Powder Coating Services for Durable, High-Quality Finishes
Cusack Electronics delivers professional powder coating services for metal fabrications, enclosures, brackets, and product assemblies. Our electrostatic spray application and controlled cure cycles produce corrosion-resistant finishes across aluminum, steel, stainless steel, and galvanized steel with precise color matching and consistent film thickness. From smooth gloss to textured matte, we coat parts that perform in demanding environments.
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Who We Are
Built for Durability and Precision Color Matching
Our powder coating services support product teams and manufacturers who need protective, professional finishes without managing their own coating line. From single prototypes to production batches, we coat brackets, panels, enclosures, chassis, frames, and finished assemblies using electrostatic spray application, controlled pre-treatment, and calibrated cure cycles that deliver consistent adhesion, film thickness, and color across every part.
- Electrostatic spray application with corona charging and fluidized bed backup for complex geometries, ensuring even coverage on recessed areas, edges, and multi-sided parts.
- Pre-treatment protocols including sandblasting, iron phosphate, and zinc phosphate conversion coatings that promote adhesion and corrosion resistance per ASTM D3359 and ASTM B117 salt spray standards.
- Thermosetting epoxy, polyester, polyurethane, and hybrid powder coatings formulated for UV resistance, chemical resistance, impact resistance, and weathering performance across indoor and outdoor applications.
- Custom color matching to RAL, Pantone, or sample with gloss, semi-gloss, matte, textured, metallic, and wrinkle finish options verified through spectrophotometry before production coating.
Our Services
Complete Powder Coating Capabilities
Every finish you need, applied to specification and delivered ready to assemble. From industrial epoxy coatings to architectural-grade polyester, our custom powder coating services handle the full range of protective and decorative finishing operations.
Electrostatic Powder Application
Corona charging and tribo charging electrostatic spray systems apply thermosetting and thermoplastic powder to flat, cylindrical, and complex geometries. Fluidized bed coating handles high-volume small parts with consistent film build and minimal overspray waste.
Altium Designer
KiCad
BLE / WiFi
Eagle CAD
IoT Ready
Multi-Layer
Custom Color Matching
Spectrophotometry-based color matching delivers custom formulations to RAL, Pantone, or physical sample with delta E verification before production. Metallic, candy, textured, and solid color options across gloss levels from 5 to 95 GU measured with a gloss meter.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Industrial Powder Coating
Heavy-duty epoxy and epoxy-polyester hybrid coatings engineered for corrosion resistance, chemical resistance, and impact resistance in industrial environments. Formulations meet AAMA 2603 and salt spray resistance per ASTM B117 for outdoor equipment and harsh service conditions.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Architectural Metal Coating
Super durable polyester and TGIC-free polyester coatings formulated for UV resistance, color retention, and gloss retention per AAMA 2604 and AAMA 2605 specifications. Meets Qualicoat and GSB International standards for architectural aluminum and commercial facades.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Surface Preparation & Pre-Treatment
Sandblasting, media blasting, and chemical cleaning remove oils, oxides, and contaminants. Iron phosphate and zinc phosphate conversion coatings create a crystalline surface profile that promotes crosslinking and adhesion during the cure cycle, verified through cross-hatch adhesion testing per ASTM D3359.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Masking & Selective Coating
High-temperature silicone plugs, tapes, and custom fixtures mask threads, holes, mating surfaces, and critical dimensions. Selective coating protects areas requiring bare metal contact, grounding paths, or post-coating machining without impacting cycle time.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Controlled Curing Cycles
Convection ovens and infrared ovens calibrated to manufacturer-specified cure schedules ensure complete crosslinking and flow-out. Peak metal temperature monitoring and dwell time control deliver consistent film properties, hardness per ASTM D3363, and flexibility per bend test protocols.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Film Thickness Measurement
Mil gauges and micron gauges verify dry film thickness across critical surfaces, ensuring coverage meets 2 to 4 mil specification on functional parts and 1.5 to 3 mil on decorative assemblies. Documented inspection supports traceability and quality requirements.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Integrated Coating Workflow
Parts move from CNC machining, wire harness assembly, or product assembly directly into our powder booth without leaving the facility. Single-source accountability eliminates handling damage, shipping delays, and vendor coordination while protecting finish quality.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Our Process
From Bare Metal to Finished Coating in Five Steps
A structured coating process designed to deliver durable, consistent finishes with full traceability and no surprises between quote and final inspection.
01
Submit Your Parts
Send CAD files, samples, or finished parts with color specification (RAL, Pantone, or sample), finish type (gloss, matte, textured), quantity, and application requirements. We review substrate material, geometry, and masking needs.
02
Color Matching & Sample Approval
Custom colors are formulated and verified through spectrophotometry. Sample panels are coated and cured to specification, then shipped for approval before production coating begins, ensuring exact color and finish match.
03
Surface Preparation & Masking
Parts are cleaned prior to coating. Threads, holes, and critical surfaces are masked with high-temperature plugs and fixtures.
04
Electrostatic Application & Curing
Thermosetting powder is applied via electrostatic spray with controlled film thickness. Parts enter the convection oven where calibrated cure cycles achieve crosslinking, flow-out, and peak metal temperature per powder manufacturer specifications.
05
Inspection & Delivery
Film thickness is measured with mil gauges, adhesion is verified through cross-hatch testing per ASTM D3359, and visual inspection confirms uniform coverage and color. Parts ship with coating certifications and full traceability documentation.
Technical Specifications
Design Capabilities at a Glance
PCB & Electronics Design Specs |
|
|---|---|
| Machining Envelope | Up to 40" × 20" × 20" (VMC), 60" × 30" × 30" (HMC) |
| Minimum Tolerance | ±0.001" (0.0254mm) standard, ±0.0005" (0.0127mm) on request ±0.001" (0.0254mm) standard, ±0.0005" (0.0127mm) on request |
| Surface Finish | Ra 32 μin standard, Ra 16 μin or better achievable |
| Hole Diameter Range | 0.040" to 4.000" with drill bits, reamers, and boring bars |
| Thread Sizes | #2-56 through 1"-8 UNC/UNF, metric M2 through M24 |
| Materials Supported | Aluminum, steel, stainless, titanium, brass, copper, plastics |
| Axis Configuration | 3-axis, 4-axis, 5-axis milling |
| Batch Sizes | 1 piece prototypes to 10,000+ production runs |
| Inspection Equipment | CMM, optical comparator, micrometers, calipers, profilometer |
| Standards Compliance | ISO 2768, ASME Y14.5, ISO 1302 |
Why Cusack Electronics
What Sets Our Powder Coating Services Apart
The advantages of working with a coating shop that treats powder coating as part of a complete product development and manufacturing workflow, not a standalone finishing service.
Same-Day Turnaround Available
Rush powder coating services deliver single parts and small batches in 24 to 48 hours. Standard production runs ship in 3 to 5 business days with no minimum order quantities, supporting tight timelines without premium pricing.
Custom Color Matching Expertise
Our spectrophotometry system formulates custom colors to exact RAL, Pantone, or sample specifications with delta E verification. Metallic, candy, and textured finishes are dialed in before production coating to eliminate rework and delays.
Prototype to Production Continuity
Start with sample coating and color approval, refine the finish, then scale directly into low-volume or high-volume production with the same powder formulation, cure cycle, and quality standards already validated.
Integrated Manufacturing Workflow
Powder coating services integrate with CNC machining, wire harness assembly, UV printing, and full product assembly in the same facility, eliminating shipping damage, finish contamination, and handoff delays between vendors.
No Outgassing or Blistering
Pre-treatment protocols and controlled cure cycles prevent outgassing, blistering, and adhesion failure on castings, welded assemblies, and porous substrates. Parts are inspected before coating to catch surface defects early.
Full Testing & Documentation
Film thickness measurement, cross-hatch adhesion testing per ASTM D3359, impact testing per ASTM D2794, and salt spray testing per ASTM B117 are available on request with certificates of conformance supporting ISO and customer-specific quality systems.
Common Powders
List of Stocked Powder Coats
We partner with Prismatic Powder Coats to help deliver you with the best polyester powder coat colors.
Popular options include:
Black - Textured Satin
PTB-7102 ($)
Our most popular black, looks great on every substrate.
Black - Stone Matte
PSS-1168 ($)
For a smoother finish, but without the gloss.
Black - VW Gloss Metal Flake
PMB-2650 ($)
High gloss option with metallic flakes.
White - Strikers Textured Matte
PTS-4310 ($)
Our white with a light textured surface.
White - Watson Semi-gloss
PSB-6649 ($)
Medium white with a solid tone.
Yellow - Canary Satin
PRB-6119 ($$)
Bright yellow with a mild texture.
Yellow - Tomic Gold II
EMB-4448 ($$)
Medium gold with a heavy metal flake.
Yellow/Orange Royal Gold
PMB-5742 ($$)
Yellow/orange with a pearlescent finish. Semi-gloss.
Red - Fire Engine Satin
PMB-5938 ($$)
Soft fire engine red color with a satin finish.
Red - Pearl Vein
PVB-6459 ($$)
Vein powder coat with a semi-gloss finish.
Red - Soft Candy
PPS-2888 ($$)
Candy Red top coat with high-gloss finish.
Pink - Matte
PSB-6357 ($$)
Slightly textured matte pink coat with a semi-gloss finish.
Purple - Grape Slurpee
PMB-6717 ($$)
Rich metallic purple with a matte finish.
Blue - Playboy
PSS-1715 ($)
Dark sky blue with high-gloss finish.
Blue - Brunken
PMB-1185 ($$)
Medium blue with heavy metallic coat and a glossy finish.
Blue - Colonial
PSB-4813 ($)
Blue/gray with a satin finish.
Gray - Teridium Texture
PTB-6696 ($)
Steel gray with a medium texture.
Gray - Weston
PMB-1776 ($$)
Dark metallic gray with a semi-gloss finish.
Gray - Baltic Silver
PMB-4866 ($$)
Silver metallic with a satin finish.
Gray - Porsche Silver
PMS-0439 ($$)
Silver metallic with a glossy finish.
Green - E.C.S
PSB-5674 ($$)
Pea green with a satin finish.
Green - Tango
PMB-4752 ($$)
Gright green metallic with a heavy silver flake and a high gloss finish
Green - Mallard
PSB-5606 ($$)
Deep teal green with a solid glossy finish.
Green - Satin China Mint
PSB-10166 ($$)
Mint green with a satin finish.
Common Enclosures
List of Stocked Enclosures
Choose from one of our many stocked Hammond style diecast aluminum enclosures, or inquire about having us powder your custom enclosure.
1590A
3.65 in x 1.52 in x 1.22 in
(93 mm x 39 mm x 31 mm)
1590B
4.43 in x 2.38 in x 1.22 in
(113 mm x 60 mm x 31 mm)
125B (1590N1)
4.78 in x 2.6 in x 1.54 in (121.3mm x 66mm x 39.2mm)
1590BB
4.7 in x 3.7 in x 1.34 in
(119 mm x 94 mm x 34 mm)
1590BBS
4.7 in x 3.7 in x 1.66 in
(119 mm x 94 mm x 42 mm)
1590XX
5.7 in x 4.72 in x 1.54 in
145mm x 120mm x 39mm
Markets We Serve
Industries We Design For
Professional Audio
Industrial Automation
IoT & Connected Devices
Consumer Electronics
Automotive & Motorsport
Test & Measurement
Featured Projects
Ready to Design & Build Your Next Product?
- Free initial consultation, no obligation
- NDA available for IP protection
- Prototype to production, all under one roof
- 100% USA designed & manufactured
Common Questions
Frequently Asked Questions
What powder coating services do you offer?
We offer electrostatic spray powder coating for metal parts and assemblies using thermosetting epoxy, polyester, polyurethane, and hybrid powder formulations. Our custom powder coating services cover gloss, matte, textured, metallic, and wrinkle finishes with custom color matching to RAL, Pantone, or sample.
What materials can you powder coat?
Aluminum, steel, stainless steel, galvanized steel, cold-rolled steel, hot-rolled steel, cast iron, zinc-plated parts, and MDF (medium-density fiberboard). Non-conductive substrates require special pre-treatment or alternative coating methods.
How durable is powder coating compared to wet paint?
Powder coating delivers superior impact resistance, abrasion resistance, corrosion resistance, and UV resistance compared to wet paint. Thermosetting powder crosslinks during the cure cycle, creating a harder, more chemically bonded film that resists chipping, fading, and chemical exposure.
What colors and finishes are available?
We stock 1000+ standard RAL colors and can custom-match any Pantone, RAL, or physical sample. Finish options include high-gloss, semi-gloss, matte, textured, metallic, candy, wrinkle, hammer tone, and clear coat with gloss levels from 5 to 95 GU.
Do you offer custom color matching?
Yes. Our spectrophotometry system formulates custom colors with delta E verification to ensure exact match. Sample panels are coated and shipped for approval before production coating begins, eliminating color variation and rework.
What is your lead time for powder coating?
Rush service delivers single parts and small batches in 24 to 48 hours. Standard production runs (10 to 100 pieces) ship in 3 to 5 business days. High-volume production is quoted based on quantity, masking complexity, and cure schedule.
Can you coat parts that need masking or selective coating?
Yes. We mask threads, holes, mating surfaces, grounding paths, and critical dimensions using high-temperature silicone plugs, tapes, and custom fixtures. Selective coating protects areas requiring bare metal contact or post-coating machining.
What testing and certifications do you provide?
Film thickness measurement, cross-hatch adhesion testing per ASTM D3359, impact testing per ASTM D2794, salt spray testing per ASTM B117, and hardness testing per ASTM D3363. Certificates of conformance support AAMA 2603, AAMA 2604, AAMA 2605, Qualicoat, and customer-specific quality requirements.
Do you handle pre-treatment and surface preparation?
Yes. Every part is sandblasted or media blasted to remove oils, oxides, and contaminants, then treated with iron phosphate or zinc phosphate conversion coating to promote adhesion and corrosion resistance. Pre-treatment is included in our powder coating services.
Can you integrate powder coating with other manufacturing services?
Yes. Parts move from CNC machining, wire harness assembly, or product assembly directly into our powder booth without leaving the facility. Integrated workflow eliminates shipping damage, finish contamination, and vendor coordination while compressing lead times.