Weight Reduction for Additive Manufacturing
Precision Cerakote ceramic coatings for aerospace, defense, and industrial components.
The Weight Problem in AM Post-Processing
Where thick coatings undo topology optimization
The challenge
Harsh environments demand coatings that hold.
The solution
ColoradoKote ceramic coating stops corrosion cold.
Why Cerakote for AM Weight Reduction
Thin-film protection built for printed geometries
200-400g savings per printed part
Cerakote at 0.5-2 mils replaces powder coating at 3-5 mils, preserving the mass savings that topology optimization and lattice structures deliver. On PA12 MJF brackets and metal AM housings alike, the thin film adds protection without measurable weight penalty relative to uncoated part weight.
Complex geometry conformance
Thin-film application follows lattice structures, conformal cooling channels, and topology-optimized features without bridging or material buildup. Internal passages remain open. Fine features remain defined. The coating conforms to the geometry rather than obscuring it, preserving the functional advantages of additive design.
Full AS9100 documentation for AM programs
Certificate of Conformance includes DFT measurements, material batch records, cure parameters, and pre- and post-coating weight data. Aerospace AM programs receive AS9100-compliant documentation with First Article Inspection reports available upon request. ITAR registration covers defense AM components.
Multi-material compatibility
One coating process covers PA12, PA11, glass-filled nylon, Ti-6Al-4V, AlSi10Mg, Inconel, and stainless steel. Mixed-material AM assemblies coat under a single work order with consistent thickness and weight documentation across all substrates, simplifying supply chain management for multi-material builds.
Weight Reduction Specs for AM Parts
How We Deliver Weight Reduction for AM Parts
Material-specific protocols that preserve printed geometry and minimize mass
Material Assessment and Surface Preparation
Each AM part is identified by substrate: PA12, PA11, Ti-6Al-4V, AlSi10Mg, or Inconel. Polymer parts receive low-pressure aluminum oxide blasting at 30-40 PSI to prepare the surface without distorting thin walls or lattice features. Metal AM parts receive tailored blasting to remove support structure witness marks. Ultrasonic cleaning follows to eliminate residual media.
Thin-Film Coating Application
Cerakote is applied via calibrated HVLP equipment targeting 0.5-2 mils. In-process DFT measurements confirm uniform thickness across complex geometry, including lattice openings and internal passages. Polymer parts cure at 250 F, below PA12 heat deflection temperature, to prevent warping. Metal AM parts follow standard cure profiles at 250-300 F.
Weight Verification and Documentation
Pre- and post-coating weight measurements quantify actual coating mass added to each part. CMM measurement confirms parts remain within the plus or minus 0.005 inch tolerance envelope. Before-and-after Ra measurements document surface finish improvement. Certificate of Conformance includes weight data, DFT readings, and dimensional verification.
Verified Weight Savings for AM Components
Weight reduction claims are verified through gravimetric analysis on every AM production lot. Pre- and post-coating measurements document the actual mass added by thin-film application, providing your engineering team with data for weight budgets and design validation.
200-400g savings per part vs powder coating
At 0.5-2 mils versus 3-5 mils, each topology-optimized component retains its designed mass advantage. For aerospace AM programs, this data feeds directly into weight and balance documentation. Surface finish improves from Ra 8-15 micrometers to under 3 micrometers simultaneously, delivering two outcomes in a single coating step.
Weight savings vs powder coating
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 AM Parts Without Adding Mass
Send part files for a weight analysis. We respond within 24 hours with coating specifications.
Frequently Asked Questions
Find answers about our coating processes and technical capabilities
Yes. ColoradoKote is registered with the Directorate of Defense Trade Controls (DDTC) under ITAR. Our facility, personnel, and processes meet all requirements for handling defense-related components and technical data. ITAR registration operates alongside our AS9100:2015 and ISO 9001:2015 certifications, so defense projects receive the same documented quality controls as our aerospace production work.
Yes. Multiple layers of marine paint, antifouling coatings, and zinc-rich primers create complex contamination that must be fully removed before applying new protective coatings. Ultrasonic cavitation assists chemical stripping by driving cleaning solution into the coating layer interfaces and substrate surface, ensuring complete removal of all old coating material. This thorough removal is critical because residual old coating prevents adhesion of the new Cerakote system and traps corrosion-initiating contaminants against the substrate.
Removing mill scale, oxide layers, and embedded contaminants through SP 10 blasting eliminates the corrosion initiation sites that undermine coating systems. The 2-4 mil anchor profile then maximizes Cerakote adhesion on the clean substrate. For industrial parts in chemical or marine environments, we recommend the full stack: blast preparation, chemical conversion or passivation where applicable, followed by Cerakote. This combination delivers salt spray protection exceeding 3,000 hours.
Yes. Abrasion resistance of 4,000 cycles per mil (ASTM D4060) and 9H pencil hardness (ASTM D3363) provide substantial protection against the grinding abrasion of soil, sand, and crop material on coulter blades, seed openers, ground-engaging tools, and conveyor surfaces. For high-wear components, the full stack of chemical conversion coating plus Cerakote maximizes adhesion so the coating stays bonded under sustained abrasive contact.
Yes. Some applications benefit from a polymer basecoat for flexibility and chemical resistance topped with Cerakote for hardness and abrasion protection. This multi-layer approach addresses applications where no single coating provides all required properties. ColoradoKote designs and applies these combined systems with documented process controls. The full stack, including surface preparation, polymer application, and Cerakote topcoat, ships with complete documentation under our AS9100 quality system.