Fusion Bonded Epoxy: The Custom Powder Coater’s Work Horse
July 2, 2024Determining the Coating System Scope with a Consultative Approach
July 30, 2024
Design Stage: The Foundation of a Successful Project
The design stage is where it all begins, and this is where the consultative approach plays a crucial role. It involves collaboration between designers, engineers, and manufacturers to ensure that the final product meets all functional and aesthetic requirements while also being feasible for production.
Despite rigorous planning and attention to detail, one critical aspect often overlooked at these stages is the finishing process. Finishing is crucial as it impacts the durability, aesthetics, and functionality of the final product. Failure to consider finishing early in the design and fabrication stages can lead to inadequate surface preparation, improper coating application, or unsuitable material selection, all of which can result in defects that are costly and time-consuming to rectify.
One key aspect of the consultative approach at this stage is considering finishing as an integral part of the design process. This includes evaluating surface preparation methods, material selection, and coating compatibility to prevent defects such as adhesion failure or poor surface finish. By involving finishing experts early on, potential issues can be identified and addressed before they become costly problems down the line.
The Growing Importance of Quality in Design and Fabrication
Quality control has never been more crucial in the engineering and design sectors. With rising customer expectations and tighter regulations, the margin for error is shrinking. This is especially true in industries where safety and reliability are non-negotiable. Engineers and designers must collaborate closely to identify and mitigate potential defects early in the project lifecycle.
The Problem with Communication and Expectations
One of the most significant challenges in any design and fabrication project is ensuring clear and consistent communication among all parties involved. Misunderstandings can frequently arise, particularly in complex projects involving multiple stakeholders such as homeowners, designers, architects, engineers, fabricators, coaters, and installers. Each party brings their own set of expectations, priorities, and technical jargon, which can lead to ambiguity and faulty assumptions if not managed properly.
Expectations can shift and evolve over the course of the project, sometimes due to changes in design requirements, unforeseen technical challenges, or even budget constraints. For instance, a homeowner’s aesthetic preferences might change, necessitating alterations in the design that could impact engineering specifications. Similarly, an architect’s vision might clash with the engineer’s practical constraints, requiring a compromise that must be communicated effectively to all stakeholders.
Without a structured and proactive communication strategy, these evolving expectations can create a cascade of misunderstandings. This often results in delays, increased costs, and, in the worst-case scenario, defects that compromise the quality of the final product. Frequent meetings, clear documentation, and the use of collaborative tools can help mitigate these issues by ensuring that every stakeholder is on the same page at each stage of the project. Moreover, establishing a single point of contact or a project manager to oversee communication can further streamline the process and reduce the risk of costly errors.
High-Level Overview Coating System From Owner to End User
Understanding the entire lifecycle of a coating system—from the owner's vision to the end user's experience—is crucial for identifying potential issues and implementing solutions.
What Is a Consultative Approach?
A consultative approach involves proactive and continuous collaboration between all stakeholders—engineers, designers, fabricators, finishers, installers and end users. It focuses on understanding the specific requirements and constraints of a project, enabling more informed decision-making and effective problem-solving.
How Do We Fit in the Process?
Engineers, architects or designers play a critical role in the lifecycle of a coating system. They are responsible for translating the end users into actionable plans and specifications. By adopting a consultative approach, they can ensure these plans are realistic and feasible, minimizing the risk of defects.
What Can We Do to Help?
We collaborate with our customers and contribute significantly by:
- Conducting thorough needs assessments to understand the project requirements and consult on the most appropriate finishing approach.
- Collaborating closely with fabricators to ensure that the chosen design is suitable for the selected materials and finishing process and identify and explain common defects.
- Providing expert guidance to help optimize the coating process, including surface preparation methods, application techniques and material selection.
- Raising awareness of applicable standards and tests which will help to verify your coating performance
- Ensuring quality control and enhanced communication during the finishing process to ensure customer expectations are met and the risk of failures is minimized.
Examples of Fabrication and Design Defects
A. Enclosed Pipe/Tube
- Sealed tubes can trap moisture and contaminants.
- When heated up - sealed tubes have the tendency to bleed out oilt. water, etc.
- Beware of product that has set outside in wet weather.
- Products that are being refurbished over time will collect moisture, sometimes baking them prior to blasting is insufficient.
- Proper design and fabrication techniques, such as using vent holes, can mitigate this risk.
A. Enclosed Pipe/Tube
- Sealed tubes can trap moisture and contaminants.
- When heated up - sealed tubes have the tendency to bleed out oilt. water, etc.
- Beware of product that has set outside in wet weather.
- Products that are being refurbished over time will collect moisture, sometimes baking them prior to blasting is insufficient.
- Proper design and fabrication techniques, such as using vent holes, can mitigate this risk.
B. Sharp Edges
- All Coatings tend to recede from edges, leaving them vulnerable to corrosion.
- Requesting deburring or rounding of edges during fabrication can help prevent this issue.
C. Laser Scale
- Oxide layers formed during laser cutting can hinder coating adhesion.
- Removing these layers through mechanical or chemical means is essential for a successful coating application.
D. Mill Scale
- Mill scale is a layer of oxide that forms during the hot rolling process.
- Despite the difficulty in removing with a grinder, it is cathodic to the base metal and will rust off long before the coating should fail.
- Coating won’t fail – the substrate will.
- You can find more information in our article "Understanding Mill Scale"
E. Welding Defects
Cracked Welds
- Can compromise the integrity of the coated product.
Weld Slag
- Weld slag is a byproduct of the welding process that can interfere with coating adhesion.
- It must be removed mechanically to ensure a strong bond.
Weld Spatter
- can create high points that are prone to corrosion.
- Abrasive blasting won't effectively remove weld spatter.
Porous welds
- Can trap contaminants that disrupt the coating process.
- Powder will not effectively seal, fill, or perform any other magic to keep corrosion away.
- Can use a torch to drive out contaminants.
Inspecting and repairing welds before coating is crucial for ensuring durability
F. Tolerance/Fit
- Designer needs to take into account the target film build.
- Hinges, bores, grease nipples might need to be masked for coating if the fit is tight.
- Hinges should be cracked masking removed while powder is warm (Not HOT)
G. Contaminants within material
- Cutting fluid in blind holes.
- Hydraulic fluid
- WD-40
- Ink (especially on aluminum)
- Grease in bearings
H. Material Quality
Powder does not double as a filler.
Layering powder up will not render a perfect smooth surface
Even grind marks can show through a primer and top coat
If you are stripping and recoating a job, know where it has come from and plan accordingly.
I. Can substrate withstand the heat?
- Never assume that your new customer understands that powder coating requires 400F temps.
- There may be a requirement for your customer to modify their fabrication process if powder is required. (foam insulation, wiring, etc).
J. Sandwiched Metal
- Moisture can penetrate where powder can not.
- If possible, have your customers assemble after their product is finished
- When a full seam weld is not possible, caulking is an option.
Conclusion
Incorporating a consultative approach at the design stage is essential for preventing fabrication and design defects. By fostering collaboration and communication among stakeholders, engineers and designers can ensure the quality and durability of the final product. Remember, the key to successful project execution lies in proactive planning, thorough assessments, and continuous monitoring.
For those looking to further refine their approach to design and fabrication, consider booking a consultation with our experts. Together, we can identify and address potential issues, ensuring your projects are executed flawlessly from start to finish.
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