Powdertech Surface Science

INTRICOAT powder coating at SubCon 2023, June 7-8, NEC

Powdertech Surface Science — 03/05/2023

Precision powder coating and masking for exquisitely machined components

We will be showcasing INTRICOAT on our stand (G120) at SubCon 2023 and look forward to meeting machinists and OEM’s keen to discover this service.

The ability and willingness to powder coat at very low volumes has always been an important aspect of the Powdertech Surface Science service offering. High-end intricately machined devices are often produced in small quantities and require delicate handling and highly accurate masking schemes - hence our separated room for this work. We also like to assist companies making prototype parts who want the best possible surface treatments and metal finishing at this stage of their R&D work.

The care and attention our INTRICOAT team pays to their work creates an exceptional finish. We like to say that INTRICOAT is founded in science and applied as an art.

SubCon 2023 gives us a great opportunity to talk to customers and potential customers face-to-face, answering their questions and explaining in detail exactly what this service offers. We will have the MUOV TiltBike on show as well - displaying INTRICOAT work completed recently for a happy customer.

Powdertech Joins Community of Modern Manufacturers

Powdertech Surface Science — 21/11/2022

Made in the Midlands is delighted to announce Powdertech Surface Science as a member of the group. After being recommended to join the group by fellow member RSD Pressings, Powdertech decided to join the organisation to be part of a community of forward-thinking manufacturers within a modern trade association that emits a positive environment.

Powdertech, based in Bicester, brands itself as the most technically advanced aluminium coating and surface treatment provider in the UK. Supplying exclusively to UK customers, the firm designs and delivers precision powder coating services to leading manufacturers in automotive, medical, aircraft interiors and other specialist sectors. Utilising their decades of expertise, the Powdertech team also works with OEM and Tier 1 companies in research projects, developing and improving coating and joining systems. Powdertech is always happy to advise on powder coating services and works closely with customers to find optimal solutions.

James Grant, Powdertech Director, said that the company had joined other trade bodies in the past but had not felt they were quite as dynamic as Made in the Midlands. James is impressed by the sleek, user-friendly member microsites that link to the Made in the Midlands domain which itself ranks at the top of Google searches for Midlands’s manufacturing. The bi-weekly virtual breakfast mornings, giving members the opportunity to network, hear best practice from leading businesses and join 30-minute roundtables on relevant topics are seen as very constructive.

James said:

“Powdertech is looking forward to connecting with industry leaders at events, especially building relationships with precision machinists and gaining industry insight from businesses big and small. Made in the Midlands is clearly well connected with the manufacturing industry, helping businesses to link up, find opportunities and share industry insight. This is perfect for Powdertech as we place a lot of value on collaboration and long-lasting customer relationships.”

Find out more about Powdetech by clicking the link:https://powdertechsurfacescience.madeinthemidlands.com/

Powdertech exhibiting & speaking at Southern Manufacturing & Electronics Expo 2026

Powdertech Surface Science — 13/01/2026

Powdertech Surface Science, experts in surface treatment (TiZr coating) and powder coating of high-value aluminium components, will be exhibiting and presenting at Southern Manufacturing & Electronics (SME) 2026, taking place on 3rd–5th February 2026 at the Farnborough International Exhibition Centre. Stand E190, between 9:30 am and 4:30 pm each day. Get your free ticket for the Southern Manufacturing & Electronics Expo, 2026

Powdertech’s seminar at SME 2026 – ‘Design your finish at the start’.

A checklist, before you begin coating, one that is tailored as per your component and its end use.

Seminar Presentation: ‘Design your finish at the Start with INTRICOAT’.
On 3rd February 2026, Powdertech’s Technical Manager, Dr. Nick Welton, and Marketing & Sales Manager Jimmy Phillips will deliver a seminar titled ‘Design your finish at the Start with INTRICOAT’.

The session will explore how picking up design, material, or finishing challenges early on means fewer rejects and fewer production delays, saving cost and time, and achieving your desired surface finish right the first time!

Meet the Powdertech team

Powdertech's team, including Managing Director James Grant, Jimmy Phillips, Vrinda Gupta, and Head of INTRICOAT, Ian Manning, will be on stand E190 to discuss surface treatment challenges, share insights, and demonstrate our commitment to delivering high-quality, precision finishes for your aluminium components.

INTRICOAT (precision powder coating) service has been developed specifically for precision masking and powder coating of complex machined components, delivering defect-free finishes even on the most intricate geometries.

Through over 40 years of expertise in powder coating and surface treatment, Powdertech understands the increasing complexity of machined components in the UK.

Powdertech Surface Science exhibiting at Manufacturing Solutions UK 2025

Powdertech Surface Science — 21/02/2025

Powdertech Surface Science will be exhibiting its INTRICOAT service for high-value machined components at Manufacturing Solutions 2025, at Yamazaki Mazak UK, Worcester on 26 February

Manufacturing Solutions 2025 is an event from UK machinists' trade associations GTMA - Manufacturing Resource Centre and The British Turned Parts Manufacturers Association.

Marketing and Sales Manager Jimmy Phillips, who will be representing Powdertech at the event, said:

“We meet several machinists at events who are looking for a partner who will take the masking and coating of components as seriously as they take the design and machining of them.

“That’s why we developed INTRICOAT, to deliver the quality needed by machinists and their customers.”

What makes INTRICOAT stand out?

Powdertech Surface Science has developed INTRICOAT for high quality aluminium components that have intricate design requiring precision CAD masking schemes and powder coating.

Powdertech has invested in a dedicated separate facility, located within their plant, to be used exclusively for handling small and advanced-designed components. INTRICOAT focuses on high degree of detail, accuracy and flawless surface finish that led Powdertech to partner with leaders in the aviation, medical, and sports sectors.

Check Powdertech's Youtube video to understand the INTRICOAT process -

Visit Powdertech stand B12 on 26th February at Yamazaki Mazak UK Ltd, Worcester from 9:00 am to 3:00pm to discuss how INTRICOAT can offer a beautiful, durable finish for your expertly designed and engineered aluminium components. You can register here: https://lnkd.in/dRu3zTU8

Won't be attending?
Connect with Powdertech’s Marketing and Sales manager Jimmy Phillips to discuss your requirements.
Or contact us at https://lnkd.in/gzscyaJW

Powdertech Surface Science exhibiting and speaking at Southern Manufacturing & Electronics event, 2025!

Powdertech Surface Science — 13/01/2025

Powdertech Surface Science has been invited to exhibit their expertise in surface treatment and powder coating of high-value aluminium products at the Southern Manufacturing & Electronics event, 2025!

Through 40 years of experience in powder coating and surface treatment, Powdertech understands the increasing complexity and artistry of machined components in the UK and has developed INTRICOAT for precision masking and powder coating of complex machined components.

At the Southern Manufacturing & Electronics event, Powdertech Surface Science is exhibiting with team members on hand to discuss how INTRICOAT provides an advanced solution for your high-value intricate aluminium components.

Powdertech’s Technical Manager, an expert in commercial aluminium surface treatment Dr. Nick Welton, and Jimmy Phillips, the Marketing and Sales Manager at Powdertech are delivering a seminar, during day one of the show. The talk, titled ‘Design your finish at the start’, will focus on how to design your component and specification to allow for efficient and ‘right first time’ powder coating and surface finishing - saving both time and money! The presentation will take place at 2.40pm during day one of the three-day event.

Visit stand G115, between 4th to 6th February at the Farnborough International Exhibition Centre. You can register as a guest using the link: https://register.visitcloud.com/survey/00mf6xsmh61zw?actioncode=NTWO000287HUM&partner-contact=0otrhgchmyp25

Powdertech’s Managing Director James Grant along Jimmy Phillips, will be present to discuss the solutions, share insights, and demonstrate Powdertech’s commitment to achieve flawless results for your products.

TiZr for enhanced bonding in Nichols N1A supercar

Powdertech Surface Science — 04/09/2023

When the work you perform is hidden from view and never to see the light of day, one’s pride resides in the finished article. 

Such it is for the Powdertech Surface Science team; we are extremely proud that our optimised TiZr service plays an essential part, albeit hidden, in the construction of the striking and phenomenal Nichols Cars N1A super car.

The curved and honed body shape utilises a revolutionary chassis design made almost exclusively from extruded aluminium parts which are adhesively bonded in preference to being welded; carbon fibre is employed in certain areas. This system is the brainchild of Bob Mustard, a veteran of automotive engineering.

Powdertech optimized TiZr pre-treatment prepares the aluminium for enhanced adhesive bonding. The Nichols N1A is undoubtedly one of the most exciting new sports cars to land in the niche vehicle arena – weighing in at around 900kg, with a 7.0-litre V8 engine making 650 bhp.

Find out more Nichols N1A supercar

Our optimised TiZr process can match the bond strength and durability of anodised treatments

Powdertech Surface Science — 25/01/2023

One of the questions we are commonly asked is whether TiZr treatments can deliver equivalent bond strength and durability to anodised treatments. We have conducted an extensive side-by-side test programme comparing our proprietary, optimised TiZr treatment to an industry standard anodised treatment using a 1K heat cured structural epoxy adhesive. Funded by Innovate and we worked with partners TWI and LEVC, a non-grant-bearing partner. Our tests included process capability and durability study of the lap joints, cyclic corrosion and SWAAT testing. Our optimised TiZr process can match the bond strength and durability of anodised treatments and has the added advantage of being a more sustainable and cost-effective solution. Get in touch to discuss our TiZr pre-treatments and test programmes further. Image courtesy of Morgan Motor Company.

Loughborough University Motorsport's electric Formula racing car with Powdertech’s advance dielectric coatings.

Powdertech Surface Science — 04/08/2025

Loughborough University Motorsport (LUMotorsport), one of the UK’s premier Formula student team, partnered with Powdertech Surface Science to achieve durable, high-performance dielectric coatings that could meet the rigorous demands of motorsport, provide electrical insulation, and protect against short circuits, electrical arcing, and overall environmental degradation.

Potential dielectric coating challenges

Honeycomb structure of the electric Formula racing car’s battery cell pack

Loughborough University Motorsport (LUMotorsport)’s electric racing car's battery pack design presented critical challenges-

Complex part geometry: The part geometry of the EV battery pack with its honeycomb-type structure presented technical challenges. The dielectric coatings on these parts needed a film build thin enough to allow battery cells to fit, but thick enough to provide the required dielectric coverage. The holes could easily fill with too much powder, preventing successful build of the battery enclosure. The shape of the battery also made testing coating thickness difficult.

Insulation requirements with environmental protection: Another critical challenge was to ensure adequate electrical insulation as per spec to prevent short circuits and thermal arcing. Protection of metal components, which were prone to wear and corrosion under a high-stress environment, can affect the reliability and durability of the battery cell pack, as it would be subjected to intense conditions of motorsport. Like all components with dielectric requirements, the coating needed to be 100% defect-free, as any weak point in the coating will lead to a failure at the testing stage.

Collaboration with Powdertech Surface Science for technically advanced dielectric coating

Powdertech's dielectric coating process met the battery assembly's fit tolerance, ensuring the right coating thickness in the cell cavities, so that the cells sit flat on the battery pack’s surface. The parts were jigged at an angle to get the required coating thickness, ensuring holes would not fill with powder.

The parts were orientated in a particular way to avoid uneven surface coating, and Eddy current gauges were used to measure the coating thickness, and the team ensured to hit the minimum threshold for the dielectric insulation properties.

The desired balance between protection and fit tolerance was achieved, a critical factor in the dielectric coating process for EV battery assemblies.

For measuring electrical insulation, the Powdertech team conducted a defect sweep using Holiday testing, followed by a high-voltage test using Hi-Pot equipment to measure the kilovolt dielectric breakdown strength at their on-site dielectric test cell.

Check out the video to experience the precision and technical expertise that went to enhance LUMotorsport's 2025 electric race car.

Achieved desired performance and reliability.

The process successfully achieved the required fit tolerance, coating thickness, and dielectric breakdown strength of 1000Kv. The holes retained shape so that battery cells could fit into the holes. The battery packs were tested with a thickness meter on flat face and a vernier on the curved edges of holes.

LUMotorsport’s team was sure that their parts met the required dielectric spec, as the parts successfully passed the Hi-Pot testing. The parts were assembled without the holes getting filled with powder, this resulted in overall successful part delivery.

Our TiZr passivation process created a stable protective layer that allowed protection against corrosion and extremely high temperatures from the intense motorsport conditions.

LUMotorsport achieved an advanced dielectric coating solution that met their technical demands without compromising the battery's fit and performance.

Through a collaborative effort, Powdertech Surface Science provided LUMotorsport with a tailored dielectric coating solution that addressed the specific technical challenges of their electric Formula racing car's battery pack.

Build the future of EV insulation together with Powdertech Surface Science.

Connect with the Powdertech team to discuss your next dielectric coating project.

Powdertech participates in ‘The Great 100, Sustainability Champions’ awards by Made in Midlands

Powdertech Surface Science — 22/07/2025

Powdertech is excited to be a part of ‘The Great 100, Sustainability Champions’ awards by Made in Midlands.

Powdertech is committed to making its entire operation more sustainable by taking accountability for efficient waste recycling and energy conservation.

Take a moment and show support by filling out the nomination form for the Sustainability Champions category, for the ‘Great 100 awards by Made in Midlands’, where they are nominating Phil Tyler, Operations Director, Ian Manning, Engineering Manager, and Richard Knight, Manufacturing Engineer at Powdertech Surface Science, the leaders behind successful sustainability projects at Powdertech.

From environmentally friendly powder coating solutions to their commitment to reducing carbon emissions, they are consistently pushing to do better and go further. And we know there’s always room for improvement, and this nomination will help them stay focused and inspired in their journey towards being sustainable.

Sustainable operations at Powdertech Surface Science -

Use of powders that emit zero or negligible volatile organic compounds (VOCs) and contain no halogens or heavy metals, with Environmental Product Declarations (EPDs), which follow the International Standard ISO 14025
Powder-coated metals can be recycled with no adverse effect, contributing to the circular system.
23 years ahead of the curve by being Chrome-free since 2001. Powdertech Surface Science, the first powder coating provider in the UK to install chrome-free pre-treatment in 2001, has extensive experience in safe, effective, and sustainable systems.
25% of the electricity usage is renewable and is generated on-site.
Introduced solar panels for electricity generation at the start of 2021 to reduce carbon output.
Underlined commitment to sustainability and eco-friendly practices through achieving ISO 14001 certification, approved by LRQA.
18000 Litres of water saved and reused per day through the installation of a newly installed water treatment plant, reducing water treatment pressure on local water authorities.

Powdertech's core values of respect, accountability, and being responsive apply equally to their concern for the environment. At Powdertech, sustainability is a journey that involves every employee, every process, and every product.

Help make a difference: Nominate Powdertech as the ‘Sustainability Champions’.

If you are someone who shares the vision for a more sustainable future, your nomination will help Powdertech continue pushing the boundaries of what’s possible. Together, let's make sustainability the standard, not the exception.

It only takes a few minutes! Simply fill out the nomination form, and learn about Powdertech's sustainability initiatives through their‘Sustainability Spotlight’ series.

#Great100 #BackingBritain #MemberNews #UKManufacturing

Cleaning aluminium prior to surface treatments

Powdertech Surface Science — 26/06/2023

How clean is clean ? And how do we know if we have cleaned your aluminium to the best possible level?

Surface contaminants, many that can’t even be seen, will impair the performance of any adhesive or coating applied to the metal.

Bond strengths will be unacceptably low, especially in wet environments when surface corrosion can initiate. For Battery Electric Vehicles (BEV) in particular, high levels of cleanliness in the component structure are vitally important to ensuring the integrity and safety of the battery system. We use XRF equipment Dyne inks and UV-Fluorescence to measure the level of aluminium surface contaminants and to demonstrate compliance to specifications detailing RFU limits.

This short video explains just how we know that your metal is as clean as it can be before we apply any surface treatment.

The complete guide to dielectric coating for EV battery assemblies: Porosity issues

Powdertech Surface Science — 29/05/2025

What is porosity in dielectric coating?

Porosity in dielectric coating refers to microscopic air pockets, bubbles, or voids that can form within the coating layer, normally due to an issue with the part or during the coating process. These are not visible on the surface but can drastically reduce the coating’s protective properties, especially in high-voltage or high-humidity environments.

Microscopic view of air bubbles in the dielectric coating of metal panels.

What are the causes of porosity in dielectric coating?

- Substrate Outgassing: Outgassing is the release of trapped gases or vapours from the metal surface during the curing process. Typical substrates that suffer from porosity in dielectric coating are castings, metal hot spray surfaces, blasted surfaces. Trapped air expands during curing process, and breaks through the coating, making bubbles as the coating gets thicker as it dries out, the air is not realised causing porosity in coating.

- Porosity from the coating processes: If the part is not dried properly after cleaning, this can cause porosity as water turns to steam as it heats. This can also happen if you do not manage your environment, and coat parts in excessively humid conditions.

Substrate outgassing on metal surface.

-Poor substrate preparation/cleaning - Insufficient cleaning or passivation leaves residues that volatises and can cause porosity, leading to visual and functional issues.

How to prevent porosity in dielectric coating?

Cleaning and passivation (TiZr) It is important to ensure parts are properly cleaned and pretreated before powder coating. At Powdertech Surface Science they recommend TiZr passivation, which creates a stable surface to allow strong and durable adhesive bonds.

The clean, TiZr passivated surface promotes better and more consistent performance, reducing the risk of porosity, cracking, or defects on the surface.

Degassing - One of the most effective ways to avoid porosity in coatings is to degas castings before coating application. This is done by heating the castings to 40-degree Celsius above the curing temperature before coating.

Degassing process at Powdertech’s on-site facility.

How to test for porosity in coated parts?

Holiday testing - This test detects pinholes, air bubbles, cracks, or thin spots in the dielectric coating (known as ‘holidays’) that may not be visible through visual inspection alone. This high-voltage inspection method sends current through the coating surface. If it detects a flaw, like a pinhole, it triggers an alarm.

This allows to verify coating integrity. At Powdertech, they conduct cross sectional analysis to find porosity is present or not. Their in-house testing facility ensures the accuracy of the dielectric coating in EV battery systems.

Powdertech’s on-site lab facility for testing dielectric coating pitfalls.

Want to know if porosity is hiding in your current dielectric process? Connect with Powertech to review your part design, materials, and pre-treatment approach.

Optimised TiZr conversion coating for enhanced structural bonding.

Powdertech Surface Science — 18/05/2023

Ensuring high structural strength in a lightweight chassis

'Retro-futuristic' is the term used to describe the Morgan Super 3 - an exciting three-wheeled lightweight open top sports car. Super-formed aluminium panels form part of the monocoque chassis and these delicate panels are critical to the strength of the lightweight build. Bonding the aluminium panels needs to be done with superior strength and precision to withstand the conditions that the vehicle will face on the road. The vehicle has a 118bhp Ford-sourced three-cylinder engine giving 0-62 mph in 7 seconds and a top speed of 130mph.

Powdertech worked with Morgan from the outset to establish the optimum TiZr pre-treatment system that would be needed to both the chassis components. We also needed to create the correct preparation for powder coating on the inner door panels to which various attachments would be made.

We have all the testing equipment required for such work at our Bicester plant. This includes XRF and RFU spectrometry for metal surface characterisation and Instron mechanical testing technology to test bond strengths following TiZr Passivation.

You can read more about the work we carried out on the Morgan Super 3 HERE

Building circular systems; Reduction of hazardous waste through efficient recycling.

Powdertech Surface Science — 17/09/2025

Circular systems in sustainability focus on designing processes where materials are reused, recycled, and kept in circulation for a long time, reducing waste and reliance on finite natural resources.

At Powdertech, they are embracing and introducing measures to make their entire operation more sustainable by continuously investing in waste reduction, whilst simultaneously making improvements to their recycling regime. Much of which is done by managing the reduction of hazardous waste generated.

Historically, powder coating and metal pretreatment businesses have had three such streams -

Mixed recyclables; Contaminated plastic chemical containers

Waste powder

Effluent discharge / contaminated water

Powdertech has invested in circular systems, so as to create coating solutions, minimise waste, and keep valuable materials in use for longer duration through efficient recycling of chemical drum containers, powder, wood, metal, and other mixed recyclables.

Mixed recyclables

Like most businesses, Powdertech also faces an abundance of packaging and waste streams; it is an incredibly easy option to just deal with these through general waste disposal. However, for Powdertech, it simply does not fit with their ethos of building a sustainable, greener, and less impactful business. So, Powdertech adopted a greener and more sustainable route in support of their values.

The approach begins with elimination –

Can they get the product to and from the site without single-use packaging?

Next,

Can the packaging received be reused?

For every plastic bag, length of bubble wrap, or cardboard box received that could be repurposed to dispatch to the customers, that’s one less item of waste that could potentially fall into a landfill.

Packaging design and specification is something Powdertech addresses as part of their NPI process. For example, if a customer wants parts packaged in plastic bags, what options can be recommended that meet their requirements but are not plastic? Sugar cane bags break down within weeks if they enter the landfill, and plastic remains for decades.

Reusable cardboard boxes at Powdertech’s Bicester facility.

Chemical storage drums

One significant waste stream - contaminated plastic barrels that are used to deliver raw chemicals.

This issue is addressed via a simple principle, making the containers clean enough to be recycled. Make them small enough to store and transport, making the project economically viable and sustainable.

So far, Powdertech has earmarked space for an automated barrel decontamination station, which will form a part of a circular system utilising the resources they already have without generating any further waste.

The station will triple-wash the containers using water already processed by the on-site water treatment works. This rinse water is then captured and returned to the water treatment works for reprocessing and to prevent any release of pollution.

In combination with this, a small industrial shredder will be installed, which will minimise the footprint of the decontaminated containers, creating an efficient means to store and transport the material. From this point, it can enter the recycling sphere for a multitude of purposes.

Through implementing this process, Powdertech would increase their self-efficacy, reduce both recycling time and cost in the future. Storage tanks are decontaminated by making them non-hazardous, and by shredding them, they are ensuring that it is getting recycled efficiently. At Powdertech, they process approximately 1000 to 1100 barrels per year.

At Powdertech, they aim to take accountability for the waste created from their processes and invest continuously to improve recycling ability at their facility.

Powder coatings are greener than you think!

Powder coating powders do not produce hazardous waste. These are dry powders and emit zero or negligible volatile organic compounds (VOCs).

The process takes place in sealed booths, and 95% of what is sprayed adheres to the metal or is collected, filtered, and reused. Any powder left over is safely disposed of as an inert powder.

The powder coating process is being carried out at Powdertech Surface Science.

Powdertech gets issued Environmental Product Declarations (EPDs), which follow the International Standard ISO 14025 . EPDs from their key powder manufacturers: Sherwin Williams , TIGER, Interpon, AZKONobel

And they have made the powders safe to dispose of and have no halogens or heavy metals. As they have progressed from hazardous to general waste, their powder disposal is now at the stage of energy reclamation means it's at the same level as that of recycled waste.

Affluent reduction in local water networks

Introduction of the water treatment plant within their Bicester facility is interlinked to hazardous waste reduction measures.

Powdertech will reduce its water consumption by approximately 18000 litres of fresh water per day, our net discharge to the network will drop by approximately 85% per month, and most importantly, the concentration of contaminants within this discharge will be reduced to levels significantly lower than those which the water authority deems safe and acceptable.

This water treatment works project will help bring other tertiary benefits, such as a reduction in tanker requirements for the most contentious process chemicals, translating to overall carbon emissions, and less road traffic attributed to the business, leading to a greener and more sustainable manufacturing process.

On-site water treatment plant at Powdertech.

Project investment and our sustainability champions

To address the elephant in the room, - ‘The Cost’ - no project is free, there’s always an element of finance involved. In the instance of ‘implementing sustainability within their operations, ’ it is through self-funding!

Although there will be a significant initial expenditure required, through the elimination of hazardous disposal, the associated costs will be repaid by roughly three to three and a half years.

The projects started in August 2024 and are getting completed by this year (2025) August, with an approximate. cost of recycling around15K.

And what does this mean for Powdertech? This would mark the end of our final hazardous waste stream!

Powdertech's Operations Director Phil Tyler, Engineering Manager Ian Manning, and Manufacturing Engineer Richard Knight are the leaders behind the execution of the hazardous waste reduction processes, setting up and for regular monitoring of these circular systems at Powdertech.

In addition to the Powdertech team, Jan Atherton has shared her expertise and support to attain and maintain the management systems standards certifications for energy, environment, health & safety, and quality management systems. Her support in delivering pre-assessment audits and helping with corrective action plans has led Powdertech to achieve ISO 9001 & 14001 certifications.

Jan’s expertise helped in the successful completion of the sustainability projects at Powdertech.

The ‘Great 100’ Made in Midlands awards

The team at Powdertech is thrilled to participate in ‘The Great 100’ awards by Made in Midlands for the ‘Sustainability Champions’ category. You can show your support by filling out the nominations form. And stay tuned to know more about sustainability projects at Powdertech through their ‘Sustainability Spotlight’ series.

#Great100 #BackingBritain #MemberNews #UKManufacturing

Powdertech’s TiZr Passivation, paved the way to a smarter choice for consistent bonding and welding of aluminium.

Powdertech Surface Science — 11/12/2024

Based out of Bicester, Oxfordshire, Powdertech Surface Science is continuing to build its reputation as the most technically advanced supplier in the powder coating Industry. The company has witnessed a marked increase in enquiries for their Titanium Zirconium (TiZr) passivation process for aluminium in the wake of the recent hexavalent chromate/chromium trioxide ban. 

Being a pioneer in the powder coating industry, Powdertech Surface Science was the first site in the UK to implement only chromate-free pre-treatments in 2001. They switched to using TiZr passivation nearly 23 years before the ban of chromium trioxide by (hse.gov.uk) and have had over 20 years to optimise the process to gain the best results for their customers and the alloys they use.

TiZr passivation in relation to anodising:

Powdertech’s optimised TiZr passivation process is a suitable alternative to anodising. As the process creates a stable, protective, and chemically modified ‘shield’ layer on aluminium and unlike anodising, TiZr is not reliant on intensive energy-based processes and is therefore more energy efficient than anodising.

The TiZr process requires less physical handling of the metal. Welding can be performed on metal that has been TiZr-pre-treated wherein after anodising, welding is not possible. TiZr pre-treatment provides a shelf life of up to 12 months before any bonding, welding or coating is done on the aluminium, unlike anodising where aluminium needs to be bonded within hours to avoid contamination of the surface. 

Powdertech Surface Science uses the latest eleven-stage Gardobond® X4591 and Gardobond® X 4707 processes. These are optimised, based on their years of experience and expertise to eliminate porosity, cracking and other defects in the metal. 

Instron 34TM-50, an electromechanical universal testing machine, at Powdertech’s on-site testing lab, able to perform a wide range of mechanical tests including tensile, compression, bend, peel, tear, friction, and shear testing.

New customers often want to know the levels of bond strength they can achieve after switching to TiZr passivation, and Powdertech has multiple data sources that show bonds created after TiZr passivation are at least as strong as those created after anodising.

On-site wet lab facility at Powdertech.

Please contact Powdertech Surface Science to discuss how TiZr passivation might benefit your project. They also provide testing services and reports, to compare TiZr to other pre-treatment process you are currently using.

Powdertech exhibiting at the UK’s leading battery shows of 2026

Powdertech Surface Science — 02/04/2026

Powdertech Surface Science will return to two of the UK’s leading battery industry exhibitions in 2026 - Battery Tech Expo and Battery Cells & Systems Expo!

Since last year, when they exhibited at the Battery Tech Expo, they have been busy ramping up their dielectric coating projects and have scaled dielectric coating over to 1,000 parts weekly with consistent, production-ready results.

Partnered with two major tier one suppliers for dielectric consultancy projects, supporting them to resolve dielectric coating challenges and to meet demanding EV battery requirements.

Exhibiting at Battery Tech Expo 2026, 23rd April at Silverstone.

Powdertech will be present at Stand A17 on 23rd April at The Wing, Silverstone Circuit, where the team will engage with industry professionals on dielectric coating solutions for EV battery components.

Since last year’s event, Powdertech has significantly expanded its dielectric coating operations, bringing in more complex projects and strengthening its in-house quality and testing processes.

Visit Powdertech stand A17 to discuss how they can support your dielectric coating requirements, including:

Consultancy support to ensure consistent, high-performance results.
Reliable dielectric strength performance as per spec requirements.
Controlled coating thickness and edge coverage.

Technical seminar at Battery Cells & Systems Expo, 8th & 9th July at NEC, Birmingham.

At this year’s seminar at BCSE, Powdertech’s Technical Manager, Dr. Nick Welton, will deliver a seminar titled:

‘Dielectric powder coating from busbars to battery enclosures – evolving an established technology.’

📅 Day 1, Wednesday, 8th July
🕛 12:00 – 12:25

The seminar session will focus on how dielectric coating is being successfully adapted for aluminium battery enclosures in EV applications.

Dr. Nick will cover:

Key risk factors that impact dielectric coating performance and timelines.
Practical strategies to mitigate coating failures.
Lessons learned from delivering successful projects for major OEMs.

👉 Visit Powdertech’s Stand 740 on 8th & 9th July at NEC, Birmingham, to continue the conversation and explore your dielectric coating project requirements in detail.

Why connect with Powdertech?

Dielectric coating for EV battery assemblies requires technical expertise and experience, where small variations can lead to significant performance challenges.

The team focuses on identifying root causes early and delivering robust, repeatable solutions that meet specification requirements to avoid encountering coating failures at later stages of production.

This is possible through years of proven experience across commercial EV projects and deep technical expertise in dielectric coating systems.

Not attending the battery shows? You can still connect with Powdertech to explore how they can help move your project forward.

Recruiting a Marketing & Sales Manager

Powdertech Surface Science — 11/01/2024

Join our lively, motivated team

With continuing growth in our services and in the sectors we serve, we are looking for a dynamic Marketing & Sales Manager to join our ambitious team and make a significant contribution to driving the business forward.

We are an innovative company with an enthusiastic and mutually supportive team, proud of our leadership position in the industry. We have a culture of technical excellence, long-term customer relationships and a desire to exceed customer expectations.

Full details of the role and how to apply can be found HERE

Dr Nick Welton joins Powdertech Surface Science

Powdertech Surface Science — 09/05/2024

Leading surface chemistry expert Dr Nicholas Welton has joined Powdertech Surface Science as Technical Manager on a permanent basis, having worked with the Bicester based company for the last nine years as Technical Consultant.

Nick, who was recently awarded a Fellowship from the Institute of Materials, Minerals and Mining (IoM3), has led Powdertech’s involvement in funded research projects that total 25m EUR in value.

On joining the company as a permanent employee, Nick said: “Working for Powdertech has allowed me to engage in challenging projects, often where there is not a known solution, and the goal is to find one.

“This has meant that both the business and I have upskilled and increased our knowledge and experience of how to deliver, test and control surface cleanliness and coating. This ultimately benefits our customers – as our experience translates into successful project delivery.”

Nick has a BSc (Hons) in Chemistry and a PhD in Polymer Chemistry. He started his career working for adhesive coating companies and powder manufacturers and began working for Powdertech Surface Science as a consultant in 2015.

As well as helping to deliver successful projects for Powdertech’s customers, Nick has led the development of the company’s industry-leading test laboratory and pilot line facility.

These facilities have allowed Powdertech to contribute to research and development programmes with major OEMs such as JLR, BMW, Rolls-Royce and Volvo. Research subjects have included EV battery enclosure manufacture, aluminium cleaning using Titanium Zirconium (TiZr), bond durability of thin wall diecast aluminium, and the development of novel composite-to-metal bonding system Powderbond.

Involvement in these projects has led Nick and Powdertech to become leaders in the field of technical aluminium surface treatments.

James Grant, Lead Director at Powdertech Surface Science, said: “Nick is the preeminent expert in commercial aluminium surface treatment and has been an integral part of our business for nearly ten years.

“We are delighted that he has joined us as a permanent member of the team. Nick is one of the key reasons that we are able to offer our customers the most technically advanced surface cleaning and powder coating solutions available in the UK.”

Nick will be on Powdertech’s stand (1427) at the Battery Cells and Systems Expo at the NEC on May 15 and 16, and he can be contacted via Powdertech’s website.

Can powder coating hide metal surface imperfections?

Powdertech Surface Science — 10/10/2025

There are lots of advantages to powder coating; the electrostatic process is known for providing a cost-effective and durable finish. It is also a more sustainable process than wet paint, as it uses less water and fewer chemicals. But a question which is often asked is:

Can powder coating cover scratches or surface imperfections on metal?

Powder coating can mask minor surface finish irregularities to some extent. However, more severe defects, like oil contaminations, cutting fluids, scratches, pinholes, flaking/chipping, and uneven corners, can not be eliminated completely, impacting coating performance.

At Powdertech, for one of their clients, they replicated some typical metal surface defects on their parts on ‘Aluminium test coupons’ to fast-track the process of determining if surface defects, such as oil contamination and deep scratches, are covered by powder coating. This enabled them to design a finishing spec for their machinists.

For this purpose, four aluminium test coupons were used to test the powder coating process over surface defects.

Coupon A - A defect-free, benchmark piece that replicates an ideal part before the powder coating process begins.

Coupon A is kept to compare coupons B, C, and D, which have surface defects like deep surface scratches, shallow scratches, and oil contamination, respectively.

The result

Powder coating will not hide deep existing surface imperfections, which are easily visible. The use of fine-textured powder, as selected by the customer for their project, has a better chance of covering small scratches in the metal as compared to gloss or matte finish powders. Nonetheless, as shown below, it cannot cover all defects.

*For this project, fine-textured powder was used as per the customer’s requirement.

Coupon B - The powder coating does not cover the scratches; instead, it follows the profile of the damage without filling it in. This can be easily seen and felt on the metal surface.

Coupon C - More likely to fill in the scratches, but witness marks are visible.

Coupon D - A shadow in the powder coating surface can be seen, and the powder has not adhered to the surface, resulting in failure of the coating. The coating is likely to flake off and fail its purpose.

Customers rely on Powdertech to ensure the coating process runs more smoothly during production with fewer delays. They stay closely involved at every stage to prevent delays, costly reworks, and production downtime, as early detection of surface defects ensures the coating performs as per the spec requirements.

Starting a new project?

Check out Powdertech's Design your finish at the start to save production time and money article and download a tailored checklist before you begin the process of coating as per your component and its end use.

By getting it right early, you can avoid surface defects mid-production, save cost and time, and achieve your desired surface finish right the first time!

Checklist to achieve your desired surface finish.

Why choose Powdertech?

Understanding you and your products is central to their approach. By building a close working relationship, they stay responsive to your business needs, helping you deliver on the promises you’ve made to your customers.

At Powdertech, high-performance powders and the latest equipment is used to ensure a consistent finish. They regularly invest in new equipment and facilities. Your metal will be pre-treated and coated to an exceptionally high standard, and their expertise extends to developing new pre-treatments and powder coatings for unique applications.

If you are looking for a dependable powder coating partner who cares about your business outcomes, you are in the right place. Get in touch with Powdertech to discuss your powder coating requirements - because getting it right early means fewer problems later.

Sustainability in action: Richard Knight leading change at Powdertech Surface Science

Powdertech Surface Science — 31/10/2025

At Powdertech Surface Science, the core values of respect, accountability, and being responsive apply equally to their concern for the environment, where sustainability is becoming part of how they think, work, and engineer every project.

Leading this transformation is Richard Knight, Manufacturing Engineer at Powdertech Surface Science, who has been nominated as Powdertech’s Sustainability Champion for ‘The Great 100’ awards by Made in the Midlands.

Since joining Powdertech, Richard has brought a refreshing mix of technical skill, strategic thinking, and genuine passion to every project. With a background in Motorsport and Performance Engineering, he approaches sustainability with an engineer’s mindset, curious, analytical, and always looking for smarter, more efficient solutions.

Check out the video, where Richard talks about Powdertech's successful sustainability projects and their sustainability goals for 2026.

One of Richard’s standout achievements is leading the implementation of Powdertech's on-site water treatment plant, saving 18,000 litres of water every single day. This initiative is a powerful example of how innovation and engineering can create meaningful environmental impact.

Richard Knight(Left) with Powdertech's Operations Director, Phil Tyler, holding the ISO14001 certificate.

Richard also spearheaded efforts to reduce hazardous waste through improved recycling, which helped Powdertech secure ISO 14001 certification and strengthened the partnerships with local sustainability organisations. His leadership has helped to go beyond in embedding sustainability in Powdertech's day-to-day operations and long-term thinking.

What truly sets Richard apart is his ability to inspire others. He leads by example, encouraging collaboration, innovation, and optimism across our teams. Thanks to his drive and vision, sustainability at Powdertech continues to grow.

For his dedication, leadership, and the real difference he’s made, Richard Knight is a true ‘Sustainability Champion’, helping shape a cleaner, smarter future for UK manufacturing.

INTRICOAT - Best-in-class products need best-in-class surface treatment

Powdertech Surface Science — 08/11/2022

Powdertech's Intricoat service has recently been the solution for Blighter Surveillance Systems who needed very precise powder coating for cast aluminium housings used in radar systems.

Blighter Surveillance Systems designs and makes electronic-scanning (e-scan) ground radar systems for national border security, counter-drone, wide area surveillance and coastline security. These products employ unique award-winning technology and are generally regarded as best-in-class.

The radar systems are used in over thirty different countries. The technology needs to operate in all environments including desert and coastal/offshore and in all weather conditions, with no deterioration of function. An hermetic seal between the components needs to be achieved making the interior cavity airtight.

Protective treatment of the aluminium used for the radar housing is therefore critical as every surface is important to the integrity of the product and its successful deployment of scanning, recording and disseminating abilities. Some parts of the metal needed to be powder coated and others left free of the powder coating, but still pre-treated for corrosion protection.

Intricoat - starts with a detailed CAD masking scheme

Powdertech’s Intricoat team designed a masking scheme on CAD, in conjunction with Blighter Surveillance Systems. This was needed in order to keep internal areas free of powder, including preventing powder penetration into over 120 small holes per unit. Powdertech has a wealth of experience in designing and implementing these schemes and we are very aware of what works and what does not.

Pre-treatment for corrosion resistance

The internal surfaces of the housing needed to be free of a final powder coating and therefore required an initial pre-treatment with high corrosion resistance. Iridite NCP was used as the high performance pre-treatment, having excellent resistance to corrosion and an ability to withstand very high temperatures. Frequently specified by regulated industry sectors such as aerospace, defence, automotive and medical, Iridite can be used both as a pre-treatment under a topcoat or as a final coating.

All components underwent Iridite treatment in our plant and were then de-gassed to force out any remaining moisture.

Masking and powder coating in our Intricoat 'clean room'

Masking was carried out following the pre-designed scheme, after which the components were powder coated, all work being carried out in the dedicated Intricoat room within the Powdertech plant. Handling of parts through the powder coating process needed bespoke jigging arrangements by Powdertech to control weight distribution and ensure consistent and even coverage.

Benefits of Intricoat - Taking care of every aspect

· Your work is in safe, experienced hands

· We take responsibility for all aspects of masking and coating so that you can concentrate on critical design and engineering.

· The final stage of manufacture, the finish, is generally under time pressure. We understand this and have invested in a dedicated separate facility, located within our plant, to be used exclusively for customers requiring Intricoat services

The complete guide to dielectric coating testing for EV battery assemblies.

Powdertech Surface Science — 22/04/2025

When you are working on critical components like EV battery assemblies, validating your dielectric coating system before full-scale production isn't just smart but essential. And that’s where aluminium coupon testing comes in, giving you a reliable way to evaluate your dielectric coating performance before undertaking full-scale production.

What is dielectric coupon testing?

Dielectric coupon testing is a low risk testing process for validating dielectric coating on aluminium components. This early-stage testing can save you time, cost and provide early validation of your dielectric coating system.

At Powdertech, dielectric coatings are applied as per your spec to small aluminium samples, known as “coupons.”

Instead of coating a high volume of full-sized components straight away (which can be expensive and time-consuming), these aluminium test coupons would simulate how your dielectric coating will perform under real-world conditions, before coating at scale.

Aluminium coupons for testing dielectric coating at Powdertech’s on-site lab.

Why does early dielectric testing matter?

Powdertech's automotive clients, particularly in the EV sector, rely on dielectric coatings to provide electrical insulation. However, even with the best coating application, coating systems can behave unpredictably when applied to complex geometries or challenging areas like sharp or rough edges, which can eventually affect insulation.

Through the coupon testing facility at Powdertech, you can test for these coating issues early on, giving you insights into:

Coating thickness and dielectric strength

Edge coverage and uniformity

Porosity control and more

Early-stage validation of dielectric coating through aluminium coupon testing, you can make informed decisions early on, before moving to volume coating, reducing the chance of costly failures down the line.

In addition to coupon testing, for high volume dielectric coating projects, Powdertech has a dedicated dielectric test cell and full in-house testing facilities, including:

Hi-Pot and Holiday testing

Isolation resistance measurement and more to validate coating performance with faster turnarounds and reliable testing data that you can act on.

Aluminium coupon testing facility for dielectric coating at Powdertech Surface Science, Bicester.

Partner with Powdertech

Over the years, Powdertech has supported major UK OEMs and Tier 1 suppliers with their dielectric coating projects for EVs, helping them optimise their coatings through upfront dielectric testing.

If you are developing a component that requires reliable dielectric insulation, don’t wait for issues to surface during full-scale production. Talk to Powdertech about aluminium coupon testing to validate your coating early on.

Contact Powdertech to see how they can support your dielectric coating project.

Powdertech Expansion and Commitment to a Robust UK Industrial Strategy

Powdertech Surface Science — 31/07/2024

Powdertech Surface Science, a leader in powder coating and surface treatment, is experiencing significant expansion marked by substantial investments in advanced technology and infrastructure. This growth comes as the company champions a broader call for a national industrial strategy led by a dedicated Minister for Manufacturing, aimed at strengthening the UK's manufacturing sector.

Recent Developments and Investments
One of the key developments in Powdertech's expansion is the introduction of a new robot into their production line. This investment is primarily driven by the need to enhance quality and operational efficiency. James Grant, Powdertech's Lead Director, explains, "The robot addresses the manual element in our operations that previously introduced variability. By automating this critical process, we aim to achieve greater consistency and uptime, allowing our staff to focus on more complex tasks and strategic initiatives."

In addition to the robotic integration, Powdertech is investing in a new conveyor system for pre-treatment and loading at the factory's far end. This system is designed to enhance safety by minimising interactions between forklifts and personnel, a historically risky area. This investment underscores Powdertech's commitment to creating a safer and more ergonomic work environment, ensuring that manual processes, which are difficult to automate, are conducted more efficiently and safely.

Significant Growth and Efficiency Gains
Powdertech's financial growth has been remarkable, with the company experiencing a 30% increase in size since September of the previous year and doubling in size over the past three years. This expansion is not merely in terms of headcount, which now exceeds 35 employees, but also in terms of efficiency. The company's revenue per employee has reached unprecedented levels, a testament to the strategic investments in technology and staff development. This enhanced efficiency has been pivotal in driving more technical and high-value work, particularly in the aluminium sector where Powdertech specialises.

Drivers of Growth
The surge in demand for Powdertech's services is largely driven by the need for technical assistance from their clients, who require expertise in development and innovation. The company has created a dedicated facility and service called INTRICOAT, designed to deliver precise defect-free, intricate powder coating with powder coat masking for low volume machined components. Powdertech offers a range of services including aluminium and magnesium powder coating, TiZr passivation (a high-performance conversion coating), and their proprietary PowderBond process for joining aluminium to polypropylene with unrivalled bond strength. By continuously investing in both technology and skilled personnel, Powdertech has positioned itself as a critical partner for clients looking to push the boundaries of design and development. This partnership approach has been particularly valuable in sectors like automotive, medical, aerospace, and robotics, where deadlines are stringent and the stakes are high.

Continuous Improvement and Development
Continuous improvement is a core principle at Powdertech, as evidenced by their comprehensive review of operating systems and participation in mastermind groups. James Grant highlights, "We've engaged a consultant to lead a development course for all office and operations staff, resulting in numerous improvement projects across various business areas, including health and safety, efficiency, and delivery."

Supporting UK Manufacturing
Powdertech's growth and success are intrinsically linked to the strength of the UK manufacturing sector. The company is a strong advocate for the "Backing Britain" campaign, which calls for a dedicated industrial strategy led by a Minister for Manufacturing. This initiative aims to ensure that UK manufacturing remains competitive and innovative. For Powdertech, supporting this campaign means encouraging local design and development, particularly in high-end, cutting-edge projects. The company believes that a robust industrial strategy is essential for fostering an environment where technical excellence and innovation can thrive.

Encouraging Careers in Manufacturing
For young people considering a career in manufacturing, Powdertech offers a compelling vision. The company emphasises the tangible impact one can make in the manufacturing sector, particularly within small and medium-sized enterprises (SMEs). Employees at Powdertech are given significant responsibilities and the opportunity to see projects through from start to finish, providing a sense of accomplishment and purpose that is often lacking in other sectors.

Conclusion
Powdertech's ongoing expansion and their advocacy for a national industrial strategy highlight the importance of a strong and vibrant manufacturing sector in the UK. With substantial investments in technology and a commitment to continuous improvement, Powdertech is well-positioned to lead by example, demonstrating how strategic growth and innovation can drive success in the manufacturing industry. By supporting initiatives like the appointment of a Minister for Manufacturing, Powdertech is not only securing its future but also contributing to the broader goal of revitalising UK manufacturing.

Powdertech continues to invest in state-of-the-art equipment to ensure highest quality output

Powdertech Surface Science — 21/11/2022

At Powdertech we are clear that our role goes further than providing exemplary aluminium surface treatments. We want to be certain that the passivation process we provide is 100% fit for any intended purpose, most especially when it comes to TiZr coating for bonding. This includes ensuring that the bonds achieved following our TiZr conversion coating consistently meet and exceed our customers’ requirements.

Analysing passivation process on aluminium alloys

We have installed world leading Instron equipment as part of our testing suite. This is an electromechanical universal testing machine, able to perform a wide range of mechanical tests including tensile, compression, bend, peel, tear, friction, and shear testing. Tests are performed on all the aluminium alloys we work with, from 3xxx series up to 7xxx series, and in all formats, cast, extruded and sheet.

The results of our Instron testing enable us to work with our clients to help them to understand the optimal surface finishing pre-treatment process they need to take their bonding strategies to the next level, and to achieve repeatability going forwards.

The Instron 34TM-50 tests materials, components, and products in accordance with ASTM, ISO and other industry standards. It has a 50kN load cell and 100kN 80mm wide grips, with a thermal chamber capable of reaching 350C.

Precision powder coating quality control: INTRICOAT’s testing and inspection process.

Powdertech Surface Science — 15/04/2026

INTRICOAT’s powder coating quality control overview

This article provides insights into structured testing and quality control processes behind INTRICOAT’s precision powder coating process.

The processes include a detailed overview of internal control systems, batch quality checks, individual part inspections, and advanced testing procedures, all designed to deliver the consistent and precise powder coating performance required in high-value aluminium components.

Pre-production analysis and process validation

At INTRICOAT, quality checks start before production begins. A process called Process Failure Mode and Effects Analysis (PFMEA) is used to identify potential risks, understand their impact, and put preventive measures in place early on. This helps to keep the coating process consistent, controlled, and aligned with customer requirements.

Regular checks using test tokens are carried out- standard sample panels that are coated alongside actual parts. These allow for monitoring coating performance without affecting customer components.

INTRICOAT’s daily process control and pre-coating system checks

Powdertech’s INTRICOAT process closely aligns with customer expectations and control plans of demanding industries, where precision and process control are critical.

The INTRICOAT process allows the technician to be closer to the parts, ensuring efficiency at each stage. Parts are checked and compared with the drawing provided by the customers before any coating begins.

INTRICOAT ensures efficiency is maintained both at lower and higher volumes of production, as the same quality process can be adapted when production gets scaled.

Before any coating begins, a series of daily checks is completed to verify that all process parameters are within specification. These controls form the foundation of stable and repeatable production.

Internal control checks - These routine checks ensure that all production systems, materials, and environmental conditions remain stable before coating begins.

Daily titration tests of process chemistry of the tanks - A chemical analysis performed daily to monitor the concentration and balance of pretreatment chemicals in process tanks.

Cleanliness & temperature checks before starting the batch process - Verification that all parts, jigs and line conditions meet required cleanliness and temperature parameters before entering the batch process, ensuring consistent coating application and adhesion.

Data logging of the oven - We continuously monitor oven temperature and curing cycles to ensure coatings are properly cured for the best performance and durability.

Powder shelf-life checks - Routine verification of powder coating materials against expiry dates and storage conditions is done to maintain consistent application of coating quality.

An overall environment check - Monitoring of ambient conditions such as temperature, humidity, and contamination levels within the coating environment to ensure stable processing of parts and to prevent defects.

Batch-level quality control and incoming part inspection

Before each batch of parts enters the pretreatment and coating stages, a series of checks is carried out to confirm that systems are running correctly and that parts are in good condition for coating.

Visual inspections of incoming parts - Visual inspection is done to check for any oil contamination and any damage in transit before parts enter the coating process.

And if contamination is suspected, Dyne inks and UV-fluorescence are used to measure the severity of aluminium surface contaminants.

Dyne test fluid is applied to the metal surface. If the liquid forms a continuous film, the surface is sufficiently clean. If it retracts into droplets, contamination is present. Proper surface cleanliness is essential for coating adhesion and long-term coating durability.

Identifying contamination early on prevents coating defects and ensures only suitable parts enter the production process.

Pre-treatment verification and surface analysis (XRF testing)

Within each batch, individual components are tested to validate the performance of the pretreatment processes.

Passivation validation, XRF testing - X-ray fluorescence (XRF) analysis measures the elemental composition of the surface.

This is a powerful, non-destructive technique for measuring elemental composition from magnesium (Mg) to uranium (U). And is used to verify the presence of a successful pretreatment passivation (TiZr) process.

At Powdertech, XRF (X-ray fluorescence) capability is available on-site. This handheld device will give immediate, lab-quality results to determine the next course of action, allowing to stay on top of the TiZr passivation quality. And this confirms that the pretreatment process has been correctly applied.

Coating performance and cosmetic quality checks at INTRICOAT

Once coating begins, performance and appearance of the coated parts are monitored to ensure both functional and aesthetic quality standards are achieved. These checks verify that coatings meet required adhesion, finish, and durability expectations before components progress further in production.

Water break - A process control test used to validate surface cleanliness (TiZr) prior to coating. Deionised water is applied to the metal surface. If the water forms a continuous cascading film, the surface is clean. If the water breaks into droplets, contamination is present. This test confirms that the surface preparation process has effectively removed oils or residues that could compromise coating adhesion.
Spot test - A passivation validation test used to confirm the presence of pretreatment layers such as Iridite or TiZr, wherein a chemical solution is applied to the treated surface. And the rate and nature of colour change would indicate whether the pretreatment layer is present and effective. Verifying the pretreatment process ensures the coating system will provide the required corrosion resistance and durability.
Crosshatch test- A type of adhesion testing to validate the process of curing. A grid pattern is cut into the cured coating, and adhesive tape is applied and removed to determine how well the coating adheres to the surface. This test dictates the success of powder application and confirms if curing conditions and application parameters have produced a strong and reliable coating bond.

Special testing and problem management (subject to a special request from the customer or if problems arise)

Hardness testing – Through this process, the team helps customers select the right powder for their components. Conducted during the powder selection stage to ensure coatings meet both functional and aesthetic requirements. This is not part of routine batch testing but helps identify the most suitable coating system for real-world performance.
Impact testing - Performed on test tokens as part of powder evaluation rather than batch testing. These tests are typically conducted before coating and are carried out when specified by the customer. In many cases, this validation is supported through their trusted powder coating suppliers.
Corrosion resistance testing (outsourced) – A salt spray testing process is conducted when required by customers to evaluate long-term corrosion performance. This testing is carried out through approved external laboratories.

Why choose INTRICOAT by Powdertech?

INTRICOAT’s structured quality control processes ensure consistent, reliable, and high-performance powder coating at every stage. Through rigorous testing, validation, and inspection, Powdertech delivers surface finishes that meet the highest industry and customer standards. For expert powder coating solutions, get in touch with Powdertech.

Powdertech 2024 – Proving the value of ‘doing it right’ across all service delivery

Powdertech Surface Science — 22/08/2024

August 2024 sees Powdertech Surface Science proudly celebrating forty years as a highly successful business, delivering high quality finishes and processes with an emphasis on technical innovation. We look forward to further achievement in the coming years as we continue to advance the business in line with market needs, helping our customers to exceed the expectations of their own customers.

Accountability, trust and respect. Powdertech was founded on one man’s understanding of the over-riding importance of excellence in customer relationships. Martyn Green had a conviction that ‘things could be done better’. He recognized a significant gap in the market for a company combining consistently reliable high-performance coatings with an interest in and understanding of customers’ own industries and markets. That focus on mutually beneficial, close customer relationships has been consistent as our overriding philosophy.

Martyn established Powdertech in Bicester in 1984, as a small company operating two shifts of six people, concentrating on coating aluminium ‘Georgian bar’ - horizontal and vertical bars placed across windows and doors to give a Georgian appearance.

By 1988 the volume and variety of work led to Powdertech being expanded into two companies. Powdertech (Corby) Ltd was established in Corby with a purpose-built plant to deal with architectural work whilst in Bicester we were becoming well-known for specialised pre-treatment services on aluminium and zinc castings for the automotive sector, in addition to powder coating for aluminium and magnesium. We installed chrome-free pre-treatment in 2001 (the first UK powder coating plant to do so) and acquired work in the aerospace, medical and specialist engineering sectors in addition to automotive. Our re-branding as Powdertech Surface Science reflects our capability in many aspects of metal surface technology. We are continually researching and developing improved surface treatment systems. In 2018 we launched PowderBond®, an innovative system for bonding light-weight metal to composite without using a separate adhesive. In 2022 we built a separate facility within our plant to offer INTRICOAT, our coating service for intricate complex coatings, requiring CAD masking schemes.

Across forty years the Powdertech philosophy remains unchanged, but our factory and offices look very different. Investment in plant and in staff development continues apace with state-of-the-art coating equipment including a robotic system. This enables us to provide a powder coating service which excels in quality, consistency and adaptability to evolving needs. We can process small, fragile aluminium components, as well as accommodating sections up to 4 metres long, in volumes from one-off prototypes through to full scale production. Also staff either have, or are working towards, NVQ Level 2 in BIT Training.

Our greatest strength remains a willingness to thoroughly understand a customer’s own businesses and market and to work together to achieve a final product at the highest level.

We'd like to say a big thank you to our committed team, and the customers and suppliers we have partnered with over the years.

We're looking ahead to the next 40 years of helping our customers keep their own business promises.

www.powdertechsurfacescience.co.uk

Powdertech’s seminar at Battery Tech Expo, 2025

Powdertech Surface Science — 08/04/2025

On March 27th, 2025, our Technical Manager, Dr. Nick Welton, delivered an insightful presentation at the Battery Tech Expo titled "From Busbars to Battery Enclosures—Evolving an Established Technology." Dr. Welton, with nearly 40 years of experience in aluminium surface finishing and a PhD in Polymer Chemistry, shared his expertise on advancing dielectric coating technology for aluminium battery enclosures in electric vehicles (EVs).

Technical Manager Dr. Nick Welton and Marketing and Sales Manager Jimmy Phillips at Battery Tech Expo.

Dielectric coating is a proven technology for insulating copper busbars. However, applying this technology to aluminium components in EV battery enclosures presents unique challenges due to the distinct properties of aluminium. Dr. Welton discussed the evolution and adaptation required to address these challenges, emphasizing the importance of:

Fit Tolerance: Ensuring the coating is thick enough to meet the specific requirements of OEMs. Coating if too thick will affect fit tolerance and thermal performance.

Edge Coverage: Achieving consistent coating thickness on edges, as sharp and irregular edges are more prone to coating failures.

Porosity: Preventing the presence of air, holes, or bubbles within the coated layer, which can affect the coating's integrity.

At Powdertech Surface Science, we distinguish ourselves through:

In-House Technical Expertise: Our PhD-qualified industry experts oversee sample processing, utilizing advanced testing equipment like XRF and INSTRON to ensure quality.

Comprehensive Services: In addition to surface treatments, we offer sub-assembly processes, direct dispatch to OEMs, and 100% component inspection on behalf of Tier 1 suppliers.

Research Projects: We participate in and often lead UK and EU-funded projects as the surface treatment partner, contributing to initiatives like the APC ALIVE project, Innovate UK-OPTIMA, Niche Vehicle Network - SOLMAC, and to more such research and development programmes.

For a summary of the seminar highlights and to learn more about how Powdertech is overcoming dielectric coating challenges in EVs, while ensuring top-tier quality control, watch the conversation between our Marketing and Sales Manager, Jimmy Phillips, and Dr. Nick Welton.

Sophisticated powder coating techniques for the latest indoor cycling experience

Powdertech Surface Science — 25/04/2023

The Muoverti TiltBike is a unique indoor cycling experience. This lightweight cycling indoor trainer tilts with you as you bank around corners. It accelerates and brakes and lets you ‘shift’ between gears on approaching gradients.

The inner-workings include an algorithm-driven physics engine that simulates real-world forces such as acceleration, incline, and braking, a digitised handlebar steering and an elastomer-guided side-to-side tilt.

High quality, small volume powder coating for demonstrator units

This is clearly a high-end product and demonstrator units needed to be powder coated with great precision and attention to aesthetic detail. Our INTRICOAT team provided technical input for masking scheme design, leaving certain component surfaces free from powder coating. INTRICOAT masking schemes are sufficiently detailed to be viewed on CAD without the need for masked prototypes, saving time and costs for our customers.

Our services provided not only precision INTRICOAT coating for exceptional aesthetic quality on machined aluminium but we also advised on the most suitable powder coating formulation and colour choice, a metallic dark grey.

Fast turnaround to meet tight deadlines

For our clients, producing prototype or demonstration products for shows and exhibitions invariably ends up being a close-to-the-wire exercise. We can alleviate the pressure this cause. We have the capability to design and implement complicated masking schemes within short timescales and to carry out detailed precision coating to meet our client’s deadlines. All of our testing, masking and coating facilities are on the same site, under the same roof.

Benefits of INTRICOAT - Taking care of every aspect

Your work is in safe, experienced hands
We take responsibility for all aspects of masking and coating so that you can concentrate on critical design and engineering.
The final stage of manufacture, the finish, is generally under time pressure. We understand this and have invested in a dedicated separate facility, located within our plant, to be used exclusively for customers requiring INTRICOAT services.

Powdertech invests in dielectric testing capacity for high-volume dielectric coating projects

Powdertech Surface Science — 11/04/2025

Powdertech has recently expanded its in-house testing capabilities with the installation of a dedicated on-site Dielectric Test Cell (DTC), further reinforcing Powdertech’s ability to deliver high-volume dielectric coating projects with precision and consistency.

Holiday Testing at Powdertech’s Dielectric Testing Cell

Dielectric coatings are a critical safety feature, especially in automotive battery systems. These coatings must meet stringent insulation requirements, and every coated part needs to pass testing at customer-specified kilovolt (kV) levels before it can be cleared for use, therefore creating a need for expert testing at scale.

The new Dielectric Test Cell allows this testing efficiently and at scale, right on-site, preventing any bottlenecks or outsourcing delays. For Powdertech customers, this translates into faster turnaround times, higher pass rates, and the confidence that their components meet performance specs every single time.

Dielectric Test Cell at Powdertech, Bicester.

At Powdertech, they don’t just talk about dielectric coatings, they do the work. With a growing track record of successful delivery on complex dielectric projects, this latest investment in their testing facility underscores their commitment to providing a dependable, scalable solution for clients needing reliable insulation coatings for automobiles in volume.

Looking for an experienced partner who understands what it takes to deliver dielectric coating projects to spec, on time, and with precision?

Talk to Powdertech.

Precision powder coating at Southern Manufacturing & Electronics, Feb 6-8 2024

Powdertech Surface Science — 07/01/2024

Nothing beats meeting people in person and being able to describe and show our work. We are looking forward to showcasing our precision powder coating service INTRICOAT at the Southern Manufacturing & Electronics Show 2024. This runs from 6-8th February and is held at the £35m Farnborough International Exhibition and Conference Centre which boasts easy access, free onsite parking and world class facilities.

The show is aimed at people involved in design, engineering production and procurement. The latest in production hardware, services, components, consumables and technology will be on display, covering a wide range of industries including Aerospace/Defence, Automotive, Electronics Assembly/ Production, Industrial Machinery, Packaging/Handling/Logistics, Energy, Marine, Medical/PharmaBio, Mechanical Engineering and Metal Processing.

INTRICOAT is our highly detailed and meticulous powder coating service for high value and complex intricate aluminium components. These include part of medical devices, radar housings, electronics, and high end sports equipment.

Visit our stand and find out what makes INTRICOAT a premium powder coating service, required by producers of premium products.

Backing Britain through sustainable manufacturing: Powdertech team honoured as ‘Sustainability Champions’ at the Great 100 Awards.

Powdertech Surface Science — 16/12/2025

Powdertech is proud to announce that their Operations Director, Phil Tyler, and QHSE Manager, Richard Knight, have been honoured as Sustainability Champions at the Great 100 Awards 2025, hosted by Made in the Midlands.

Representing Powdertech at the Great 100 awards night, Operations Director, Phil Tyler and Marketing Executive, Vrinda Gupta,

Driving sustainability in surface finishing

Held at the Century Club in London on 4th December 2025, the Great 100 Awards brought together industry innovators, mentors, and manufacturing leaders from across the UK who are backing Britain by driving growth, strengthening local supply chains, supporting the next generation of engineers, and championing sustainable manufacturing.

Phil Tyler and Richard Knight’s recognition reflects Powdertech’s long-standing commitment to responsible manufacturing and efficient leadership in making Powdertech's entire operations sustainable.

Their work has been instrumental in:

Recycling 18,000 litres of water every day via on-site water treatment plant
Generating 25% of electricity on-site through solar panels, reducing their carbon footprint
Implementing low-VOC, recyclable coating systems
Enhancing waste reduction, energy efficiency, and sustainable production practices across the facility
Achieving ISO certifications.

Their leadership continues to inspire teams, strengthen their sustainability progress, and shape the future of environmentally responsible surface finishing.

This award is more than a milestone; it’s encouragement to Powdertech's commitment to sustainability, innovation, and responsible manufacturing.

The Powtertech team is incredibly proud of Phil Tyler and Richard Knight for this recognition. Because of leaders like them, Powdertech remains a trusted and environmentally responsible partner for advanced surface finishing.

New talent at Powdertech Surface Science: Welcoming NPI expertise and administrative support.

Powdertech Surface Science — 25/04/2025

UK's technical experts in metal finishing, Powdertech Surface Science, welcome two new members, Colin Greaves, who has joined as the New Product Introduction (NPI) Manager, and Molly Hedges, in the office administration department at Powdertech.

Colin Greaves, NPI Manager at Powdertech.

On 22nd April 2025, Colin Greaves joined Powdertech, bringing over 25 years of experience in developing and launching new products in the aircraft seating industry. Colin has years of experience in creating innovative and bespoke solutions marked by a passion for precision, process, and problem-solving.

Before joining Powdertech, Colin worked with global leaders, like Acro Aircraft Seating as Manufacturing Engineering Manager, and with Meech International as Production Engineer.

As the NPI manager at Powdertech, Colin will be closely working with clients, ensuring new projects get off the ground smoothly, on schedule, with the required quality standards.

Molly Hedges, Office Administration at Powdertech.

Molly Hedges has joined Powdertech as Office Administrator. Having worked in retail for 3 years, Molly brings in a strong customer service background. Her organised and detail-oriented approach with an eye for efficiency makes her a fantastic addition to the Powdertech team.

Molly brings structure, support, and a fresh perspective to the workplace, and she has already made an impression with her enthusiastic attitude and positive spirit.

Powdertech's newest members, Colin and Molly, bring in a perfect blend of deep industry experience with fresh energy and perspective.

We are recruiting !

Powdertech Surface Science — 22/03/2023

New position available - Powder Coating Engineer

An exciting new role at Powdertech Surface Science

A new role has arisen as part of our ongoing investment in growth and development. We are looking for a coating engineer with the ability to cover a range of tasks using machinery and hands-on precision work. This role is an important one in contributing to the company’s growth strategy through our flagship service ‘INTRICOAT’.

The job description can be found HERE

Apply, with CV to john.m@acqui-tal.com.

Powdertech Surface Science exhibiting and speaking at the Battery Tech Expo, 2025!

Powdertech Surface Science — 20/03/2025

Powdertech will be exhibiting its expertise in dielectric coating and pre-treatment of aluminium in EV applications at the Battery Tech Expo, 2025!

Powdertech’s Technical Manager, Dr. Nick Welton, an expert in commercial aluminium surface treatment, will be delivering a seminar. The talk, titled ‘Dielectric powder coating from busbars to battery enclosures—evolving an established technology,’ will draw on Nick’s extensive experience in delivering successful dielectric coating projects for major OEMs.

The presentation will take place at 2:00 pm, in hall 2, during day two of the two-day event.

Dielectric powder sprayed on aluminium components at Powdertech’s lab by Dr. Nick Welton.

Over recent years, Powdertech has worked on several dielectric coating projects, gaining extensive commercial experience in designing, developing, and validating dielectric coating systems that work to solve critical insulation challenges for aluminium in EVs.

At Battery Tech Expo, Powdertech will demonstrate how to identify the risk factors that can delay or derail your dielectric coating project and how to mitigate them.

Nick said: “Dielectric power coating is an established technology that has worked on copper busbars since the 1960s. Applying this technology to much thinner aluminium components for battery enclosures is a relatively new challenge.

“This talk will explore what we have learned about how coating processes need to be tweaked to ensure successful project delivery.”

Visit stand B44, on 26th March and 27th March at the International Conference & Exhibition Centre Silverstone.

You can register for the event HERE.

Powdertech’s Managing Director James Grant along with Jimmy Phillips, Marketing and Sales Manager, will be present to discuss Powdertech’s expertise in dielectric science, precision application, and supply chain integration that makes Powdertech your go-to partner for aluminium battery enclosures in EVs.

The complete guide to dielectric coating for EV battery assemblies: TiZr passivation

Powdertech Surface Science — 04/08/2025

Why is metal pre-treatment the key to the dielectric coating process?

The titanium zirconium passivation (TiZr) is a chrome-free conversion coating that is applied to aluminium components. Through this process, the natural oxide layer is replaced with a stable, chemically modified ‘shield’ layer.

This series of articles discusses some of the key challenges that need to be overcome to deliver a satisfactory dielectric coating solution.

The process of TiZr-passivation

The pre-treatment process removes surface dirt, oils, contamination, and the natural oxide layer and replaces it with a thin (approx. 20nm) stable Titanium/ Zirconium conversion layer. This results in a firm foundation for dielectric coating, providing long-term durability.

Pre-treating the aluminium results in additional protection against corrosion, a significant factor for environments where the aluminium component may be exposed to moisture, chemicals, or high temperatures.

Check out the video on how Dr. Nick Welton, Technical Manager at Powdertech, is using XRF equipment, Dyne inks, and UV-Fluorescence to measure metal surface cleanliness before and after TiZr- passivation.

Common surface defects affecting dielectric coating performance.

Metal pre-treatment: A key step towards achieving stated properties in technical data sheets.

To deliver the design coating properties as stated on technical data sheets, like required insulation resistance, corrosion resistance, and any mechanical properties, you need to have a high-performance pre-treatment system to minimise defects to deliver a dielectric coating system that satisfies your specification requirements as mentioned in technical data sheets.

Partner with Powdertech

Over the years, Powdertech has supported major UK OEMs and Tier 1 suppliers with their dielectric coating projects for EVs, helping them optimise their coatings through upfront dielectric testing.

If you are developing a component that requires a reliable dielectric coating solution, don’t wait for issues to surface during production; act early on.

Contact Powdertech to see how they can support your dielectric coating project.

Powdertech Surface Science achieves ISO14001 certification.

Powdertech Surface Science — 30/01/2025

Powdertech Surface Science has underlined its commitment to sustainability and eco-friendly practices through achieving ISO14001 certification, approved by LRQA.

Powdertech’s Operational Director Phil Tyler said, “As a business, doing things the right way is important to us. Over the last four years we have invested £1.6m in our facilities and, more importantly to me, we have also invested in our team through recruitment and extensive staff training.’’

“The knowledge and commitment of our Manufacturing Engineer Richard Knight has been crucial to us gaining full accreditation. He has organised and implemented the physical measures required throughout our business and set up systems to ensure that the necessary documentation is up to date at all times.”

“Our work towards ISO14001 was supported throughout by independent management systems consultant, Jan Atherton, an expert in ISO certification. Jan’s expertise and assistance was invaluable.”

Richard Knight (left) and Phil Tyler with the ISO14001 certificate.

To achieve ISO 14001 certification, Powdertech:

1.Regularly monitors and reviews control measures to drive continuous improvement and these efforts are tracked through green KPIs, to ensure that the processes align with their environmental goals.

2. Dedicates an average of 4-6 hours each week to maintaining and refining their Environmental Management System (EMS), reflecting a proactive approach to environmental management.

3.Collaborates with waste collection services at least once a month to ensure responsible disposal and recycling practices.

4.Conducts regular audits of both the Quality Management System (QMS) and EMS. These audits verify that Powdertech adheres to ISO 14001’s stringent standards and are constantly improving their systems and processes.

What does ISO 14001 mean for Powdertech’s customers and partners?

Powder coating is a ‘greener’ process than wet paint. It is Volatile Organic Compound (VOC) free, non-toxic, and uses less energy and water than other coating methods. By aligning with best practices defined under ISO 14001, customers and partners can be assured that their operations prioritise sustainability and environmental responsibility. ISO 14001 certification demonstrates Powdertech’s dedication to delivering high-quality products and services while minimizing the impact on the planet.

Powdertech Surface Science operates under an Integrated Management System (IMS) that combines; a Quality Management System (QMS) and an Environmental Management System (EMS). This holistic approach ensures that high standards are maintained across all areas of their business.

Phil Tyler said: “For Powdertech, ISO 14001 is more than a certification; it’s a reflection of our values. Together, we are building a greener and a more sustainable future for our business”.

Powdertech Surface Science announces key appointments

Powdertech Surface Science — 15/05/2025

Eva Hedges steps up as Account Manager

Eva Hedges, has taken on a new role as the Account Manager at Powdertech Surface Science!

Joined as a Finance Assistant, over the past 15 years, she’s become a familiar and trusted face, with her dedication and sharp financial skills and for her supportive role within Powdertech's production office over the last five years.

Eva has a deep understanding of Powdertech's internal processes and long-standing relationships with the customers, she’s confident in her ability to bring even more value in her new role.

“Stepping into a more customer-facing position feels like a natural next step, I am excited and confident to wear the new hat,” says Eva. “I know the customers, their product preferences, and how we work at Powdertech. ’’I’m really looking forward to putting that knowledge into action and being more customer-focused. As Powdertech grows, I’m excited to grow with it.”

Powdertech is incredibly proud of Eva and can’t wait to see the impact she’ll have in this next chapter. Congratulations, Eva!

Chris Phillips joins Powdertech as Production Team Leader

On the 24th of March, Powdertech welcomed Chris Phillips as the new Production Team Leader. Chris brings a wealth of knowledge and leadership experience in manufacturing and quality management, having previously held key roles such as Quality Manager at Swan Foundry and Composite Inspector at MCT Engineering. Chris has a proven track record in monitoring quality performance and improving productivity and efficiency across manufacturing lines.

With a Business & Management degree from De Montfort University, Chris combines practical expertise with strategic thinking, making him a valuable addition to the Powdertech team. At MCT Engineering, he was deeply involved in overseeing the end-to-end composite manufacturing process, from casting to processing, ensuring high standards across operations.

Since joining Powdertech, Chris has already started making a positive impact with his confident leadership and approachable nature.

Powdertech Surface Science appoints Steve McCarthy as Head of Manufacturing

Powdertech Surface Science — 18/06/2025

Steve McCarthy, Head of Manufacturing

Steve McCarthy has joined Powdertech as Head of Manufacturing, bringing over 30 years of experience in the aerospace and automotive industries to Powdertech’s production team. A six-sigma master black belt and certified lean coach, Steve has played leadership roles in managing quality systems and improving process efficiency.

For the past two and a half years, he has been working with Powdertech on a consultative basis, focusing on manufacturing leadership. Steve is delighted to now being a part of the team on a permanent basis.

On joining the company, Steve said: “I am delighted to be joining Powdertech during an exciting period of growth for the company. Our progress has been based on winning technical projects in niche and cutting-edge sectors – I see my role as ensuring our team grows and scales with the business.”

(Steve McCarthy, Head of Manufacturing at Powdertech)

In his new role, Steve will lead efforts to further improve operational performance, as Powdertech continues to implement 5S principles across the business. These initiatives aim to build upon Powdertech’s continuous improvement culture, supporting the company's growth plans and ensuring high standards are met in operations, process efficiency, and quality.

Andrew Simpkins steps up as Material, Planning and Logistics Manager

(Andrew Simpkins, Material, Planning and Logistics Manager, at Powdertech)

Andrew Simpkins has been promoted to the position of Materials, Planning, and Logistics (MP&L) Manager. Having been with Powdertech for five years, Andrew has demonstrated strong leadership and a deep understanding of the company's operations.

Powdertech is proud to have a strong leadership team on board.

Powdertech Surface Science to attend Battery Cells and Systems Expo, NEC 15 & 16 May

Powdertech Surface Science — 02/05/2024

Powdertech Surface Science is increasingly being called upon to provide their surface treatment expertise on projects related to electric vehicle battery enclosures.

Having recently enjoyed a successful day at Battery Tech Expo at Silverstone, Director James Grant is looking forward to discussing upcoming projects at the two-day Battery Cells and Systems Expo at the NEC in May.

He said: “We are finding that EV production in the UK is starting to ramp up, and as surface treatment and powder coating specialists with significant automotive and EV experience, our expertise is increasingly in demand.

“In this industry our clients need suppliers who understand their requirements and can deliver a solution that works, in the time agreed. When it comes to TiZr passivation and dielectric powder coating – we know the work, the common pitfalls and how to avoid them.”

At the Silverstone show, Powdertech’s stand was busy with a steady stream of engineers looking to expand their knowledge on surface treatment for battery enclosures. The company is expecting the same at stand 1427 on May 15 and 16.

The company has recently been providing surface treatment expertise to the Advanced Propulsion Centre’s (APC) ALIVE project, which is aimed at building a world class battery enclosure manufacturing supply chain in the UK. The other companies in the research consortium are Constellium, BMW, Brunel University, Expert Tooling & Automation, Innoval Technology, Volvo, and Warwick Manufacturing Group.

Powdertech also has significant experience on commercial EV projects. Bob Mustard CTO of Watt Electric Vehicles said: “Having worked with Powdertech over many years I am continually impressed by the team’s expertise at the forefront of emerging technologies and exemplary level of service.”

You can meet Powdertech’s expert team at stand 1427 at the Battery Cells and Systems Expo at the NEC on May 15 and 16, or find more information on the EV pages of their website.

Powdertech Surface Science exhibiting at the Battery Cells & Systems Expo 2025!

Powdertech Surface Science — 15/05/2025

Powdertech Surface Science excited to return to Battery Cells and Systems Expo for 2025, in the 12 months, since Powdertech last exhibited at the show, they have increased the volume of dielectric coating projects and expanded their QA and testing facilities.  

Visit the stand 1430, to gain technical insights on dielectric coating in EV battery assemblies, something that they have been perfecting through multiple commercial and research projects over the recent years.

“Our customers rely on us as their technical partner and problem solver when it comes to dielectric coating. In fact, a number of projects reach us after our customer has been having issues with a project where resicoat has been specified but previous suppliers have been failing to meet dielectric pass criteria.

“This exhibition offers those with dielectric projects a chance to come and pick our brains ahead of a project starting.” says Powdertech’s Marketing and Sales Manager, Jimmy Phillips, who would be present with Director, James Grant and Marketing Executive Vrinda Gupta to discuss how Powdertech’s expertise makes them your go-to partner for dielectric coating application in EV battery assemblies.

At Powdertech, it’s about understanding the dielectric coating process nuances that can affect the performance and addressing them right from the start, to achieve the right dielectric coating that matches your spec requirements. Powdertech’s hands-on experience means that they know the common pitfalls that can derail a project, and more importantly, how to avoid them!

The team at Powdertech, would love to connect and explore how they can help power your dielectric coating project!

Be ready to connect between –

-9th - 10th July
-9 am - 4 pm
-NEC, Birmingham, UK.

✅Won't be attending?

Connect with , Jimmy Phillips, to discuss your dielectric coating requirements!
or
Contact at https://lnkd.in/gzscyaJW

Powdertech offers bespoke masking techniques to prevent burr formation.

Powdertech Surface Science — 12/02/2025

When metals are powder coated, excess powder can gather against the edge of the masking material that creates a rough edge or 'burr'. Burrs can present challenges when parts are assembled and can affect the aesthetic appeal of the surface.

The traditional masking process can result in burr formation that requires a de-burring process to get rid of the excess powder. This process can add time and cost to the project, and sometimes aluminum can get damaged because of the force that is applied to perform de-burring.

At Powdertech Surface Science, it is important to understand customers' specifications and the performance requirements of their components, before offering the correct masking option, including:

3D masking technique for intricate components -

To provide a higher level of accuracy in powder coating on low volume complex parts 3D masks, designed on CAD, are used. As 3D masks are removed before curing, no burrs form. Through the application of 3D masking, the de-burr process is avoided altogether, saving time and retaining product quality.

Bespoke Bungs for higher volume components -

With high volume components there is a need to mask areas quickly, while ensuring burrs do not form. Flexible high temperature masks are designed on CAD and made in moulds. The mask design, part orientation and spraying parameters ensures that burrs do not form.

Powdertech Surface Science aims to work in parallel with their customers' manufacturing processes and production timelines. It is vital for them to take the time to understand the performance requirements of their customers’ components. Powdertech’s engineering team has many decades of experience, both in producing finishing specifications and selecting and designing the right masking scheme. This can be the key to ensuring that machined components meet aesthetic and performance standards, while moving through the finishing process within time and budget.

Get in touch with one of the engineers at Powdertech Surface Science to discuss your requirements.

Using Powdertech TiZr passivation for enhanced adhesive bonding

Powdertech Surface Science — 21/11/2023

Within the recently launched lightweight commercial vehicle from Watt Electric Vehicle Company (WEVC), our optimised TiZr passivation is used to enhance adhesive bonding for the lightweight aluminium chassis.

On lightweight aluminium, Powdertech TiZr passivation matches anodising for enhanced adhesive bonding strength. Read our technical paper and case study.

TiZr for enhanced structural bonding, in preference to anodising

Optimised TiZr passivation of the aluminium enables strong and repeatable bonding of the high strength aluminium adhesive, delivering a rigid core structure.
WEVC has used TiZr for this vehicle build, in preference to anodising, as it enhances adhesive bonding to the same degree, and uses less energy. The stable layer formed is also suitable for welding.

Innovation in the build

Lightweighting is key. A unique vehicle architecture, the PACES platform, is formed from lightweight aluminium extrusions.
The extrusions interlock and bond together using a patented innovation known as FlexTech®.
This is the first commercial electric vehicle to be using recycled aluminium for its chassis build.
The battery base plate utilises another Powdertech Surface Science process - PowderBond - an adhesive-free surface treatment to bond polypropylene composite material to aluminium. PowderBond has been used to create a lightweight, strong and rigid 'sandwich' laminate of aluminium and composite material for the fully integrated structural battery case. For more on PowderBond visit https://www.powderbond.co.uk/

Sustainability with purpose: Powdertech's sustainability partnerships, driving the real change!

Powdertech Surface Science — 10/10/2025

Powdertech takes accountability for efficient waste recycling, energy conservation and is committed to making its entire operation more sustainable. Beyond standard recycling streams, the company partners with specialised organisations to responsibly handle materials such as metal, wood, and even waste powder - traditionally considered difficult or hazardous to recycle.

The partnership goes beyond sustainability - it’s also an ethical commitment to supporting local businesses and charities. With the backing of their sustainability partners, including L.C. Hughes Partnership, Oxford Wood Recycling, Lovibond Water Testing UK, Bucks Recycling, SERFILCO, Plastratum Limited, and Sirfilco International, Powdertech remains consistently motivated to improve and push the boundaries of responsible practice.

Partners in Sustainability

Powder waste, a traditionally hazardous waste stream, is generally disposed of via specialist contractors and processed at a landfill. For this, they have been able to partner with Bucks Recycling, who assists in finding ways of processing non-hazardous waste, and organise a disposal route into the energy reclamation sector.

For metal recycling, Powdertech is in partnership with a local family-owned firm in Bicester, LC Hughes Partnership, specialising in metal reclamation and recycling. Helping to support local employment and minimising the transport mileage.

Oxford Wood Recycling, a registered charity based in Oxford for wood recycling. They offer a service of collection, sortation, and repurposing via their online store, or processing into the agricultural or energy reclamation sectors, and can process almost any form of wood on-site with minimal impact to a business operation.

To manage wastewater, they partnered with Sirfilco International, Plastratum, and Lovibond to create a system to fully manage and treat the wastewater stream. They provide a high-spec system that caters to everything from tank-by-tank testing, continual flow or batch filtration of process water, and capture of contaminants in solid form for disposal, to final processing of end-of-life chemicals.

The ‘Great 100’ Made in Midlands awards

Powdertech is thrilled to participate in ‘The Great 100’ awards by Made in Midlands for the ‘Sustainability Champions’ category. Show support by filling out the nominations form and nominate - Operations Director, Phil Tyler, Engineering Manager, Ian Manning, Manufacturing Engineer, Richard Knight, the leaders behind Powdertech's successful sustainability projects. Stay tuned to know more about sustainability projects at Powdertech through their ‘Sustainability Spotlight’ series.

Ian Manning steps up as the Head of INTRICOAT (precision powder coating) at Powdertech Surface Science

Powdertech Surface Science — 27/02/2026

Powdertech Surface Science is pleased to announce that Ian Manning has stepped up as the Head of INTRICOAT, a precision powder coating service designed for complex, high-quality machined components.

“What makes INTRICOAT unique is the level of precision and engineering that goes into every project. I am further strengthening our processes, advancing our masking capabilities, and working closely with customers to refine our precision powder coating process and support the complex requirements of niche sectors.” - Ian Manning, Head of INTRICOAT.

Strengthening leadership in precision powder coating

Ian joined Powdertech in 2020 and became a key technical figure within the business. A go-to expert for powder coating, wet paint, advanced 3D CAD-designed masking, assembly, and testing. Ian brings in extensive hands-on technical leadership required in demanding engineering applications and a meticulous approach to quality and process control at INTRICOAT.

Before joining Powdertech, Ian spent many years at Triumph Motorcycles Ltd, where he played a pivotal role in helping to establish overseas coating plants. This background has given him a deep understanding of scalable processes, quality systems, and the importance of consistency across complex coating operations.

His experience, attention to detail, and passion for quality align perfectly with Powdertech's commitment to delivering high-performance coatings in sectors that require demanding powder coating applications.

Supporting customers with precise, engineered & defect-free surface finishing solutions.

INTRICOAT is Powdertech’s precision powder coating service, developed specifically for intricate components requiring high-quality coatings.

At INTRICOAT, complete ownership of the project is undertaken to move it forward, wherein customers don’t have to assign more resources with every step. The service is widely used by customers in niche sectors like medical, aerospace, defence, robotics, and lighting, where quality finish, aesthetics and masking accuracy are of critical importance.

As the Head of INTRICOAT, Ian leads in-

1. Driving continuous improvement in precision powder coating processes

2. Overseeing advanced masking techniques using 3D CAD-designed solutions

3. Maintaining the highest standards of quality control and inspection

4. Working closely with customers to develop bespoke coating solutions for complex parts

A step towards continued development and innovation in quality surface finishing services.

Powdertech Surface Science has built a reputation for over 40 plus years in tackling coating challenges and surface treatments. And Ian’s technical leadership at INTRICOAT strengthens this capability further, ensuring the customers benefit from deep technical knowledge & collaborative problem-solving.

Ian’s focus will be on ensuring every INTRICOAT project delivers a defect-free finish, reliable performance, and a consistently high standard, even for the most complex and challenging geometries.

Investing in quality, reliability and consistency: Lesta robot MVA6 6axis.

Powdertech Surface Science — 25/02/2025

Powdertech Surface Science has invested in Lesta robot MV A6 6 axis to enhance the consistency of finish on high-volume aluminium components. They have introduced robotic powder coating for consistency and precision in those areas which previously were refinished by hand.

Robot video You Tube link - Aluminium powder coating robot : Lesta Robot MV A6 6 axis

In components with deep holes and recesses, the electrostatic charge required to attract the dry powder to the metal surface can create the ‘Faraday effect,’ partially repelling the powder from the edges of holes. In order to achieve complete coverage, prior to oven curing, these areas were carefully coated by hand.

Now Powdertech Surface Science is using robotic refinishing, bringing important benefits-

For customers:

Consistent thickness of finish across edges and into recesses.

Repeatability - every batch of components will meet the same high standards.

Intricate and complex designs, often requiring masking, will be dealt more easily - robots can be configured to follow intricate paths and coat areas that would have been difficult for manual operators to reach adequately.

For the business:

For Powdertech, using the robot for this phase of coating operation provides reassurance that the finished product reaches the high standards demanded by the team at Powdertech on behalf of their customers. The robot can be programmed for each design, making it easy to switch between projects. Bottlenecks are reduced as the robot can work without needing breaks! – and the capacity of the plant is increased.

Powdertech’s Production Director Phil Tyler said: “At Powdertech our aim is to help our customers deliver their promises to their own customers. Reliability, precision and consistency are central to achieving this. Our manual application for tricky areas has always been excellent but the robot just takes it one step further. And with that part of the process in good hands, our powder coaters can concentrate on other requirements. We invest in premium equipment, and talented people, to ensure that we remain at the cutting edge of the aluminium surface finishing sector in the UK.”

Discover how Powdertech supports their customers with high quality innovative solutions HERE

Powdertech's latest investments drive technical excellence

Powdertech Surface Science — 28/05/2024

Powdertech Surface Science are proving themselves as leaders in the powder coating industry after making investments into cutting edge equipment and top-tier experts. Made in the Midlands spoke with Powdertech Marketing and Sales Manager Jimmy Phillips who discusses the developments and innovations driving the business forward in order to deliver high-quality, especially in areas requiring technical finesse.

Based in Bicester, Powdertech are celebrating their 40th year of business this year and position themselves as “The most technically advanced aluminium powder coating and surface treatment provider in the UK”. From automotive to medical equipment, the firm supplies premium chemical pre-treatment, powder coating and bonding services to a variety of niche market sectors.

Specialising in challenging powder coating tasks, the company focuses on precision and excellence by building a clear understanding of their customer’s requirements during preproduction consultation. Their investments extend beyond physical infrastructure to include a dedicated engineering team and a technical manager, Dr Nick Welton, with a PhD in polymer chemistry.

The company's commitment to technical prowess is evident in their investment in "INTRICOAT," a specialised facility designed for intricate coating processes. Led by Ian Manning, formerly of Triumph Motorcycles, this facility combines a laboratory-like environment with bespoke masking schemes tailored to each project's unique requirements.

(Ian Manning, Engineering Manager at Powdertech)

Powdertech's technical expertise isn't confined to their physical facilities. Dr. Nick Welton, their technical manager, brings a wealth of experience in surface treatments and chemistry, enabling them to participate in cutting-edge research projects. Their recent involvement in the "ALIVE" project, alongside automotive giants like BMW and Volvo, underscores their reputation as leaders in surface treatment and powder coating expertise.

(Dr Nick Welton, Technical Director at Powdertech)

In addition to human expertise, Powdertech has embraced automation and digital advancements. Jimmy Phillips, Marketing and Sales Manager, said: “We’ve invested in robotic technology to enhance consistency and quality in coating processes, significantly improving reliability and lead times for our customers. The quality control lab boasts state-of-the-art XRF and Instron equipment for testing metal cleanliness and bonding strength.” The latest developments are proving that the company is setting new standards for quality assurance in the industry.

Whilst their focus on electric vehicles (EVs) is evident, Powdertech’s ambitions extend beyond this sector. They aim to be the most technically advanced powder coater in the UK, leveraging their automotive and EV expertise to penetrate aerospace, defence, and medical device industries more frequently.

Looking ahead, Powdertech sees their investments and innovations as a springboard for future growth. They invite businesses facing challenging coating tasks to engage with their team, confident in their ability to deliver industry-leading solutions.

Find out more about Powdertech by heading to their microsite https://powdertechsurfacescience.madeinthemidlands.com/

Not a member of Made in the Midlands? Contact us now.

Design your finish at the start - Save production time and money.

Powdertech Surface Science — 04/09/2025

Does this sound familiar? Your component is halfway into production before anyone realises that something in the finish spec is not quite right.

The result?

Problems with your coating, costly production reworks and lost time, and, in some cases, redesigns that delay your project.

Imagine having a checklist in hand before you begin coating, one that is tailored as per your component and its end use. By getting it right early, you can avoid surface defects mid-production, save cost and time, and achieve your desired surface finish right the first time!

Understand your component’s journey -

Performance specifications -
This step looks at the end use first. How will your component work in the real world? Will it face corrosion? Harsh weather? Heavy wear? This determines the level of resistance, durability, and protection the finish needs to deliver to the component.

Material selection & forming process -

The way your part is formed - cast, extruded, or machined- has a direct influence on the finish. For example, castings may require degassing during the curing stage to prevent porosity or metal outgassing. Understanding this early on means your coating has a higher chance of performing better.

Building your finishing specification

Here’s how Powdertech helps you set up for success -

A/B/C surface zones -They work with you to map your component into priority zones, clearly identifying the surfaces that matter most for function and appearance.
Complex component masking -
Engineers at Powdertech are experienced in designing masking schemes that keep the areas you need to be free of powder, as per your spec requirement, without causing problems like powder burrs in other areas of the part. Powdertech has invested in a dedicated INTRICOAT facility, located within their plant, to be used exclusively for handling complex components.

3. Choosing the right powder as per your spec -

With Powdertech, you choose powders and finishes based on components’ functional needs and aesthetic goals - gloss, satin, matt, metallics, textures, ensuring they meet both visual and technical requirements.

Check out the video to understand INTRICOAT process at Powdertech

The team at Powdertech knows the common pitfalls before they happen and how to prevent them. Picking up design, material, or finishing challenges early on, means fewer rejects and fewer production delays

Get the details right early, and make surface defects, costly re-production processes, and wasted time a thing of the past. Connect with Powdertech team to discuss your powder coating requirements.

The complete guide to dielectric coating for EV battery assemblies: Edge issues

Powdertech Surface Science — 29/05/2025

Epoxy powder coatings have been successfully used to insulate copper buss bars used in
electrical switchgear for decades. The development of high-voltage battery systems used in
modern BEV vehicles has increased demand for insulation coatings to prevent arcing between
metal components within the battery enclosure. However, repurposing these proven insulation
coatings from the simple geometry of copper buss bars to thin-gauge, complex aluminium
components presents a number of challenges for successful implementation.

This series of articles discusses some of the key challenges that need to be overcome to deliver
a satisfactory solution.

Challenge 1 – Cut edges issues in dielectric coating process.

Dielectric coatings tend to thin at edges, particularly around sheared metal corners and smallradius features, where the geometry can resist even coverage. Even a minor reduction in coating thickness at an edge can lower insulation resistance below acceptable thresholds, leading to
partial discharge, electrical arcing, or outright machine failure.

Microscopic view of a sheared edge.

What are the key challenges in getting electrical insulation properties around cut
edges?

The primary purpose of a dielectric coating is to electrically insulate components to a specified
voltage. The dielectric strength of the coating, measured in kV/mm, allows a simple calculation
of the minimum coating thickness required to provide insulation resistance.

On flat surfaces, dielectric coating is easily accomplished, but cut edges provide a challenge.
Due to a surface tension effect, coatings have a tendency to pull away from sharp edges,
reducing the thickness and, hence, the isolation resistance in the case of dielectric coatings

Microscopic view of how the coating pulls away around the edges.

Both the shape and edge radius contribute to the reduction in paint thickness.
The edge geometry is determined by the forming process so shearing, laser cutting, stamping,
sawing will develop a different profile.

Different edges formed based on forming techniques.

At Powdertech, they understand this and advise involving experts from the prototype stage and
not just post production to ensure that the coating is right the first time.

They have studied different coating systems and their interaction with different edge geometries
to provide a working solution for a variety of applications.

Tackle edge burrs in dielectric coating process with Powdertech.

- By altering the edge geometry, pre-treatment compatibility, masking strategies and
thickness targets they can tailor the properties to the required specification requirements.

- Tailoring your powder coating process, including coating thickness, number of coats and
other elements, to ensure you reach the required insulation properties as per your spec.

-Powdertech advise on handling the parts right, this is a crucial aspect to avoid edge defects
as thin aluminium components are more prone to edge damage.

Dielectric Coating Testing at Powdertech

Testing is crucial and Powdertech’s team brings decades of technical experience to support all
your needs from start to finish.

They conduct HI-Pot testing, Holiday testing and cross-sectional microscopy to gauge if dielectric
coating has met specifications. This allows them to verify coating integrity before final
deployment.

At Powdertech, they have an in-house testing facility to ensure the accuracy of the dielectric
coating in EV battery systems.

Dielectric coating represented through edge A has the higher passing rate when tested via Holiday testing. The test and dielectric coating were conducted for one of their biggest automotive clients.

Powdertech’s lab-tested methods, dielectric coating experience, and collaboration at each
stage means your dielectric coating performs where it matters most, even at the edges. Contact Powdertech to see how they can support your dielectric coating project.

18,000 Litres of water saved daily : Reusing and minimising wastewater through newly installed water treatment plant.

Powdertech Surface Science — 22/07/2025

Powdertech has recently invested in an on-site water treatment plant to improve their water treatment processes. The newly installed water treatment plant allows to save and reuse circa 18,000 litres of water per day, a significant reduction in their daily water consumption.

The plant also ensures that all discharged water is free of contaminants like aluminium, titanium, zinc, magnesium, and more, which helps in reducing environmental impact and contributes positively to the local water network.

Powdertech has designed this water treatment system to extract the chemicals, metals, and other contaminants from their pre-treatment rinse tanks (generated as part of their TiZr and Passivation processes), by filtering the liquid and recirculating it for reuse.

Investing in the water treatment plant shows Powdertech's proactive steps to reduce contaminants, conserve water, and minimise waste.

Water treatment plant set up at Powdertech Surface Science

Water treatment plant structure.

The water treatment plant comprises a 5,000-6,000-litre holding tank, activated charcoal process tanks, and four filter media stations for filtration, which ensure that contaminants such as zinc, magnesium, and aluminium are safely filtered out.

The system also integrates an innovative regeneration process for the filter media, allowing them to reuse materials and reduce the need for frequent replacements. This sustainable approach extends the life of the resources and minimises waste, while ensuring the quality of the water discharge.

The process uses two chemicals – hydrochloric (acidic) and caustic (alkaline). This ionises the water, balances the pH levels to neutralise it before it is returned to the tanks for reuse. Contaminants are captured within the four stages of filter media, which will be periodically emptied and then regenerated.

They repurposed their old Keronite process line and saved on unnecessary construction, avoiding disruption. This demonstrates Powdertech's long-term commitment to reducing waste and making efficient use by repurposing the resources they already have.

Benefits beyond Powdertech

Metals, such as magnesium, nickel, copper, iron, titanium, chromium, zinc, and more, when discharged in controlled levels, can easily be treated by wastewater management authorities like Thames Water.

Secondly, Powdertech's local Wastewater Treatment Works (WTW) features biodigesters, which use microbes to create natural gas by digesting the solids recovered from the sewage stream.

The byproduct of this process is a “cake” that is used within fertiliser. This provides an important revenue stream for Thames Water. By controlling the discharge onto the water streams, microbes in the biodigesters are protected, supporting continuous production of natural gas without any hindrance.

This on-site water treatment plant makes Powdertech more self-reliant by repurposing its wastewater before discharging into the water stream, reducing the dependency on Thames Water to process heavy effluents.

Periodically, the water would be discharged as part of regular plant maintenance, but this discharge will be contaminant-free and 100% safe to enter the local Thames wastewater treatment works.

Polishing of wastewater through filters to enable reuse of valuable water.

Sustainability champions behind the project

The estimated cost of the water treatment project is around 120-130k. Powdertech started the project in 2024, and it is aimed to be completed by the end of July 2025. Powdertech's Operations Director, Phil Tyler, and Manufacturing Engineer, Richard Knight, are the leaders behind the execution of the water treatment plant set up and its regular monitoring.

Key driving factors - The bigger picture.

The major driving factor to set up this process was:

To improve the quality of water discharge.
Reduce and reuse the amount of water consumed by circa 18,000L per day.
Introduce fewer contaminants to the water network.

Steps towards sustainability - One project at a time!

This project is just one example of how Powdertech is continuously leading by example. From being the first company to go chrome-free in the UK since 2000 to being proactive towards sustainable water management solutions.

Powdertech is proud to be part of the British manufacturing industry, a sector that is steadily improving its environmental footprint. With ISO 14001 and ISO 9001 certifications, Powdertech is building a culture of responsibility that will help to make their operations more sustainable, demonstrating responsible manufacturing practices that contribute to British circular systems.

The ‘Great 100’ Made in Midlands awards

Powdertech is thrilled to participate in 'The Great 100’ awards by Made in Midlands for the ‘Sustainability Champions’ category. Show your support by filling out the nominations form. And stay tuned to know more about sustainability projects at Powdertech through their ‘Sustainability Spotlight’ series.

#Great100 #BackingBritain #MemberNews #UKManufacturing

Dielectric coating consultancy: Powertech's best-in-class dielectric coating solutions with Gema Switzerland.

Powdertech Surface Science — 19/05/2026

Dielectric coating requires a higher level of control of several variables to achieve high pass rates. As the process is designed to provide electrical insulation, a critical safety feature, the coating must be within specified thicknesses, provide a given level of dielectric strength, and be free of porosity, pinholes, and other surface defects.

Parts must also function as part of the vehicle as a whole, meaning typical elements like corrosion resistance, bond strength, and durability must also be managed.

Dielectric coating at the Powdertech Bicester facility.

Powdertech’s visit to Gema, Switzerland.

Powdertech team, including Head of Sales and Marketing Jimmy Phillips, Technical Manager Nick Welton, and Production Engineer Stuart Hutt, visited Gema Switzerland in March 2026 as part of a major consultancy and development project with an OEM that they are working with for dielectric coating trials.

Powdertech team at Gema, Switzerland.

Powdertech’s Head of Sales and Marketing, Jimmy Phillips, said:

“At our own facility in Bicester, we have shown that parts can be coated to specification. We’ve designed a system where parts have the requisite dielectric strength on faces and edges, without going over thickness specs. It was a pleasure watching Nick and Stuart work with the experienced team at Gema to deliver a best-in-class solution for our client.”

Powdertech has a lot of experience within the challenging field of dielectric coating, having worked with major UK OEMs and tier one suppliers over the last five years. And are increasingly being approached to provide consultancy services in the field, as well as coating thousands of parts a week on-site at their own powder coating lines.

For this project, Powdertech has been involved in advising on the dielectric coating of EV battery assembly components.Initial work on the project has taken place at Powdertech’s Bicester facility, where trials have been conducted on how to coat various parts of the EV battery pack as per the client’s specifications.

Facing a dielectric coating challenge?

Powdertech has been providing dielectric coating for over five years and consultancy for the last three. You can reach out to the team or contact them to discuss your dielectric coating project requirements.

Powdertech's INTRICOAT powder coating service at Subcon 2023

Powdertech Surface Science — 12/06/2023

June 8^th-9^th we were at SUBCON 2023 at the NEC - our thoughts following our first ever show....

Three days well spent (set up included) learning more about our customers, exchanging ideas and exploring potential collaborations. Thank you to everyone who stopped by and chatted with us. Your professional expertise and feedback on the services we provide is greatly appreciated. The Muov TiltBike, showcasing our exceptional INTRICOAT powder coating was a good draw - sorry that we couldn't risk letting anyone having a go ! It's not ours, but kindly lent to us by MUOV.

In addition to thanking Chris Staunton at MUOV (including his assistance putting up our stand) we'd also like to thank our clients Morgan Motor Company and Blighter Surveillance Systems who allowed us to use their promotional videos in our show reel. Finally a huge thank you to Ben Cottman at Aerial Film and Photo - Media Production for everything show related - including artwork printed and set in place, our superb show reel and a van-based taxi service to get us to the NEC and back.

As we all know, nothing beats chatting with professionals in your industry sector. You can learn a lot, as well as creating a more tangible awareness of your brand and service offering.

INTRICOAT is our premium powder coating service, designed for complex low-volume machined aluminium components. By low volume we mean as low as a single item - we often work on prototype designs that need aesthetic perfection. With CAD masking schemes designed in consultation with you and conscientious attention to detail and quality control, we relieve you of the hassle of ensuring a perfect coating – it is our responsibility.

Powdertech Surface Science

INTRICOAT powder coating at SubCon 2023, June 7-8, NEC

Precision powder coating and masking for exquisitely machined components

Powdertech Joins Community of Modern Manufacturers

Powdertech exhibiting & speaking at Southern Manufacturing & Electronics Expo 2026

Powdertech’s seminar at SME 2026 – ‘Design your finish at the start’.

Meet the Powdertech team

Powdertech Surface Science exhibiting at Manufacturing Solutions UK 2025

Powdertech Surface Science exhibiting and speaking at Southern Manufacturing & Electronics event, 2025!

TiZr for enhanced bonding in Nichols N1A supercar

Our optimised TiZr process can match the bond strength and durability of anodised treatments

Loughborough University Motorsport's electric Formula racing car with Powdertech’s advance dielectric coatings.

Potential dielectric coating challenges

Collaboration with Powdertech Surface Science for technically advanced dielectric coating

Achieved desired performance and reliability.

Powdertech participates in ‘The Great 100, Sustainability Champions’ awards by Made in Midlands

Powdertech is excited to be a part of ‘The Great 100, Sustainability Champions’ awards by Made in Midlands.

Sustainable operations at Powdertech Surface Science -

Help make a difference: Nominate Powdertech as the ‘Sustainability Champions’.

Cleaning aluminium prior to surface treatments

How clean is clean ? And how do we know if we have cleaned your aluminium to the best possible level?

The complete guide to dielectric coating for EV battery assemblies: Porosity issues

What is porosity in dielectric coating?

What are the causes of porosity in dielectric coating?

How to prevent porosity in dielectric coating?

How to test for porosity in coated parts?

Optimised TiZr conversion coating for enhanced structural bonding.

Ensuring high structural strength in a lightweight chassis

Building circular systems; Reduction of hazardous waste through efficient recycling.

Mixed recyclables; Contaminated plastic chemical containers

Waste powder

Effluent discharge / contaminated water

Mixed recyclables

Can they get the product to and from the site without single-use packaging?

Can the packaging received be reused?

Chemical storage drums

This issue is addressed via a simple principle, making the containers clean enough to be recycled. Make them small enough to store and transport, making the project economically viable and sustainable.

Powder coatings are greener than you think!

Affluent reduction in local water networks

Project investment and our sustainability champions

And what does this mean for Powdertech? This would mark the end of our final hazardous waste stream!

The ‘Great 100’ Made in Midlands awards

Powdertech’s TiZr Passivation, paved the way to a smarter choice for consistent bonding and welding of aluminium.

Powdertech exhibiting at the UK’s leading battery shows of 2026

Exhibiting at Battery Tech Expo 2026, 23rd April at Silverstone.

Technical seminar at Battery Cells & Systems Expo, 8th & 9th July at NEC, Birmingham.

Why connect with Powdertech?

Recruiting a Marketing & Sales Manager

Join our lively, motivated team

Dr Nick Welton joins Powdertech Surface Science

Can powder coating hide metal surface imperfections?

Can powder coating cover scratches or surface imperfections on metal?

The result

Starting a new project?

Why choose Powdertech?

Sustainability in action: Richard Knight leading change at Powdertech Surface Science

INTRICOAT - Best-in-class products need best-in-class surface treatment

Intricoat - starts with a detailed CAD masking scheme

Pre-treatment for corrosion resistance

Masking and powder coating in our Intricoat 'clean room'

Benefits of Intricoat - Taking care of every aspect

The complete guide to dielectric coating testing for EV battery assemblies.

Powdertech Expansion and Commitment to a Robust UK Industrial Strategy

Powdertech continues to invest in state-of-the-art equipment to ensure highest quality output

Precision powder coating quality control: INTRICOAT’s testing and inspection process.

INTRICOAT’s powder coating quality control overview

Pre-production analysis and process validation

INTRICOAT’s daily process control and pre-coating system checks

Batch-level quality control and incoming part inspection

Pre-treatment verification and surface analysis (XRF testing)

Coating performance and cosmetic quality checks at INTRICOAT

Special testing and problem management (subject to a special request from the customer or if problems arise)

Why choose INTRICOAT by Powdertech?

Powdertech 2024 – Proving the value of ‘doing it right’ across all service delivery

Powdertech’s seminar at Battery Tech Expo, 2025

Sophisticated powder coating techniques for the latest indoor cycling experience

Powdertech invests in dielectric testing capacity for high-volume dielectric coating projects

Precision powder coating at Southern Manufacturing & Electronics, Feb 6-8 2024

Backing Britain through sustainable manufacturing: Powdertech team honoured as ‘Sustainability Champions’ at the Great 100 Awards.

Driving sustainability in surface finishing

What are the key challenges in getting electrical insulation properties around cut
edges?