Recent trends in powder-coating technologies

A review of low-temperature/UV-curable approaches, aesthetic finishes, durability-driven architectures, functional additives, corrosion-protection routes, and dielectric coating applications.

Powder coating is positioned as a solvent-free approach for reducing VOC-associated impacts while extending functional and substrate capabilities through tailored chemistries and process innovations.

Low-temp/UV cure

Functional surfaces

Durability & protection

Background and objective Body

Environmental regulation and increasing attention to VOC reduction motivate interest in coating routes with reduced solvent dependence. Powder coating is discussed as a dry, free-flowing application pathway that can reduce solvent-related emissions and expand into domains traditionally constrained by curing temperature and substrate compatibility. The article surveys recent application-driven directions and enabling technologies, with emphasis on curing innovations and functional performance additions.

Low-temperature and UV-enabled processing Body

Conventional powder coatings typically require elevated curing temperatures (noted as ≥180 °C for many systems), limiting use on heat-sensitive substrates (e.g., wood-derived boards and certain polymers). Emerging low-temperature cure approaches and UV-assisted routes are presented as enabling strategies. In UV-curable powder systems, a thermal step is generally required to melt/level the deposited powder before UV exposure initiates crosslinking, imposing constraints on flow, reactivity, and storage stability.

Heat-sensitive substrates (low-temperature cure)

Substrate class: Wood/MDF, selected plastics

Constraint: Elevated cure temperature sensitivity

Process direction: Lower-temperature cure chemistries; controlled reactivity

Core function: Enables coating formation while reducing thermal load on temperature-sensitive substrates.

UV-curable powder route (two-step cure)

Process sequence: Melt/flow → UV-triggered crosslinking

Key control: Balancing flow time with UV conversion

Constraint: Reactivity vs storage stability trade-off

Core function: Produces crosslinked films after melt leveling using UV initiation, expanding processing options for heat-limited substrates.

Chrome-look finish (metallic aesthetic)

Finish objective: Metallic appearance analogous to chrome-like aesthetics

Approach: Metallic pigment integration and controlled film formation

Application emphasis: Components requiring metallic visual performance

Core function: Achieves metallic visual effects via pigment placement and film formation control.

Wood-effect finish (aesthetic replication)

Substrate: Often metal (e.g., aluminum)

Transfer method: Pattern transfer via sublimation-based film approach

Outcome: Wood-like appearance without wood substrate

Core function: Delivers wood-like visual textures on non-wood substrates through pattern transfer post-coating.

Durability-driven architectural systems Body

Architectural exposure conditions elevate the importance of weathering and long-term durability. The article describes “super durable” powder coatings in relation to extended service horizons (noted as ~15–25 years) and references alignment with established architectural qualification frameworks (e.g., Qualicoat, AAMA, GSB). Resin selection and monomer chemistry are emphasized as contributors to durability.

Functional powder-coating additives and new application domains Body

Functionalization is described through antibacterial additives (notably silver-based systems) and easy-clean/anti-graffiti approaches that reduce staining/adhesion through surface-energy and porosity control. The review further highlights fusion-bonded epoxy (FBE) powder coatings applied to reinforcement bars to mitigate corrosion drivers (chloride ingress, oxygen and moisture transport), and discusses epoxy-based powder coatings as potential dielectric/insulating layers for electrical components, contingent on dielectric property tailoring and impurity control.

Super durable architectural powders

Target horizon ~15–25 years (as stated)

Qualification context Architectural standards (e.g., Qualicoat/AAMA/GSB)

Material basis Specialized polyester resin chemistry

Core function Provides enhanced long-term durability in exterior architectural exposure conditions.

Antibacterial powders (silver-based additive)

Active mechanism Silver-ion mediated antimicrobial action (as described)

Use contexts High-contact surfaces and hygiene-critical environments

Performance intent Inhibition of bacterial/fungal growth on coated surfaces

Core function: Introduces antimicrobial functionality via additive-enabled ion-mediated effects at the surface.

Easy-clean / anti-graffiti powders

Surface strategy Reduced porosity + reduced surface energy

Chemistry cues Polyurethane-based approaches and silicone additives (as described)

Functional intent Limits marker/spray adhesion and improves cleanability

Core function: Improves stain resistance and cleanability by controlling surface morphology and energetics.

FBE on reinforcement bars (corrosion mitigation)

Process outline Shot blasting → preheating (~235 °C noted) → electrostatic powder application

Corrosion driver Chloride/oxygen/moisture ingress through concrete porosity

Barrier role Restricts transport of water/oxygen/chlorides to steel surface

Core function: Acts as a barrier coating system to reduce corrosion initiation and propagation risks on embedded reinforcement steel.

Technical considerations across the reviewed directions

Elevated cure temperatures restrict compatibility with substrates prone to thermal deformation or degradation. Low-temperature cure strategies require careful control of reactivity to maintain storage stability while enabling adequate conversion and film properties under reduced thermal input.

Cure-temperature constraint (heat-sensitive substrates)

curable powder systems typically require a preliminary thermal step to melt and level the powder film before UV exposure drives crosslinking. The window between melt flow and UV conversion becomes a governing parameter affecting leveling, defect formation, and final film performance.

UV-curable powder sequence (flow then cure) UV

Metallic finishes depend on pigment selection and distribution within the film, as well as process parameters that influence surface uniformity and optical appearance. Achieving a consistent metallic aesthetic can require additional attention to coating formation and post-application appearance retention.

Aesthetic metallic effects (chrome-look)

Wood-effect coatings combine powder film formation with subsequent pattern transfer, commonly via sublimation-based methods. Process integration and thermal management are central to preserving pattern fidelity, maintaining adhesion, and ensuring the final appearance remains stable under use conditions.

Wood-effect replication (pattern transfer)

Architectural structures

Exterior and structural elements requiring long-term durability and qualification.

Automotive components

Metallic aesthetic finishes and durable protective films on parts.

Healthcare environments

High-contact coated surfaces where antimicrobial functionality is relevant.

Public transport and shared spaces

Surfaces benefiting from hygiene and cleanability considerations.

Reinforced concrete assets

Bridges, tunnels, and structures where rebar corrosion mitigation is relevant.

Electrical equipment

Rotors, stators, busbars, and connectors requiring dielectric insulation coatings.

Search

Trending Queries

Quick Links

Actions

Best Results