Can You Powder Coat Over Powder Coat?

Powder coating applies a consistent layer to the surface of furniture, automotive parts, and other objects to improve wear resistance and corrosion resistance. The coating is then heated in a UV or conventional oven to melt and cure the powder for a protective finish.

This process results in a durable, smooth, and beautiful finish that can last years with proper maintenance. Over time, fading and chipping can compromise the coating, necessitating professional assistance. The process typically involves removing the previous layer and applying a fresh coat. 

Stripping the damaged layer is preferable because it creates a better bond and smoother finish. It also reveals any issues with the underlying material, such as wear and corrosion. Powder coating over powder coat can be a practical option if the previous coating is smooth and free of defects or damage.

Can You Powder Over Powder Coat?  

Re-powdering can be a low-effort way to refresh the performance and look of worn-out items. Powder coating on powder coat is possible as long as the new powder can bond with the old coat based on its chemical structure. When determining whether to recoat over an existing finish or strip the old layer, consider these factors:

• Surface integrity: If the existing coating has no defects, you may be able to recoat over the top of the existing finish.
• Compatibility of the powder coats: The old and new powder coating should properly adhere for a proper finish.
• Quality of the powder coat: Both the powder coatings should be of high quality to avoid over-layering, which can lead to cracking and poor adhesion.
• Environmental factors: If the items are exposed to weather elements and chemicals, stripping away the old layer and recoating will offer better protection.
• Costs: Weigh the price of recoating against future repair and recoating issues.

In cases where the existing coat is damaged or incompatible with the new powder, stripping the old coating to start with a clean surface helps you achieve a fresh, uniform, and durable finish. Minor imperfections in the existing coat can be touched up with painting, though the paint may cause bonding issues. It is a cost-effective approach suitable for localized problems to preserve the original coating’s integrity.

Note that you cannot use powder coating to touch up only a small part of a surface since it must be applied all at once to the entire object. There’s no way to address specific spots because lines would be visible where the touch-up was applied. 

Preparation for Powder Coating Over Powder Coat

Proper surface preparation ensures the coating’s longevity and effectiveness as a protective barrier. Cleaning, degreasing, roughening, and treatment help achieve adequate adhesion:

• Ensure the existing coating can tolerate high temperatures in the curing oven.
• Examine the object for imperfections such as chipping and bare patches.
• Use a gentle solvent to clean the surface to remove dirt, dust, oils, and other contaminants that might affect adhesion.
• Scuff the surface to texture or profile the old finish and create a better surface that helps your new powder coat adhere.
• Place the parts in an oven to outgas, which eliminates trapped moisture and volatile substances that could cause defects like pinholes or poor adhesion in the final coating.  

Application Process

Powder coating over an old layer should be done by professionals who have experience and specialized tools to perform the job efficiently. They will be able to assess the adhesion, quality, and color of the new coat on top of the old one.

Application using an electrostatic spray gun ensures a uniform finish. After application, the object is transferred into an oven for curing. Heat melts the powder so it flows and bonds evenly with the substrate. 

To apply powder over existing paint, adjust the setting on the equipment to a lower KV setting than the one used on a new product surface. You may also have to increase the amount of powder to ensure the surface is fully covered for a uniform finish.

Benefits of Powder Coating Over Powder Coat 

Recoating with a powder coat can be a quicker and more cost-effective process than stripping and reapplying. Powder coating is resistant to fading, chipping, scratching, and wear. It is an ideal option for objects that are constantly exposed to sunlight, humidity, and other environmental factors. Parts for farm equipment, exercise equipment, vehicle bumpers, marine equipment, and railings can maintain their finish for a long time.

Powder coating has a long shelf life and uses fewer raw materials and equipment, lowering costs. The application process doesn’t produce much waste, and the powder can be reclaimed and reused, saving you costs. The process of powder coating is faster than other painting methods as there is no waiting time for drying. Recoating offers the flexibility of switching colors and finishes without a lengthy process. 

Achieve Superior Finish With EpiX MP

EpiX superoxalloy has smaller and tougher abrasive particles to produce a clean, uniform finish in one step without scraping or harsh chemicals. At 10X Engineered Materials, our superoxalloy abrasives deliver exceptional surface quality at higher production speeds. They increase safety and minimize material use for blasting operations, making them a more practical, cost-effective, and sustainable solution than traditional sandblasting media.

Talk to our experts today to learn which blasting product is suitable for your application.