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. Agricultural OEMs use distinctive brand colors across their equipment lines, and replacement or aftermarket components need to match. We capture your brand color standard by spectrophotometer and verify every production lot to Delta E 1.5. Cerakote's abrasion resistance of 4,000 cycles per mil and chemical resistance to fertilizers, herbicides, and UV exposure means your brand color survives field conditions that destroy conventional paint within a single growing season.
Additive manufacturing parts have inherent porosity, layer lines, and often thin-wall geometries that cannot withstand standard 80-100 PSI blasting. Our 40-60 PSI low-pressure blasting removes loose powder and partially sintered particles, reduces surface roughness peaks, and creates adequate anchor profile for Cerakote adhesion without distorting thin walls, collapsing lattice structures, or peening delicate features. This controlled approach preserves the geometric complexity that makes AM valuable.
Passivation is essential for stainless steel oil and gas components exposed to H2S, CO2, saltwater, and other corrosive media downhole and at the surface. The ASTM A967 process removes free iron that can initiate pitting and crevice corrosion in these aggressive environments. With no dimensional change, passivation preserves the sealing surfaces and thread tolerances that pressure-rated oil and gas hardware demands.
Additive-manufactured aluminum parts are especially vulnerable to corrosion due to their higher surface porosity compared to wrought stock. Chemical conversion coating per MIL-DTL-5541 creates a uniform protective layer that follows complex AM geometries without building thickness. Type I delivers 168-240+ hours of salt spray resistance (ASTM B117), and the sub-micron layer preserves the dimensional accuracy your additive process was designed to achieve.
Yes. We passivate aerospace stainless steel components to ASTM A967 and AMS 2700 specifications. The acid bath process removes free iron and surface contaminants, bringing chromium to the surface to form a robust passive oxide layer. There is no dimensional change, making passivation ideal for precision aerospace stainless parts. Our facility has processed over 20,000 parts with zero quality issues, including work spec-proven for major aerospace OEMs.