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
AS9100:2015 is the aerospace industry's quality management standard, requiring documented processes, lot traceability, corrective action protocols, and continuous improvement systems. ColoradoKote holds AS9100 alongside ISO 9001, ITAR registration, and Cerakote Advanced Applicator certification. This complete stack means your procurement team can qualify one vendor for ceramic coating, chemical conversion, and passivation instead of managing multiple suppliers.
Yes. Additive manufacturing excels at producing complex geometries like optimized flow paths, integrated mounting features, and weight-reduced structures that are impossible to machine conventionally. ColoradoKote's post-processing at 40-60 PSI preserves these complex AM geometries while adding the corrosion protection and surface quality maritime service demands. From custom hull fittings to sensor housings to drainage components, the AM-plus-Cerakote combination delivers marine-grade finished parts from digital designs.
Yes. Medical device OEMs often require precise brand color matching on instrument handles, device housings, and equipment panels. Our spectrophotometer-verified matching to Delta E 1.5 ensures your devices maintain consistent brand identity across production lots and reorders. Cerakote's durability through sterilization and clinical use preserves brand appearance far longer than paint or pad printing alternatives.
Downhole tools, valve trim, and pipeline fittings require tight tolerances for proper sealing and function under high pressure. Cerakote's 0.5 to 2 mil application preserves these critical dimensions while providing full corrosion and chemical protection. Thicker coatings like powder coat at 4 to 6 mils can interfere with seal surfaces, thread engagement, and bore clearances on precision oilfield equipment.
Passivation ensures the stainless substrate is clean and corrosion-resistant, while Cerakote provides a hard ceramic topcoat that resists scratching, abrasion, and impact. At 0.5-2 mils of Cerakote thickness, this stack handles wear far better than bare or passivated-only stainless while maintaining tight tolerances. For parts facing both corrosive environments and mechanical wear, this combination outperforms powder coating (4-6 mils) in both durability per mil and overall corrosion resistance.