What Is Custom Powder Coatings
News 2026-09-02
Custom powder coatings are non-standard powder coating products specially developed and manufactured according to customers’ specific requirements for color, gloss, texture, curing conditions, or special properties (such as antibacterial and easy-to-clean properties), with the aim of meeting differentiated design or specific application requirements.
This article systematically introduces the concept, customization content, functions, application fields, precautions for powder coating customization, and common problem-solving measures of custom powder coatings, with a particular focus on the applications of custom powder coatings, to help readers better understand what custom powder coatings are and what benefits they offer.
What Are Custom Powder Coatings
Custom powder coatings refer to a service model involving specialized formulation design, color matching, and manufacturing based on customers’ non-standard technical requirements. Unlike general standard products available off the shelf, their core lies in “development according to requirements and precise matching.”
What Can Be Customized for Powder Coatings
Powder coating customization includes the following types:
| Customization Type | Core Characteristics | Typical Application Scenarios |
| Artistic/Decorative Type | Focuses on appearance effects, including: – Textures and finishes: sand texture, wrinkle texture, hammer texture, leather texture, 3D stone-like texture, etc. – Special colors: metallic sparkle colors, pearlescent colors, Morandi color palettes, etc. | Enhancing the appearance and quality of products, such as high-end refrigerators, washing machines, range hoods, etc. |
| Functional Type | Provides specific functions to the coating to meet special requirements, such as: – Easy-to-clean/self-cleaning: the surface is oleophobic and hydrophobic, making grease less likely to adhere. – Antibacterial/antiviral: antibacterial agents are added to inhibit bacterial growth. – Anti-corrosion/ultra-weather-resistant: enhanced resistance to salt spray and ultraviolet radiation for outdoor or harsh environments. | Kitchen appliances (easy-to-clean), medical/food-related products (antibacterial), outdoor air-conditioning units (weather resistance), etc. |
| Process-Adaptive Type | Customized to adapt to specific production lines or substrates, such as: – Low-temperature curing: the curing temperature is reduced to 140-160°C to save energy and accommodate thin sheets or heat-sensitive substrates. – Thin-coating type: reduces powder consumption, increases spraying coverage, and lowers costs. | Production lines sensitive to energy consumption, as well as coating of unconventional substrates such as medium-density fiberboard (MDF). |
| Resin System Type | Different resin systems are selected as the main materials according to basic performance requirements, such as: – Epoxy-polyester hybrid: combines decorative and anti-corrosion properties and is the most commonly used system for household appliances. – Pure polyester: outstanding weather resistance and suitable for outdoor products. – Polyurethane, acrylic, etc., providing specific properties. | This is the underlying classification that determines the core properties of the coating, such as basic corrosion resistance and weather resistance. |
What Are the Functions of Custom Powder Coatings
The main characteristics of custom powder coatings are as follows.
- Precise Performance Matching
This is the core value of customization. The coating performance is no longer at an “average” level, but is specially enhanced according to the actual operating environment of the household appliance.
(1) Targeted Functional Enhancement: Specific properties can be enhanced according to requirements. For example, an ultra-oleophobic and hydrophobic easy-to-clean surface can be developed for range hoods, an antibacterial coating can be developed for refrigerator interiors, and an ultra-weather-resistant, gloss-retaining coating can be developed for outdoor air-conditioning units. These are difficult to achieve simultaneously with general-purpose powder coatings.
(2) Process Adaptability: It can perfectly match the customer’s specific production line. For example, fast-curing formulations can be customized to accommodate high-speed production lines; low-temperature curing formulations, such as those curing at 140-160°C, can be customized to reduce energy consumption or accommodate composite materials containing different materials, such as composite panels with plastic components, thereby addressing deformation or energy consumption problems caused by conventional high-temperature curing.
- Unique Appearance
Customization can achieve unique aesthetics based on brand design and create product recognition.
(1) Precise Reproduction of Colors and Effects: Whether based on Pantone color numbers or physical samples, highly consistent color reproduction can be achieved (color difference ΔE < 1), while gloss can be precisely controlled from 2% ultra-matte to more than 95% high gloss.
(2) Differentiated Textures and Tactile Effects: Special effects that are difficult to achieve with general-purpose powder coatings can be developed, such as leather-like tactile finishes, 3D stone-like textures, and high-quality metallic powders containing metallic sparkling particles, creating differentiation in both tactile and visual aspects.
- Optimization of Production and Application
Customization is concerned not only with the final product but also with the manufacturing process itself.
(1) Improved Application Efficiency: By optimizing the powder’s charging properties, atomization effect, and melt flow properties, powder deposition efficiency and edge and corner coverage can be improved, while reducing losses and rework during spraying.
(2) Batch-to-Batch Stability: Professional customization services usually include dedicated production lines and strict quality control systems to ensure a high degree of consistency in color, performance, and application parameters between different batches, which is crucial for large-scale household appliance production.
- Potential Contribution to Sustainability
Customization also provides new approaches to environmental protection and cost optimization.
(1) Reduced Material Waste: After accurately matching process requirements, the scrap rate and overspray losses can be reduced, improving coating utilization.
(2) Energy Conservation and Emission Reduction: Low-temperature curing technology directly reduces energy consumption during the curing process, in line with the low-carbon development trend of the household appliance manufacturing industry.
Which Fields Require Custom Powder Coatings
Which fields may use custom powder coatings? The specific application fields are as follows:
Household Appliance Industry: Customization of appearance colors, textures (such as metallic sparkle and stone-like textures), and special functions (such as easy-to-clean, antibacterial, and weather-resistant properties) for refrigerators, washing machines, air conditioners, range hoods, etc., while accommodating specific process requirements such as low-temperature curing.
Automotive Industry: Used for automotive interior and exterior components (such as B-pillars and wheels), with customized high-gloss black or metallic-finish coatings featuring high weather resistance and stone-chip resistance, as well as scratch-resistant, matte, or special tactile coatings required for interiors.
Architecture and Building Materials: Applied to outdoor building materials such as aluminum curtain walls and doors and windows, with customized architectural color codes and textures (sand texture, wood grain), as well as performance requirements for long-term outdoor weather resistance, UV resistance, and pollution resistance.
Special-Purpose Vehicles: Used for sanitation vehicles, fire trucks, hazardous chemical tank trucks, etc., with customized coatings offering ultra-strong corrosion resistance (such as salt spray resistance of more than 1.000 hours), long outdoor service life (more than 10 years), and specific colors and gloss levels.
General Industry and Consumer Products: Includes security doors, computer cases, furniture, fitness equipment, etc. Customization can achieve personalized decorative effects (wood grain, marble texture), scratch resistance, antibacterial properties, and other special protective functions.
Anti-Corrosion and Pipeline Industry: Used for water supply and drainage pipelines, chemical pipelines, etc., with customized thick-film protective coatings featuring excellent resistance to chemical media, high-temperature resistance, or insulation properties.
How to Customize Powder Coatings
When selecting custom powder coatings, we often do not know how to make the right choice. Based on our industry experience, we recommend focusing on the following aspects when selecting custom powder coatings.
- Requirement Communication and Solution Definition
At this stage, the specific requirements should be comprehensively understood.
(1) Define the Application Conditions: What product will the coating be used on (household appliances, automotive components, building materials)? Will it be used indoors or outdoors? Will it be exposed to high temperatures or chemicals, or subjected to wear?
(2) Determine Performance Targets: What mandatory performance indicators need to be achieved? For example, how many hours of salt spray resistance are required, what hardness level needs to be achieved, or whether special functional requirements such as antibacterial or conductive properties are needed.
(3) Finalize Appearance Details: This is the most direct reflection of “customization.” Color standards, such as Pantone color numbers or physical samples, should be provided, and the gloss level (high gloss, matte) and surface texture (sand texture, metallic sparkle, etc.) should be determined.
(4) A professional technical white paper and third-party inspection report are often key to establishing initial trust.
- Formulation Design and Sample Preparation
Based on the information collected during the first stage, our R&D team will begin the development work.
(1) Design the Basic Formulation: Select an appropriate resin system, such as epoxy or polyester, and combine it with curing agents, pigments, and additives to establish a formulation framework that meets the performance requirements.
(2) Trial Production and Bonding Process: The formulation is mixed, extruded, and ground into powder in the laboratory. If a metallic sparkle effect is required, a “bonding” process may also be used to bond pearlescent powder and other materials to the powder particles through heating.
(3) Internal Preliminary Evaluation: The completed samples are first evaluated internally by the manufacturer for basic properties such as color, gloss, leveling, and adhesion.
The goal of this stage is to produce customized powder samples that meet the requirements.
- Sample Validation and Optimization Iteration
The powder samples will be sent to you for on-site application trials. This is often the “final step” in determining whether cooperation can proceed.
(1) Customer On-Site Spray Trial: Spraying is carried out on your production line to verify the powder’s application performance, appearance, and coating properties.
(2) Feedback and Optimization: If any problems are identified during the trial, such as poor adhesion, color deviation, or cracking under extreme environmental conditions, we will promptly adjust the formulation and prepare new samples.
(3) Performance Re-Verification: The optimized samples are subjected to more rigorous evaluations, such as QUV accelerated weathering evaluation, to ensure that the performance meets the requirements.
Common Problems and Solutions for Custom Powder Coatings
The most common problems encountered during the use of custom powder coatings are mainly reflected in the following aspects. Based on our industry experience, we propose corresponding solutions to help effectively address the powder coating problems you may encounter.
- Inconsistent Color and Metallic Effect
Problem Description: The finished product color deviates from the standard sample (color difference ΔE > 1), or uneven light and dark “clouding” or “mottling” appears on the surface of metallic powder coatings.
Main Causes:
(1) Formulation/process fluctuations between batches, including pigment dosage and bonding process stability.
(2) Application parameters deviate from the sample preparation conditions, such as changes in spraying voltage, air pressure, or distance.
(3) The proportion of recovered powder is uncontrolled, particularly changes in the content of aluminum powder/pearlescent powder in metallic powders.
(4) Excessive curing causes pigment discoloration, such as yellowing of light-colored powders.
Solutions:
(1) Sign a color difference control standard with the supplier (ΔE < 1) and require comparison of retained samples between batches.
(2) Strictly reproduce the sample preparation process parameters: fix the voltage (usually 60-90 kV), air pressure, and gun-to-workpiece distance (15-25 cm), and spray evenly in thin layers.
(3) Control the proportion of recovered powder: for ordinary metallic powders, the recommended proportion of recovered powder is ≤1/3; for high-metallic-content powders, ≤1/5. Conduct a color evaluation before adding recovered powder.
(4) Use a temperature profiling instrument to measure the actual workpiece temperature to avoid local overheating or excessive curing time in the curing oven.
- Poor Coating Surface Smoothness (Orange Peel/Poor Leveling)
Problem Description: The coating surface exhibits an orange-peel texture and lacks a mirror-like effect, affecting the appearance quality.
Main Causes:
(1) Uncontrolled Film Thickness: Both excessive thinness (<40 μm) and excessive thickness (>120 μm) can impair leveling.
(2) Curing Temperature Rising Too Quickly: The coating surface gels first before the interior has sufficient time to level.
(3) Insufficient Design of the Powder’s Leveling Agent/Resin System: The leveling agent or resin system of the powder itself is insufficiently designed.
Solutions:
(1) Control the film thickness within the optimum window (60-80 μm) by adjusting gun movement speed and powder feed rate.
(2) Optimize the heating curve to ensure that the workpiece has sufficient preheating time before entering the high-temperature zone, allowing the powder to fully melt and level.
(3) Select a customized formulation with an ultra-leveling grade, or add leveling agents within the permitted range.
- Coating Surface Defects (Cratering/Pinholes)
Problem Description: Circular depressions appear on the coating surface (cratering, sometimes with a core), or small penetrating holes (pinholes) appear.
Main Causes:
(1) Contamination: Oil and water in compressed air, pretreatment residues, and silicone/oil mist in the environment.
(2) Substrate Outgassing: Gas escapes from castings or porous substrates, such as MDF, when heated.
(3) Excessive Film Thickness in a Single Application: The film thickness exceeds 150 μm, preventing bubbles from escaping.
Solutions:
(1) Purify the Source: Install oil-water separators to ensure compressed air quality; prohibit the use of silicone-oil-containing products in the spraying environment; and ensure thorough rinsing during pretreatment.
(2) Pre-Bake the Substrate: For porous substrates, pre-bake them before curing at a slightly higher temperature, such as 10-20°C above the curing temperature, for 10-15 minutes to release gas in advance.
(3) Control Film Thickness: Keep the film thickness of a single application within the recommended upper limit, usually ≤120 μm.
- Coating Adhesion Failure (Peeling/Cracking)
Problem Description: The coating peels from the substrate in sheets or spots, or cracks appear during subsequent processing such as bending.
Main Causes:
(1) Pretreatment Failure (Root Cause): Inadequate degreasing or poor phosphating is the fundamental cause of poor adhesion.
(2) Insufficient Curing: The actual workpiece temperature does not reach the required level, resulting in incomplete cross-linking.
(3) Insufficient Formulation Flexibility: During customization, hardness and decorative performance are emphasized while subsequent bending requirements are overlooked; alternatively, excessive film thickness or over-curing increases brittleness.
Solutions:
(1) Strictly Implement Pretreatment: Regularly check the concentration of each process bath to ensure sufficient degreasing, rust removal, phosphating, and rinsing.
(2) Verify Curing with a Temperature Profiling Instrument: Ensure that the workpiece surface reaches the recommended temperature and curing time rather than relying solely on the oven instrument.
(3) Clarify Subsequent Processing Requirements During Customization: If bending or stamping is required, specify this during the formulation stage and control the film thickness toward the lower limit, such as 50-60 μm. It is recommended that the forming process be performed as early as possible.
If you require custom powder coatings, please feel free to contact us at any time to obtain professional technical support, discuss solutions together, and promote the development of the powder coating industry.
We hope this article can provide you with a professional and reliable reference regarding the powder coating industry. We sincerely welcome you to consult us regarding product performance, industry standards, application methods, precautions, or any other questions related to powder coating products. Please feel free to leave a message or contact us directly at any time so that we can provide you with more detailed product information, demonstration videos, or customized solutions to help you fully understand the various functions and advantages of our products.
