01The powder coating process
Pretreatment
Cleaning and a chromate-free conversion coating for adhesion and corrosion resistance.
Application
Electrostatic spray guns charge the powder so it wraps evenly around the profile.
Curing
Oven curing melts and cross-links the powder into a continuous film.
Inspection
Film thickness, gloss, color and adhesion checked against the approved panel.
02Durability grades
| Grade | Performance | Typical use |
|---|---|---|
| Standard polyester | Good outdoor durability | Windows, doors and general exterior (Qualicoat class 1, AAMA 2603/2604 tier) |
| Super-durable polyester | Higher gloss and color retention in strong sunlight | Facades and high-UV regions (Qualicoat class 2) |
| Hyper-durable / premium | Maximum retention for landmark facades | Specified projects (Qualicoat class 3) |
| Epoxy / hybrid | Hard and chemical resistant; not UV stable | Interior and equipment parts |
03Colors and effects
Any RAL or matched color is possible, from full gloss to deep matte. Fine textures hide handling marks and fingerprints; metallic powders mimic anodized looks; and wood-grain sublimation transfers a printed grain pattern into the cured coating for timber-look windows and facades.
04Designing for powder coating
- Allow for film thickness on fits, slots and gasket grooves
- Deep, narrow recesses may coat thinner (the Faraday cage effect)
- Mark visible faces so application and inspection focus on them
- Specify masked areas for threads and electrical contact
05Frequently asked questions
How thick is powder coating on aluminum?
Typically 60–120 µm. Architectural specifications set a minimum — commonly 60 µm on visible faces.
Does powder coating fade in sunlight?
Polyester powders are UV resistant, and super-durable grades hold color and gloss markedly longer. Epoxy powders chalk outdoors and are for interior use.
Can powder coating match a RAL color?
Yes. RAL and custom colors are matched against a reference panel approved before production.
Last updated September 17, 2026 · Reviewed by the CharMax Aluminum engineering team