Poor adhesion - Volatile solvents - Environmental impact	Low	Interior decoration, small-batch production	5–10 years
Powder Coating	Powder coating using electrostatic spraying and heat curing	- High durability - No solvent pollution - Eco-friendly	- High cost - Color matching is difficult	Medium to high	Industrial equipment, automotive parts	30 years
Abrasive Blasting	Surface cleaning and preparation using abrasive media	- Thorough surface preparation - Suitable for complex shapes	- High cost - Dust pollution	Medium	Metal surface pre-treatment	5–10 years
Arc Spraying	Metal wire melted by electric arc and sprayed	- Strong bonding strength - Suitable for metal coatings	- High equipment cost - High cost	High	Metal structure repair	30+ years
CGDS (Cold Gas Dynamic Spraying)	Cold gas dynamic spraying without high-temperature heating	- Suitable for high-melting materials - No thermal damage to the substrate	- High cost - Technical complexity	High	Ceramics, metal coatings	10–20 years
Plasma Spraying	High-temperature plasma arc to melt and spray materials	- High-quality coatings - Suitable for high-temperature materials	- High equipment cost - Complex operation	Very high	Ceramic and metal coatings	10–20 years
Flame Spraying	Flame heating of metal wire to form coatings	- Strong bonding strength - Suitable for metal coatings	- High cost - Flame pollution	High	Metal structure repair	10–20 years
Air Spraying	Liquid paint atomized by compressed air	- Easy to operate - Suitable for large-area coating	- Poor adhesion - Solvent evaporation	Low	Interior decoration	5–10 years
Airless Spraying	High-pressure pump to atomize paint	- Uniform coating - Suitable for high-viscosity paints	- Requires maintenance - High cost	Medium	Industrial equipment	5–10 years
Electrostatic Spraying	Electrostatic charge to attract powder or liquid paint	- Uniform coating - Suitable for complex shapes	- Requires special equipment - High cost	Medium	Industrial equipment, automotive parts	5–10 years

Other Surface Treatment

Cases of Spraying Coating

Aluminum Rocker Panel

Automotive Component

Switch Kit

Drop Leveling Lowering Shackles Kit

Handrail Bracket Square

Mounting Bracket

Post Caps

Solid Telescopic Stabilizer

Guidelines for Inspection Standards of Spray-Coated Parts

Test Item	Inspection Standard
Salt Spray Test	Continuous saltwater spray of 5% concentration at 35°C, with duration as specified by the customer.
Salt Spray Test	No formation of bubbles or rust should be observed.
Appearance	1. Color should match the color card and have a glossy finish within sample limits.
	2. The surface must be free of scratches, fingerprints, or particles.
	3. No rust or signs of corrosion are allowed.
	4. There should be no uneven spraying or discoloration.
	5. Cut edges must be smooth without sharp burrs or jagged edges.
Cross-cut Test	No more than 5% of the paint should peel off the tested surface.
Coating Hardness	Sharpen the pencil tip to a right angle, then apply a 1KG force to draw an 8CM straight line on the paint surface at a 45-degree angle.
Coating Hardness	The pencil hardness should be above H, with no damage or scratches visible on the paint surface.
Paint Compliance	The paint used must be accompanied by a relevant report and comply with ROHS regulations.

Frequently Asked Questions

Can KingStar Mold customize spray coatings for specific applications?webadmin2025-06-13T02:19:54+00:00

Can KingStar Mold customize spray coatings for specific applications?

Absolutely. KingStar Mold specializes in customizing spray coatings to match the exact needs of each application. We work closely with clients to understand their performance goals—whether it’s wear resistance, thermal insulation, corrosion protection, or electrical conductivity. Based on those requirements, we select the ideal coating material, spraying method, and process parameters. Our in-house engineering team ensures that every customized solution meets both functional demands and dimensional tolerances, even for complex geometries or high-precision parts.

What’s the typical thickness range of spray coatings?webadmin2025-06-13T02:19:10+00:00

What’s the typical thickness range of spray coatings?

Spray coatings typically range from 50 microns to several millimeters thick, depending on the application. Thinner coatings are used for surface enhancement or anti-corrosion layers, while thicker coatings may be applied for wear protection or dimensional restoration. At KingStar Mold, we tailor coating thickness to meet exact functional and tolerance requirements for each project.

Is thermal spraying suitable for repairing worn or damaged parts?webadmin2025-06-13T02:18:47+00:00

Is thermal spraying suitable for repairing worn or damaged parts?

Yes, thermal spraying is an effective method for restoring worn components. It can rebuild surface dimensions, improve durability, and extend the service life of parts such as shafts, rollers, pistons, and turbine blades. KingStar Mold often uses spraying techniques as part of its precision refurbishment services to reduce downtime and replacement costs for clients.

How does KingStar Mold ensure high-quality spray coatings?webadmin2025-06-13T02:17:54+00:00

How does KingStar Mold ensure high-quality spray coatings?

KingStar Mold ensures high-quality spray coatings through a combination of advanced equipment, strict process control, and expert engineering. We begin by carefully selecting the appropriate spraying method—whether it’s plasma spray, HVOF, arc spray, or cold spray—based on the specific material, part geometry, and performance requirements. Our technicians monitor critical parameters such as particle velocity, temperature, spray distance, and feed rate in real time to maintain consistency and coating integrity. In addition, all coatings undergo thorough inspection, including adhesion testing, thickness measurement, and surface quality evaluation, to ensure they meet customer specifications and industry standards.

What is thermal spray?webadmin2025-06-13T02:16:57+00:00

What is thermal spray?

Thermal spray is a coating process that uses thermal energy to deposit material onto a surface. It typically involves three steps: (1) preparing the coating material in the proper form—usually powder, but sometimes wire or rod; (2) melting the material using a heat source; and (3) propelling the molten particles onto the substrate, where they rapidly cool and form a coating.

The heat required to melt the material can come from various sources:

Detonation spray (D-gun): Uses combustion gas explosions to generate thermal and kinetic energy
Flame-based methods: Include flame spray and high-velocity oxygen fuel (HVOF), where fuel combustion creates the heat
Plasma spray: Relies on a high-temperature plasma arc generated by electrical discharge
Arc spray: Involves an electric arc struck between two consumable wires; the molten material is atomized by compressed air and sprayed onto the surface

*Detonation Gun Process

What is cold spray?webadmin2025-06-13T02:13:18+00:00

What is cold spray?

Cold spray is a low-temperature coating process where particles are deposited using high-velocity impact rather than heat. Developed in Russia in the 1980s, it uses a convergent–divergent (CD) nozzle to accelerate a gas—typically air, nitrogen, or helium—to supersonic speeds (Mach 2–4). Powder particles (1–50 µm) are injected into the gas stream and propelled at velocities of 500–1000 m/s toward the substrate. While the gas can be heated up to 700 °C to boost velocity, the temperature remains below the melting point of the material, avoiding thermal damage.

Upon impact, the particles undergo plastic deformation and bond with the substrate in a process similar to micro-scale explosive welding. Strong coatings can be formed from metals, composites, and NiCoCrAlY alloys, achieving bond strengths of 34.5–48.9 MPa (5–10 ksi). Cold spray offers high deposition rates and excellent coating quality with minimal oxidation, no phase changes, and little to no thermal distortion.

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