Powdertech Surface Science

INTRICOAT powder coating at SubCon 2023, June 7-8, NEC

Powdertech Surface Science — 03/05/2023

Precision powder coating and masking for exquisitely machined components

We will be showcasing INTRICOAT on our stand (G120) at SubCon 2023 and look forward to meeting machinists and OEM’s keen to discover this service.

The ability and willingness to powder coat at very low volumes has always been an important aspect of the Powdertech Surface Science service offering. High-end intricately machined devices are often produced in small quantities and require delicate handling and highly accurate masking schemes - hence our separated room for this work. We also like to assist companies making prototype parts who want the best possible surface treatments and metal finishing at this stage of their R&D work.

The care and attention our INTRICOAT team pays to their work creates an exceptional finish. We like to say that INTRICOAT is founded in science and applied as an art.

SubCon 2023 gives us a great opportunity to talk to customers and potential customers face-to-face, answering their questions and explaining in detail exactly what this service offers. We will have the MUOV TiltBike on show as well - displaying INTRICOAT work completed recently for a happy customer.

Powdertech Joins Community of Modern Manufacturers

Powdertech Surface Science — 21/11/2022

Made in the Midlands is delighted to announce Powdertech Surface Science as a member of the group. After being recommended to join the group by fellow member RSD Pressings, Powdertech decided to join the organisation to be part of a community of forward-thinking manufacturers within a modern trade association that emits a positive environment.

Powdertech, based in Bicester, brands itself as the most technically advanced aluminium coating and surface treatment provider in the UK. Supplying exclusively to UK customers, the firm designs and delivers precision powder coating services to leading manufacturers in automotive, medical, aircraft interiors and other specialist sectors. Utilising their decades of expertise, the Powdertech team also works with OEM and Tier 1 companies in research projects, developing and improving coating and joining systems. Powdertech is always happy to advise on powder coating services and works closely with customers to find optimal solutions.

James Grant, Powdertech Director, said that the company had joined other trade bodies in the past but had not felt they were quite as dynamic as Made in the Midlands. James is impressed by the sleek, user-friendly member microsites that link to the Made in the Midlands domain which itself ranks at the top of Google searches for Midlands’s manufacturing. The bi-weekly virtual breakfast mornings, giving members the opportunity to network, hear best practice from leading businesses and join 30-minute roundtables on relevant topics are seen as very constructive.

James said:

“Powdertech is looking forward to connecting with industry leaders at events, especially building relationships with precision machinists and gaining industry insight from businesses big and small. Made in the Midlands is clearly well connected with the manufacturing industry, helping businesses to link up, find opportunities and share industry insight. This is perfect for Powdertech as we place a lot of value on collaboration and long-lasting customer relationships.”

Find out more about Powdetech by clicking the link:https://powdertechsurfacescience.madeinthemidlands.com/

Recruiting a Marketing & Sales Manager

Powdertech Surface Science — 11/01/2024

Join our lively, motivated team

With continuing growth in our services and in the sectors we serve, we are looking for a dynamic Marketing & Sales Manager to join our ambitious team and make a significant contribution to driving the business forward.

We are an innovative company with an enthusiastic and mutually supportive team, proud of our leadership position in the industry. We have a culture of technical excellence, long-term customer relationships and a desire to exceed customer expectations.

Full details of the role and how to apply can be found HERE

TiZr for enhanced bonding in Nichols N1A supercar

Powdertech Surface Science — 04/09/2023

When the work you perform is hidden from view and never to see the light of day, one’s pride resides in the finished article. 

Such it is for the Powdertech Surface Science team; we are extremely proud that our optimised TiZr service plays an essential part, albeit hidden, in the construction of the striking and phenomenal Nichols Cars N1A super car.

The curved and honed body shape utilises a revolutionary chassis design made almost exclusively from extruded aluminium parts which are adhesively bonded in preference to being welded; carbon fibre is employed in certain areas. This system is the brainchild of Bob Mustard, a veteran of automotive engineering.

Powdertech optimized TiZr pre-treatment prepares the aluminium for enhanced adhesive bonding. The Nichols N1A is undoubtedly one of the most exciting new sports cars to land in the niche vehicle arena – weighing in at around 900kg, with a 7.0-litre V8 engine making 650 bhp.

Find out more Nichols N1A supercar

Our optimised TiZr process can match the bond strength and durability of anodised treatments

Powdertech Surface Science — 25/01/2023

One of the questions we are commonly asked is whether TiZr treatments can deliver equivalent bond strength and durability to anodised treatments. We have conducted an extensive side-by-side test programme comparing our proprietary, optimised TiZr treatment to an industry standard anodised treatment using a 1K heat cured structural epoxy adhesive. Funded by Innovate and we worked with partners TWI and LEVC, a non-grant-bearing partner. Our tests included process capability and durability study of the lap joints, cyclic corrosion and SWAAT testing. Our optimised TiZr process can match the bond strength and durability of anodised treatments and has the added advantage of being a more sustainable and cost-effective solution. Get in touch to discuss our TiZr pre-treatments and test programmes further. Image courtesy of Morgan Motor Company.

Cleaning aluminium prior to surface treatments

Powdertech Surface Science — 26/06/2023

How clean is clean ? And how do we know if we have cleaned your aluminium to the best possible level?

Surface contaminants, many that can’t even be seen, will impair the performance of any adhesive or coating applied to the metal.

Bond strengths will be unacceptably low, especially in wet environments when surface corrosion can initiate. For Battery Electric Vehicles (BEV) in particular, high levels of cleanliness in the component structure are vitally important to ensuring the integrity and safety of the battery system. We use XRF equipment Dyne inks and UV-Fluorescence to measure the level of aluminium surface contaminants and to demonstrate compliance to specifications detailing RFU limits.

This short video explains just how we know that your metal is as clean as it can be before we apply any surface treatment.

Optimised TiZr conversion coating for enhanced structural bonding.

Powdertech Surface Science — 18/05/2023

Ensuring high structural strength in a lightweight chassis

'Retro-futuristic' is the term used to describe the Morgan Super 3 - an exciting three-wheeled lightweight open top sports car. Super-formed aluminium panels form part of the monocoque chassis and these delicate panels are critical to the strength of the lightweight build. Bonding the aluminium panels needs to be done with superior strength and precision to withstand the conditions that the vehicle will face on the road. The vehicle has a 118bhp Ford-sourced three-cylinder engine giving 0-62 mph in 7 seconds and a top speed of 130mph.

Powdertech worked with Morgan from the outset to establish the optimum TiZr pre-treatment system that would be needed to both the chassis components. We also needed to create the correct preparation for powder coating on the inner door panels to which various attachments would be made.

We have all the testing equipment required for such work at our Bicester plant. This includes XRF and RFU spectrometry for metal surface characterisation and Instron mechanical testing technology to test bond strengths following TiZr Passivation.

You can read more about the work we carried out on the Morgan Super 3 HERE

Recruiting a Marketing & Sales Manager

Powdertech Surface Science — 11/01/2024

Join our lively, motivated team

Full details of the role and how to apply can be found HERE

INTRICOAT - Best-in-class products need best-in-class surface treatment

Powdertech Surface Science — 08/11/2022

Powdertech's Intricoat service has recently been the solution for Blighter Surveillance Systems who needed very precise powder coating for cast aluminium housings used in radar systems.

Blighter Surveillance Systems designs and makes electronic-scanning (e-scan) ground radar systems for national border security, counter-drone, wide area surveillance and coastline security. These products employ unique award-winning technology and are generally regarded as best-in-class.

The radar systems are used in over thirty different countries. The technology needs to operate in all environments including desert and coastal/offshore and in all weather conditions, with no deterioration of function. An hermetic seal between the components needs to be achieved making the interior cavity airtight.

Protective treatment of the aluminium used for the radar housing is therefore critical as every surface is important to the integrity of the product and its successful deployment of scanning, recording and disseminating abilities. Some parts of the metal needed to be powder coated and others left free of the powder coating, but still pre-treated for corrosion protection.

Intricoat - starts with a detailed CAD masking scheme

Powdertech’s Intricoat team designed a masking scheme on CAD, in conjunction with Blighter Surveillance Systems. This was needed in order to keep internal areas free of powder, including preventing powder penetration into over 120 small holes per unit. Powdertech has a wealth of experience in designing and implementing these schemes and we are very aware of what works and what does not.

Pre-treatment for corrosion resistance

The internal surfaces of the housing needed to be free of a final powder coating and therefore required an initial pre-treatment with high corrosion resistance. Iridite NCP was used as the high performance pre-treatment, having excellent resistance to corrosion and an ability to withstand very high temperatures. Frequently specified by regulated industry sectors such as aerospace, defence, automotive and medical, Iridite can be used both as a pre-treatment under a topcoat or as a final coating.

All components underwent Iridite treatment in our plant and were then de-gassed to force out any remaining moisture.

Masking and powder coating in our Intricoat 'clean room'

Masking was carried out following the pre-designed scheme, after which the components were powder coated, all work being carried out in the dedicated Intricoat room within the Powdertech plant. Handling of parts through the powder coating process needed bespoke jigging arrangements by Powdertech to control weight distribution and ensure consistent and even coverage.

Benefits of Intricoat - Taking care of every aspect

· Your work is in safe, experienced hands

· We take responsibility for all aspects of masking and coating so that you can concentrate on critical design and engineering.

· The final stage of manufacture, the finish, is generally under time pressure. We understand this and have invested in a dedicated separate facility, located within our plant, to be used exclusively for customers requiring Intricoat services

Powdertech continues to invest in state-of-the-art equipment to ensure highest quality output

Powdertech Surface Science — 21/11/2022

At Powdertech we are clear that our role goes further than providing exemplary aluminium surface treatments. We want to be certain that the passivation process we provide is 100% fit for any intended purpose, most especially when it comes to TiZr coating for bonding. This includes ensuring that the bonds achieved following our TiZr conversion coating consistently meet and exceed our customers’ requirements.

Analysing passivation process on aluminium alloys

We have installed world leading Instron equipment as part of our testing suite. This is an electromechanical universal testing machine, able to perform a wide range of mechanical tests including tensile, compression, bend, peel, tear, friction, and shear testing. Tests are performed on all the aluminium alloys we work with, from 3xxx series up to 7xxx series, and in all formats, cast, extruded and sheet.

The results of our Instron testing enable us to work with our clients to help them to understand the optimal surface finishing pre-treatment process they need to take their bonding strategies to the next level, and to achieve repeatability going forwards.

The Instron 34TM-50 tests materials, components, and products in accordance with ASTM, ISO and other industry standards. It has a 50kN load cell and 100kN 80mm wide grips, with a thermal chamber capable of reaching 350C.

Sophisticated powder coating techniques for the latest indoor cycling experience

Powdertech Surface Science — 25/04/2023

The Muoverti TiltBike is a unique indoor cycling experience. This lightweight cycling indoor trainer tilts with you as you bank around corners. It accelerates and brakes and lets you ‘shift’ between gears on approaching gradients.

The inner-workings include an algorithm-driven physics engine that simulates real-world forces such as acceleration, incline, and braking, a digitised handlebar steering and an elastomer-guided side-to-side tilt.

High quality, small volume powder coating for demonstrator units

This is clearly a high-end product and demonstrator units needed to be powder coated with great precision and attention to aesthetic detail. Our INTRICOAT team provided technical input for masking scheme design, leaving certain component surfaces free from powder coating. INTRICOAT masking schemes are sufficiently detailed to be viewed on CAD without the need for masked prototypes, saving time and costs for our customers.

Our services provided not only precision INTRICOAT coating for exceptional aesthetic quality on machined aluminium but we also advised on the most suitable powder coating formulation and colour choice, a metallic dark grey.

Fast turnaround to meet tight deadlines

For our clients, producing prototype or demonstration products for shows and exhibitions invariably ends up being a close-to-the-wire exercise. We can alleviate the pressure this cause. We have the capability to design and implement complicated masking schemes within short timescales and to carry out detailed precision coating to meet our client’s deadlines. All of our testing, masking and coating facilities are on the same site, under the same roof.

Benefits of INTRICOAT - Taking care of every aspect

Your work is in safe, experienced hands
We take responsibility for all aspects of masking and coating so that you can concentrate on critical design and engineering.
The final stage of manufacture, the finish, is generally under time pressure. We understand this and have invested in a dedicated separate facility, located within our plant, to be used exclusively for customers requiring INTRICOAT services.

Precision powder coating at Southern Manufacturing & Electronics, Feb 6-8 2024

Powdertech Surface Science — 07/01/2024

Nothing beats meeting people in person and being able to describe and show our work. We are looking forward to showcasing our precision powder coating service INTRICOAT at the Southern Manufacturing & Electronics Show 2024. This runs from 6-8th February and is held at the £35m Farnborough International Exhibition and Conference Centre which boasts easy access, free onsite parking and world class facilities.

The show is aimed at people involved in design, engineering production and procurement. The latest in production hardware, services, components, consumables and technology will be on display, covering a wide range of industries including Aerospace/Defence, Automotive, Electronics Assembly/ Production, Industrial Machinery, Packaging/Handling/Logistics, Energy, Marine, Medical/PharmaBio, Mechanical Engineering and Metal Processing.

INTRICOAT is our highly detailed and meticulous powder coating service for high value and complex intricate aluminium components. These include part of medical devices, radar housings, electronics, and high end sports equipment.

Visit our stand and find out what makes INTRICOAT a premium powder coating service, required by producers of premium products.

We are recruiting !

Powdertech Surface Science — 22/03/2023

New position available - Powder Coating Engineer

An exciting new role at Powdertech Surface Science

A new role has arisen as part of our ongoing investment in growth and development. We are looking for a coating engineer with the ability to cover a range of tasks using machinery and hands-on precision work. This role is an important one in contributing to the company’s growth strategy through our flagship service ‘INTRICOAT’.

The job description can be found HERE

Apply, with CV to john.m@acqui-tal.com.

Using Powdertech TiZr passivation for enhanced adhesive bonding

Powdertech Surface Science — 21/11/2023

Within the recently launched lightweight commercial vehicle from Watt Electric Vehicle Company (WEVC), our optimised TiZr passivation is used to enhance adhesive bonding for the lightweight aluminium chassis.

On lightweight aluminium, Powdertech TiZr passivation matches anodising for enhanced adhesive bonding strength. Read our technical paper and case study.

TiZr for enhanced structural bonding, in preference to anodising

Optimised TiZr passivation of the aluminium enables strong and repeatable bonding of the high strength aluminium adhesive, delivering a rigid core structure.
WEVC has used TiZr for this vehicle build, in preference to anodising, as it enhances adhesive bonding to the same degree, and uses less energy. The stable layer formed is also suitable for welding.

Innovation in the build

Lightweighting is key. A unique vehicle architecture, the PACES platform, is formed from lightweight aluminium extrusions.
The extrusions interlock and bond together using a patented innovation known as FlexTech®.
This is the first commercial electric vehicle to be using recycled aluminium for its chassis build.
The battery base plate utilises another Powdertech Surface Science process - PowderBond - an adhesive-free surface treatment to bond polypropylene composite material to aluminium. PowderBond has been used to create a lightweight, strong and rigid 'sandwich' laminate of aluminium and composite material for the fully integrated structural battery case. For more on PowderBond visit https://www.powderbond.co.uk/

Powdertech's INTRICOAT powder coating service at Subcon 2023

Powdertech Surface Science — 12/06/2023

June 8^th-9^th we were at SUBCON 2023 at the NEC - our thoughts following our first ever show....

Three days well spent (set up included) learning more about our customers, exchanging ideas and exploring potential collaborations. Thank you to everyone who stopped by and chatted with us. Your professional expertise and feedback on the services we provide is greatly appreciated. The Muov TiltBike, showcasing our exceptional INTRICOAT powder coating was a good draw - sorry that we couldn't risk letting anyone having a go ! It's not ours, but kindly lent to us by MUOV.

In addition to thanking Chris Staunton at MUOV (including his assistance putting up our stand) we'd also like to thank our clients Morgan Motor Company and Blighter Surveillance Systems who allowed us to use their promotional videos in our show reel. Finally a huge thank you to Ben Cottman at Aerial Film and Photo - Media Production for everything show related - including artwork printed and set in place, our superb show reel and a van-based taxi service to get us to the NEC and back.

As we all know, nothing beats chatting with professionals in your industry sector. You can learn a lot, as well as creating a more tangible awareness of your brand and service offering.

INTRICOAT is our premium powder coating service, designed for complex low-volume machined aluminium components. By low volume we mean as low as a single item - we often work on prototype designs that need aesthetic perfection. With CAD masking schemes designed in consultation with you and conscientious attention to detail and quality control, we relieve you of the hassle of ensuring a perfect coating – it is our responsibility.