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
Cerakote applies at 0.5 to 2 mils versus 4 to 6 mils for powder coat, reducing coating mass by 50 to 85 percent on a per-part basis. On aircraft with thousands of coated components, this difference translates directly to fuel savings over the life of the platform. The thinner film also preserves engineering tolerances on precision-fit parts where powder coat buildup would require masking or post-machining.
Clean substrate surfaces are the foundation for all downstream AM post-processing. Residual powder, oils from handling, and manufacturing residue create adhesion failures and surface defects in the finished coating. Ultrasonic cleaning integrated into the AM post-processing sequence, before blasting and coating, ensures every part starts from a verified-clean condition. This contributes to the consistent quality results that allow us to maintain our 20,000+ parts track record with zero quality issues.
Our ultrasonic tank accommodates parts ranging from small medical components and AM builds to mid-size aerospace brackets and industrial valve bodies. Parts are fixtured to ensure full submersion and cavitation coverage on all surfaces. For components too large for the ultrasonic tank, we use alternative precision cleaning methods to achieve equivalent cleanliness. Contact us with your part dimensions for a cleaning capability assessment.
Yes. Our spectrophotometer-verified color matching creates a documented color standard for your program that we reference on every production run. Delta E within 1.5 ensures parts coated today match parts coated months or years from now. This level of consistency matters for aircraft cabin interiors, branded equipment, and any application where batch-to-batch color variation is unacceptable.
We coat hydraulic cylinders, pump housings, valve bodies, bearing housings, gear assemblies, conveyor components, mixing equipment, and custom tooling. The same AS9100 and ISO 9001 process controls that govern our aerospace work apply to industrial projects, ensuring consistent coating quality regardless of application. Contact us with your component specifications for a technical assessment and quote.