Weight Reduction for Aerospace
Precision Cerakote ceramic coatings for aerospace, defense, and industrial components.
The Weight Problem in Aerospace Coating
Where every gram compounds across a fleet
The challenge
Harsh environments demand coatings that hold.
The solution
ColoradoKote ceramic coating stops corrosion cold.
Why Cerakote for Aerospace Weight Reduction
Thin-film protection that preserves design intent
200-400g savings per part
Cerakote at 0.5-2 mils replaces powder coating at 3-5 mils, removing 200-400g of unnecessary coating weight from each component. Across thousands of parts per airframe, the cumulative savings translate directly to improved fuel efficiency and increased payload capacity.
Dimensional precision maintained
A 1 mil application adds only 0.001 inches per side, preserving interference-fit fastener dimensions and press-fit tolerances. Parts coat to specification without post-coating machining, eliminating a rework step that adds cost and lead time to aerospace production programs.
Full AS9100 traceability
Every coating parameter is documented per AS9100 requirements. Certificate of Conformance includes material batch numbers, DFT measurements, cure records, and inspection results. Weight calculations are recorded for each production lot, giving your engineering team verified data for airworthiness documentation.
Universal substrate compatibility
Cerakote bonds to aluminum, steel, titanium, Inconel, and polymer substrates. One thin-film coating system protects your entire parts portfolio regardless of alloy, simplifying supplier management and consolidating documentation across mixed-material assemblies.
Weight Reduction Specs for Aerospace
How We Deliver Weight Reduction for Aerospace
Thin-film application with full traceability from intake through inspection
Substrate-Specific Surface Preparation
Each aerospace alloy follows a tailored cleaning and profiling sequence. Aluminum, titanium, and steel substrates receive specific blast media and pressure settings to achieve optimal adhesion without removing base material. Masking protects critical threads, bearing surfaces, and mating interfaces identified on engineering drawings.
Controlled Thin-Film Application
Cerakote is applied via calibrated HVLP equipment targeting the 0.5-2 mil range. In-process DFT measurements confirm thickness at multiple points on each part, ensuring uniform coverage without excess buildup. Application parameters, including air pressure, spray distance, and layer count, are documented for traceability.
Curing, Verification, and Weight Documentation
Parts cure per the prescribed schedule in temperature-monitored ovens. Final inspection verifies coating thickness, adhesion per ASTM D3359, and visual appearance. Pre- and post-coating weight measurements are recorded on the Certificate of Conformance, providing your engineering team with verified weight data for fleet documentation.
Verified Weight Savings for Aerospace
Weight reduction claims are verified through gravimetric analysis and dry film thickness measurement on every production lot. AS9100 documentation captures pre- and post-coating weight, DFT readings, and dimensional data for your airworthiness records.
200-400g savings per part vs powder coating
At 0.5-2 mils versus 3-5 mils, each component carries a fraction of the coating weight while retaining 9H pencil hardness and chip resistance 2-3x superior to powder coating. Across fleet-scale production volumes, the cumulative weight savings reduce fuel burn and increase available payload.
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
Reduce Your Aerospace Coating Weight
Request a weight analysis for your aerospace parts. We respond within 24 hours with specifications.
Frequently Asked Questions
Find answers about our coating processes and technical capabilities
Raw AM parts typically exhibit Ra 8-15 micrometers depending on build orientation and process. Our post-processing sequence, controlled blasting at 40-60 PSI followed by Cerakote application at 0.5-2 mils, reduces surface roughness to below 3 micrometers. This transformation converts rough, porous AM surfaces into smooth, sealed, production-quality finishes with the added benefits of corrosion protection exceeding 3,000 hours salt spray and abrasion resistance of 4,000 cycles per mil.
Yes. Raw AM surfaces harbor bacteria in their inherent porosity and texture, making them unsuitable for clinical settings. Cerakote seals surface porosity and reduces roughness from Ra 8-15 micrometers to below 3 micrometers, creating a smooth, cleanable surface compatible with hospital disinfectants and autoclave sterilization. The sealed surface prevents microbial adhesion while the coating withstands thousands of cleaning cycles without degradation. This transforms AM builds into clinical-grade components.
Passivation per ASTM A967 is commonly applied to automotive stainless steel exhaust headers, downpipes, turbo housings, and performance hardware. The process removes free iron from welding and fabrication, restoring full corrosion resistance against road salt, moisture, and thermal cycling. For high-heat applications, pairing passivation with Cerakote adds thermal management properties and 3,000 hours of salt spray resistance at just 0.5-2 mils.
AM parts used in functional applications like jigs, fixtures, tooling, and end-use mechanical components benefit from Cerakote's 9H hardness and 4,000 cycles per mil abrasion resistance. The coating transforms the relatively soft surface of SLS nylon or the porous surface of metal AM into a hardened, wear-resistant finish. This extends the service life of AM production tooling and makes printed parts viable for high-wear applications.
Every polymer-coated medical device order ships with a Certificate of Conformance documenting the coating formulation, lot traceability, thickness measurements, adhesion test results, and visual inspection findings. Our ISO 9001:2015 quality system maintains controlled records supporting FDA 21 CFR Part 820 and EU MDR requirements. Polymer formulation identification and chemical resistance data are included to support your regulatory file for device clearance or approval submissions.