In the world of metal fabrication, finishing processes like powder coating and screen printing can make a huge difference in both the aesthetics and durability of products. But what exactly are these processes?
Powder Coating
At its essence, powder coating is all about particle behavior. Here's a more in-depth look:
- Electrostatic Charge: Using an electrostatic gun (or corona gun), a positive electric charge is imparted to the powder particles. This charge ensures the powder adheres to the grounded metal piece, optimizing coverage and minimizing waste.
- Curing Process: Once coated, the metal enters an oven. The heat causes the powder particles to melt, flow, and chemically react to form long molecular chains. This polymer structure gives the coating its durability and resilience.
- Finish Varieties: Powder coatings aren't one-size-fits-all. From matte to high-gloss, textures to metallics, and even anti-graffiti coatings, the possibilities are vast. The choice depends on both aesthetics and functionality. For instance, a rough texture might be chosen for its anti-slip properties.
Mika Metal Fabricating takes pride in its state-of-the-art equipment, ensuring precision and quality in every project. With two Nordson Spray Booth Systems measuring 7.5’ x 7.5’ x 7.8’, and another two at 6’ x 6’ x 7.2’, we can accommodate various project sizes. These booths are complemented by three Jensen Batch Ovens and one Ace 161FM Burn-Off Oven. Mika employs a Nordson Encore Manual Powder Coating Spray Gun System, which ensures uniform and efficient powder application.
Mika can shoot a diverse range of powder-coating shades, some of which we conveniently have in stock. Have a specific hue, gloss, or finish in mind? Don’t hesitate to contact us—we are happy to accommodate your needs. Moreover, thanks to our collaborations with top-tier manufacturers, we have the expertise to match your provided RAL or even a custom color.
When it comes to masking, we don't just see it as a task, but an art. Whether your project requires straightforward or intricate masking, Mika's team is adept at handling every specification according to your prints. 
Powder coating, though transformative, does come with its set of challenges. It's common to face issues like hook marks (Fig. 1), runs and sags (Fig.2), pinholes (Fig.3), batch color variations, problematic edge breaks (Fig. 4) and unwarranted paint buildup (Fig. 5). Such setbacks can negatively affect cosmetically critical surfaces and worse, may cause paint to flake, allowing moisture and other environmental elements to seep in and cause rust and corrosion. Rest assured that with Mika at the helm, such concerns are significantly curtailed. Our seasoned team leans on years of experience to provide a flawless finish that will last for years to come.
Fig. 1 Example of hook mark Fig. 2 Example of paint sags Fig. 3 Example of pinholes
Fig. 4 Example of edge break Fig. 5 Example of paint build up
Screen Printing
Screen printing on metal surfaces has its own set of nuances:
- Mesh Selection: The mesh screen's density influences the amount of ink deposited. A tighter mesh offers finer detail, while a more open mesh delivers a thicker ink layer. The ink's viscosity also plays a role, with thicker inks often requiring more open meshes.
- Ink Choices: Depending on the end-use, different ink formulations might be chosen. UV-cured inks, for example, offer quick drying through exposure to UV light, while epoxy-based inks are chosen for their extreme durability.
- Post-Printing Curing: This is where screen printing gets its longevity. The ink, after being laid on the metal (especially post-powder coating), is cured, typically using heat. This not only dries the ink but also binds it to the surface, ensuring resistance to wear, chemicals, and environmental factors.
We go above and beyond to ensure your brand stands out. Our screen-printing process involves applying anything from simple product identification to intricate logos after the powder coating, which are then baked in ovens.
This ensures the vibrancy and longevity of your logos and designs in a way that stickers, decals or mylar overlays may not. Plus, with Pantone (PMS) Color Matching available, you can be confident that your brand's colors will be accurately represented.
Discover the Mika difference today
Founded on the principles of quality, precision, and dedication, Mika Metal Fabricating has long been a trusted name in the metal fabrication industry. With advanced equipment and a skilled team, we’ve been delivering top-tier services to clients across various sectors since 1939. Whether your bespoke project is a simple part or a complex assembly, Mika has the expertise and equipment to bring your vision to life.
Beyond our technical prowess, what sets Mika apart is our commitment to client satisfaction. From the initial consultation to the final product delivery, Mika ensures transparency, timeliness, and top-notch quality. The modern business landscape is rife with challenges, one being vendors who remain unresponsive or evasive. Mika challenges this norm, ensuring prompt and clear communication, be it feedback on RFQs, updates on project statuses, or clarifications on technical intricacies.
Navigating the nuances of metal fabrication requires a reliable partner, one that combines technical expertise with a keen understanding of modern business dynamics. Mika Metal Fabricating embodies this blend. Whether you're new to the field, reassessing vendor relationships, or simply aiming for the best, Mika offers unmatched service quality, underpinned by transparency and dedication.
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https://blog.mikafab.com/en-us/sheet-metal-fabricating-101-7-quick-part-design-tips
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