AM Post-Processing for Aerospace
Precision Cerakote ceramic coatings for aerospace, defense, and industrial components.
Why Aerospace AM Parts Need Post-Processing
Raw AM finish does not meet aerospace standards
The challenge
Harsh environments demand coatings that hold.
The solution
ColoradoKote ceramic coating stops corrosion cold.
Why ColoradoKote AM Post-Processing for Aerospace
Production-grade finish with aerospace documentation
Ra below 3 micrometers from Ra 8-15
Cerakote fills micro-voids and smooths layer lines that define raw AM surfaces. Stylus profilometer verification confirms surface roughness reduction from Ra 8-15 micrometers to below 3 micrometers on both polymer and metal AM substrates. Vapor polishing and tumbling remove material to reduce roughness but do not add corrosion resistance, wear protection, or color. Cerakote delivers all four improvements in a single process step.
Dimensional tolerance preservation at 0.005 inches
Application at 0.5-2 mils adds only +0.001 to +0.002 inches per surface. CMM measurement before and after coating confirms tolerances within plus or minus 0.005 inches. This precision matters for aerospace AM brackets, ducts, and cabin hardware where fit and assembly tolerances are non-negotiable. Material-specific blast pressures, 40-50 PSI for PA12 and MJF nylon, 50-60 PSI for Ti-6Al-4V, prevent dimensional distortion during surface preparation.
AS9100 documentation for AM parts
ColoradoKote applies the same AS9100:2015 quality system to AM post-processing that governs traditional aerospace coating. Every part receives incoming dimensional verification, material confirmation, process parameter recording, and post-coating CMM measurement. Certificate of Conformance documents surface roughness data, dimensional verification, coating thickness, adhesion results, and complete traceability from receiving through shipment. ITAR registration covers defense AM applications.
Material-specific protocols for polymer and metal AM
PA12 and MJF nylon receive fine glass bead blasting at 40-50 PSI to create adhesion profile without damaging thin-walled structures. Ti-6Al-4V, AlSi10Mg, Inconel, and 316L receive aluminum oxide blasting at 50-60 PSI with cure profiles validated to prevent embrittlement. Each material class follows a documented preparation protocol. Pencil hardness reaches 8H-9H (ASTM D3363), and adhesion achieves 5B rating (ASTM D3359) across all AM substrates.
AM Post-Processing Specs for Aerospace
How We Post-Process AM Parts for Aerospace
Material-specific protocols with AS9100 documentation from intake through shipment
Aerospace AM Intake and Preparation
AM parts arrive with build material and process documentation (SLS, MJF, PBF-LB). Quantities are verified against the purchase order, and incoming condition is documented with photographs and build orientation data. Unfused powder is removed through compressed air blasting for polymer parts and ultrasonic cleaning for metal AM parts. Surface preparation follows material-specific protocols: PA12 and MJF nylon receive glass bead blasting at 40-50 PSI, while Ti-6Al-4V and metal substrates receive aluminum oxide blasting at 50-60 PSI. Post-blast CMM measurement verifies dimensional tolerances remain within plus or minus 0.005 inches.
Controlled Cerakote Application
Coating thickness is matched to the tolerance budget. Tight-tolerance aerospace parts receive 0.5-1.0 mil application, adding only +0.001 to +0.002 inches per surface. Cosmetic-priority cabin hardware receives up to 2.0 mils for maximum surface smoothing. Multiple thin coats prevent buildup on complex AM geometries. Climate-controlled spray booth monitors temperature and humidity throughout application. Parts cure at material-appropriate temperatures: 250-300 F for metal AM and lower profiles for polymer substrates to prevent thermal distortion.
Multi-Point Verification and Documentation
Every aerospace AM part undergoes coating thickness measurement (DFT gauge), adhesion testing per ASTM D3359 (5B rating target), surface roughness verification via stylus profilometer (target Ra below 3 micrometers), and color consistency check (spectrophotometer, Delta E ≤1). CMM dimensional verification confirms tolerance maintenance at plus or minus 0.005 inches. Certificate of Conformance documents all measurements with full traceability. PPAP and first article inspection reports are available upon request.
Proven AM Post-Processing for Aerospace
Surface finish improvement is verified through stylus profilometer measurement, not visual assessment. Every AM part receives quantitative Ra measurement before and after post-processing, documented under AS9100 controls on your Certificate of Conformance with full lot traceability.
Ra below 3 micrometers from Ra 8-15
Raw AM parts from SLS, MJF, and metal PBF-LB processes arrive with surface roughness between Ra 8-15 micrometers. After Cerakote post-processing, profilometer verification confirms Ra below 3 micrometers on both polymer and metal substrates. This surface finish improvement occurs while maintaining dimensional tolerances within plus or minus 0.005 inches, verified by CMM. Metal AM parts gain 3,000+ hours corrosion resistance (ASTM B117) in addition to the surface improvement. Capacity of 200 parts per week with standard 7-10 business day turnaround supports production-volume aerospace programs.
Micrometers surface roughness (from 8-15)
Other services to consider
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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
Get Your AM Parts Aerospace-Ready
Submit AM parts for evaluation. We respond within 24 hours with material-specific pricing.
Frequently Asked Questions
Find answers about our coating processes and technical capabilities
When a downhole tool or surface component fails, traditional manufacturing replacement can take weeks or months. AM production combined with ColoradoKote's expedited 3-day post-processing delivers finished, coated replacement parts in a fraction of that timeline. The combination of additive manufacturing flexibility and our controlled post-processing sequence, including corrosion protection exceeding 3,000 hours salt spray, means replacement parts meet the same performance standards as originally manufactured components.
The 2-4 mil anchor profile created by blasting gives Cerakote mechanical interlocking sites across the entire substrate surface. On wear components subject to sliding contact, impact, or particle erosion, this mechanical bond keeps the coating in place under forces that would delaminate a coating applied to a smooth surface. Combined with Cerakote's 4,000 cycles per mil abrasion resistance, proper blast preparation delivers maximum wear life.
Yes. Performance and racing applications frequently require custom team colors, sponsor colors, and distinctive finishes. We match any target color to Delta E 1.5 using spectrophotometer verification. Cerakote's thin-film application at 0.5-2 mils adds minimal weight while providing color durability that survives heat, vibration, chemical exposure, and track debris that would damage conventional paint. Custom color formulations are retained for reorder consistency across race seasons.
Color coding is widely used in medical devices for instrument identification, size differentiation, and sterile versus non-sterile designation. Cerakote provides durable color that withstands autoclave sterilization cycles without fading, chipping, or color shift. We match your specified identification colors to Delta E 1.5 and verify consistency across production lots so that color-coded instruments remain reliably identifiable throughout their service life.
Yes. Beyond autoclave steam cycles, medical devices face chemical sterilization with glutaraldehyde, peracetic acid, hydrogen peroxide, and enzymatic cleaning solutions. Cerakote's ceramic-polymer matrix resists this chemical exposure without softening, delamination, or color shift. For AM parts with their inherent surface porosity, the sealed Cerakote barrier also prevents sterilization chemicals from penetrating into the substrate, which would create contamination concerns on subsequent patient contact.