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
Standalone ultrasonic cleaning turnaround is typically 3-5 business days from receipt of parts. Cycle time per batch is 10-30 minutes depending on contamination severity, but turnaround includes intake, pre-assessment, cleaning, verification, and documentation. For parts proceeding to coating, cleaning is integrated into the coating schedule and does not add separate lead time. Contact us at 970.541.7331 for current scheduling availability.
We use a multi-method verification approach. Water-break testing confirms DI water sheets uniformly across surfaces with zero beading, verifying the absence of oils and films. White-glove inspection checks for particulate transfer. For critical aerospace applications, dyne pen testing measures surface energy against your specified threshold. Rinse water conductivity is verified below 10 microsiemens per centimeter. Parts that fail any verification step are re-cleaned before release.
Yes. While ultrasonic cleaning is frequently performed as surface preparation before coating application, we also provide it as a standalone precision cleaning service. Standalone cleaning orders receive the same AS9100 process controls, documentation, and verification as cleaning performed before coating. Parts are returned clean with a Certificate of Conformance documenting all cleaning parameters and verification results.
Ultrasonic cavitation removes machining fluids, cutting oils, coolant residue, fingerprint oils, mold release agents, flux residue, carbon deposits, embedded particulates, and additive manufacturing support material. The cavitation action reaches contaminants in blind holes, internal passages, threads, and lattice structures that manual cleaning and spray methods cannot access. Solution chemistry is selected based on the specific contamination type and substrate material.
No. Ultrasonic cavitation is a non-contact cleaning method that does not mechanically abrade or distort parts. Cleaning solution chemistry is matched to the substrate material to prevent chemical attack. Alkaline solutions are used for aluminum, neutral formulations prevent hydrogen embrittlement on titanium, and polymer-safe solutions protect additive manufacturing parts. We have cleaned parts with wall thicknesses under 0.5mm without damage or dimensional change.