Powder Coat vs. Spray Paint: Differences in Durability, Cost & More

Powder coating and spray painting both provide excellent protection but it’s difficult to determine which one is best for certain circumstances. While there are many similarities between the two, they both have drawbacks and limiting factors. Here, we’ll discuss the pros and cons of both and the best applications of each method.

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Difference Between Powder Coat & Paint

While both protect from the elements and corrosion, there are more differences than similarities.

Spray Paint	Powder Coat
Moderate durability but can be touched up	Extreme durability but cannot be touched up
Wet application	Dry application
Done on-site	Done off-site at a specialty shop
For all surface types – cured at room temp	Only high-temp objects – cured in an oven at 380 F or above
24 hours until usable	4 days minimum with shipping
Higher waste with overspray	Low waste
Low to moderate environmental impact	Low environmental impact

What is Powder Coating?

Powder coating uses an oven-cured dry powder to provide a thick, highly-durable coating for metal and other high-temperature resistant objects such as a fence, appliance face or deck furniture. The parts require disassembly and shipping because it is done offsite at a specialty shop.

Spray Painting

Painting uses a wet finish sprayed or electrostatically applied in a thin coat for both corrosion protection and appearance. Usually done on-site, it requires masking for overspray and curing times of up to 24 hours.

What is Powder Coating Spray Paint?

Professionals use two different processes for powder coating – electrostatic spray and fluidized bed dipping. Both methods require high temperatures and use a dry powder but come with some minor differences.

Differences Between Powder Coat Methods

Electrostatic Spray	Fluidized Vat or Bed
Metal only	Metal & high-temp plastics
Better for thin applications	Better for medium to thick applications
Oven cured after application	Preheated before dipping with oven cure after

• Spray methods electrostatically charge the powder and objects. Objects are suspended and coated by a fine, low-pressure mist. The electrostatic charge attracts the powder to the object. Then, the piece cures in an oven to give it a lasting finish.

• Fluidized beds use a large vat with air pumped up through the bottom to fluidize the dry powder. Objects are then preheated and dipped. The longer the dip, the thicker the coat. Most parts require additional oven curing as the final step.

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Powder Coating vs. Painting

	Powder Coat	Painting
Durability	Most durable finish available	Moderate strength Depends on number of layers and type of paint.
Moisture & Rust Resistance	Extremely high resistance to corrosion	High resistance to corrosion Requires more upkeep
Material Cost	Included in application costs DIY Kits run $100-$200	$15-$50+ per gallon
Application Cost	$50-$600 per piece.	$25-$100 per hour
Better for DIYers	Limited DIY kits available Requires practice and space Difficult to correct mistakes	DIY friendly with many equipment options Requires less space and experience Easy to correct mistakes
Environmental Friendliness	Low VOCs Almost no waste	VOCs depend on paint type 20%-50% waste with overspray
Maintenance & Length of Life	Low maintenance 7-15 years depending on surface prep and powder type.	Moderate maintenance depending on the surface 5-10 years depending on the substrate material.
Best Uses	High-use metal and high-temp objects	All surface types

Both have strengths and weaknesses while performing better under different circumstances. Here we’re comparing powder coats to standard paints. We’ll get into specialty paints like hardened enamels and electrostatic painting later.

Durability

Moisture & Rust Resistance

Cost

Better for DIYers

Powder Coat

While great for the hobbyist, is best left to the professionals for bigger projects as mistakes are tough to fix and the cost can quickly add up.

• Pros:
  • Affordable DIY kits are available that include guns, ovens, and powders.
  • DIY kits range anywhere from $100 to $200 but are only useful for small objects.
  • Best for small projects like door handles and car engine parts.
• Cons:
  • Easy to make mistakes and tough to redo.
  • Need large ovens for large objects, increasing equipment investment and space required.
  • Requires extreme detail during surface preparation.

Paint

Though painting can make a great DIY project, it can quickly turn into a disaster without the right preparation, materials or experience.

• Pros:
  • Easy to do with rental equipment making even large projects accessible to DIYers.
  • Mistakes are relatively easy to correct.
• Cons:
  • Requires a longer time investment in preparation and cleanup.

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Environmental Friendliness

Maintenance & Length of Life

Best Uses

Powder Coat

They can only be used on items that can resist the high temperatures of the curing process. Because of its incredible durability, it’s best used on high-use and high-traffic metal objects.

• Outdoor objects — Metal fences, railings, handles, deck, and patio furniture.
• Appliances with metal parts — range hoods, fixtures.

Paint

Because you apply paint at room temperature and on-site to almost any surface type, it is convenient for virtually any object.

• Outdoor — siding, decks
• Indoor — ceilings, walls, trim

Electrostatic Painting vs. Powder Coating

Electrostatic Paint	Powder
Applied on-site or in a shop with wet paint	Always done in a shop with dry methods
Thinner layer	Thicker layer
Moderate durability	The most durable finish available
No heat required to finish	Uses a heated curing process above 385 degrees
Few texture options	Textured surfaces available
Wide range of color choices	Tough to color match

Both use electrostatically charged particles and metal objects to evenly layered for durability and low waste.

Plasti-Dip vs. Powder Coat vs. Spray Paint

	Plasti-Dip	Paint	Powder Coat
Durability	Low	Moderate	High
Cost	Lowest	Moderate	Highest
Lifespan (in years)	1-3	5-10	7-20
DIY Friendly	Yes	Yes	No
Uses	Limited	Flexible	Limited

Plasti-Dip

Plasti-dip is an aerosolized rubber finish that cures to a semi-hardened finish.

• Pros:
  • Cheap and DIY friendly.
  • Protective finish.
  • Easy to remove.
  • Rubberized texture for gripped surfaces like handles.
• Cons:
  • Lasts 1 to 3 years.
  • Very Thick.
  • Few color options.
  • Hard to remove.
  • Easy to gouge and chip.

Powder Coat

• Pros:
  • Extremely durable.
  • Textured finishes available.
  • Last up to 20 years or more.
• Cons:
  • Tough to remove.
  • Can’t touch up.

Paint

• Pros:
  • Flexible uses on many surfaces.
  • Easy to touch up.
  • Lasts 5 to 10 years.
• Cons:
  • Few textured options.
  • Not as durable.
  • Higher maintenance needs.

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E-Coating or Powder Coating

E-coat refers to using a water-based solution that contains a paint emulsion. Electric voltage passed through the solution causes the paint to attach to the metal in an even layer. Just like with powder coating, you’ll finish the object in a curing oven.

It’s a better choice when covering an object that requires a thinner protective shell with tough-to-reach areas. For example, the hinges on a door require clearance to move correctly. A thick layer stops it from functioning.

Baked Enamel vs. Powder Coat

Powder Coat	Baked Enamel
Slightly tougher finish	Tough finish
Evenly applied	Shows runs and brush strokes
Thicker	Thinner

A type of wet paint, baked enamel uses high temps to cure it for a more durable finish.

Despite the differences, both products rely heavily on the pretreatment of the object, the type of resins used, the quality of the product and the quality of the professional applying it. A high-quality enamel applied correctly to a properly prepared substrate is better than an incorrectly-done powder coat – and the same applies in reverse.

Chrome Powder Coating versus Chrome Plating

Chrome powder coating is a process of adding a chrome-like finish to a metal part. Typically done to engines and other car parts, it provides a protective finish at a rate 70 to 90 percent cheaper than plating.

However, it doesn’t perfectly replicate an actual chrome, or chromium, plating process. If you’re looking to restore a classic car or historic home to its original condition, opt for chrome plating.

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1 Comments

1. Andre, February 10:

   Hi, my name is Andre. I am making a paper about metals.

   Do you happen to know if iron metal powders where used in paints like back in year 2000?, or you cant find any iron metal powders in a regular building at that time maybe?.
   ​
   Best regards,
   Andre ​