The rack-spray method involves hanging or placing a part on a fixture and then spraying the coating utilizing either electrostatic guns, HVLP guns, or a combination of both. Parts most suited for rack-spray are flat or nearly flat components (like washers which can stick together in bulk applications, metal stampings with recessed pockets where coating could pool if bulk processed, components that can become tangled or distorted when bulk processed (like snap rings or wire forms), heavy components, and anything that requires masking.
The Pro: A nice, cosmetic finish
The Con: Only covers surfaces reachable by the spray
Dip-spin works kind of like a washing machine—only we’re using coating instead of water. Usually priced by the pound, in a dip-spin, bulk application coating process parts are dumped into a perforated basket and immersed into a coating. The basket is then raised from the vat and spun at a high RPM, which removes any excess coating with centrifugal force. The parts are then cured, and the process is repeated as needed depending on the coating recipe or thickness requirements.
The Pro: Coverage over every exterior surface
The Con: A rougher finish
Important Note: In almost every case, dip-spin pricing is less expensive than a rack-spray price. However, this is true if you take the dip-spin pricing vs the rack-spray pricing at face value only. When taking into account the cost of poor quality (COPQ) of a dip-spin application for certain parts, rack-spray pricing could end up more advantageous in the long run.
The Best of Both
There are certain cases where a component would benefit from both rack-spray and dip-spin processes—giving the component full coverage on every surface, no matter how complex its geometry. Some may see this as overkill – and on most products, it probably would be – but certain products, especially premium products, could benefit from this double process.
At DECC, we’ve recommended both dip-spin and rack-spray processes more than a few times with amazing results. And as far as we know, we’re the only company that provides this approach at this time.
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