Abrasion and Wear Protection for Additive Manufacturing
Precision Cerakote ceramic coatings for aerospace, defense, and industrial components.
The Wear Problem in Additive Manufacturing
Porosity turns end-use parts into wear liabilities
The challenge
Harsh environments demand coatings that hold.
The solution
ColoradoKote ceramic coating stops corrosion cold.
Why Cerakote for AM Wear Protection
Hardness and surface finish in a single coating step
Abrasion resistance on porous substrates
8,000+ wear cycles per mil (ASTM D4060) on PA12, PA11, and metal AM substrates. Cerakote fills the micro-porosity that makes raw AM surfaces vulnerable to accelerated wear. Teflon coatings fail at under 1,000 cycles under identical test conditions, making them inadequate for AM end-use applications requiring extended service life.
Tolerance preservation at 0.5-2 mils
Thin-film application adds only 0.001 to 0.002 inches per coated surface, keeping parts within the plus or minus 0.005 inch tolerance envelope. Topology-optimized lattice structures, conformal cooling channels, and lightweighted brackets retain their design geometry. Powder coating at 4-6 mils per surface pushes AM parts outside tolerance, requiring CNC post-machining that destroys optimized features.
AS9100 documentation for aerospace AM
Every wear coating parameter is documented per AS9100 requirements for aerospace additive manufacturing programs. Certificate of Conformance includes before-and-after Ra measurements, DFT data, material batch records, and cure parameters. ITAR registration covers defense AM articles. First Article Inspection reports available upon request.
Multi-material AM compatibility
Cerakote bonds to PA12, PA11, glass-filled nylon, Ti-6Al-4V, AlSi10Mg, Inconel, and stainless steel AM substrates. One coating partner and one quality system for your entire AM parts portfolio, whether polymer or metal. Material-specific preparation protocols ensure maximum adhesion on each substrate type.
Wear Protection Specs for AM Applications
How We Deliver Wear Protection for AM Parts
Material-specific protocols for polymer and metal AM wear coating
AM Substrate Assessment and Surface Preparation
Every AM part begins with substrate identification: PA12, PA11, glass-filled nylon, Ti-6Al-4V, AlSi10Mg, Inconel, or stainless steel. Polymer parts receive low-pressure aluminum oxide blasting at 30-40 PSI to avoid distortion of thin-walled features and lattice structures while creating the surface profile required for wear coating adhesion. Metal AM parts receive preparation tailored to alloy type, removing support structure witness marks.
Wear-Optimized Coating Application
Cerakote is applied via calibrated HVLP equipment at 0.5-2 mil thickness, targeting maximum abrasion resistance. Polymer parts cure at 250 F, below PA12 heat deflection temperature, to prevent warping. For applications requiring low-friction wear performance, Elite Series formulations deliver a coefficient of friction of approximately 0.11. In-process DFT measurement confirms dimensional compliance on every part.
Dimensional Verification and Wear Performance Documentation
Post-coating CMM measurement confirms parts remain within the plus or minus 0.005 inch tolerance envelope. Before-and-after Ra measurements document surface roughness improvement from Ra 8-15 to under 3 micrometers. Certificate of Conformance includes hardness verification, dimensional data, material batch records, and cure parameters.
Proven Wear Protection for AM Components
Wear protection performance on AM substrates is verified through standardized ASTM testing under AS9100 quality controls. Before-and-after Ra measurements and post-coating CMM dimensional data ship with every order, giving AM production managers the evidence they need to qualify coated parts for end-use service.
8,000+ wear cycles per mil
Validated against ASTM D4060 Taber abrasion standards on both polymer and metal AM substrates. Teflon coatings fail at under 1,000 cycles under identical conditions. For AM production tooling, fixtures, and end-use components, this performance translates to service life that justifies the investment in additive manufacturing over traditional fabrication.
Wear cycles per mil (ASTM D4060)
Other services to consider
Explore what else we offer.
Weight Reduction for Oil and Gas Equipment
Thick coatings add mass to equipment transported to remote wellsites and offshore platforms. Cerakote at 0.5-2 mils saves 200-400g per part versus powder coating. ISO 9001 certified.
Weight Reduction for Medical Device Components
Surgical instruments must be light enough for hours of precise use. Cerakote at 0.5-2 mils saves 200-400g per part versus powder coating without compromising protection. ISO 9001 certified.
Weight Reduction for Maritime Equipment
Heavy coatings add mass to marine hardware that affects vessel performance and handling. Cerakote at 0.5-2 mils saves 200-400g per part versus powder coating. ISO 9001 certified.
Weight Reduction for Industrial OEM Components
Thick coatings add unnecessary mass to engineered equipment. Cerakote at 0.5-2 mils delivers 200-400g savings per part versus powder coating while preserving tolerances. ISO 9001 certified.
Certified and compliant for your industry
Protect Your AM Parts From Wear
Send part files for a wear protection RFP. We respond within 24 hours with pricing.
Frequently Asked Questions
Find answers about our coating processes and technical capabilities
Some AM applications require both the flexibility of polymer coating and the hardness of Cerakote on different surfaces of the same part. Polymer coating protects flex zones, vibration-dampening features, and chemical immersion areas while Cerakote protects wear surfaces, handling areas, and aesthetic surfaces. ColoradoKote designs and applies these combined systems with precision masking to ensure each surface receives the optimal coating. The full multi-layer stack ships with complete process documentation.
Every part is solvent-cleaned and degreased, then media-blasted at 80-100 PSI with blast media selected for the specific substrate material. Aluminum, titanium, steel, and polymer substrates each receive tailored preparation to create the optimal surface profile for Cerakote adhesion. For parts requiring maximum corrosion protection, we apply chemical conversion coating and passivation before Cerakote, running the full stack under our AS9100 quality system.
Passivation per ASTM A967 / AMS 2700 removes free iron and surface contaminants from stainless steel through a controlled acid bath, bringing chromium to the surface to form a robust passive oxide layer. This restored passive layer is what gives stainless steel its corrosion resistance. The process adds no dimensional change, making it suitable for precision components. For maximum protection, passivation followed by Cerakote delivers 3,000 hours of salt spray resistance (ASTM B117).
Wear-resistant coating performance depends on adhesion across the entire contact surface. Any contamination-related adhesion weakness becomes the failure initiation site under abrasive or sliding contact loads. Ultrasonic cleaning ensures the substrate is completely free of oils, particles, and films before blasting and coating. This contributes to uniform Cerakote adhesion across the wear surface, allowing the full 4,000 cycles per mil abrasion resistance to be realized in service.
Yes. Vibration isolation mounts and dampeners often involve rubber-to-metal interfaces and constant flexing under load. Polymer coating provides corrosion protection and chemical resistance on these components without the rigidity that would interfere with damping function. The coating flexibility accommodates the continuous movement and deformation that is the normal operating condition of these parts. All aerospace polymer coating work is documented under our AS9100 quality system.