How to solve the problem of fat edge in powder electrostatic spraying?
How to solve the problem of fat edge in powder electrostatic spraGreat question! **”Fat edge” (or edge Great question! **”Fat edge” (or edge build-up)** in powder electrostatic spraying is a common problem where excess powder accumulates on the edges or corners of the workpiece. It leads to thick coatings, runs, and poor appearance after curing.
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## ✅ **Why Fat Edge Happens:**
– Electrostatic forces naturally attract more powder to sharp edges.
– Higher electric field strength at corners pulls more charged particles.
– Over-spraying or incorrect gun settings worsen the effect.
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## 🔧 **Effective Solutions to Control Fat Edge:**
### 1️⃣ **Adjust Electrostatic Settings**
– **Lower the voltage (kV) to 30–50 kV** when spraying edges and corners.
– Reduce microamps to limit charge accumulation.
– Avoid holding the spray gun too close to edges.
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### 2️⃣ **Control Spray Distance and Angle**
– Maintain **6–12 inches (15–30 cm) spray distance**.
– Spray edges at an angle rather than head-on.
– Move the gun **quickly across the edge** to avoid over-depositing.
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### 3️⃣ **Use Advanced Powder Coating Guns with Smart Control**
– Some guns have **”edge coating” or “Faraday mode”** to reduce voltage automatically when detecting complex shapes or edges.
– Flow control settings help minimize powder release near edges.
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### 4️⃣ **Optimize Powder Flow Rate**
– **Reduce powder output** slightly when spraying near edges.
– Too much powder flow increases edge build-up risk.
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### 5️⃣ **Pre-heat Large or Complex Parts (Optional)**
– Slight preheating helps even out the powder layer but must be carefully controlled to avoid premature curing.
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### 6️⃣ **Powder Selection Matters**
– Use powders with better flow characteristics designed for **Faraday cage areas or complex geometries**.
– Finer powders tend to stick more to edges—choose a balanced particle size.
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### 7️⃣ **Manual Touch-up or Masking (For Critical Applications)**
– Use **edge masking tapes or shields** if consistent fat edge is unavoidable.
– Sand down excess before curing if caught early.
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## ⚠️ **Consequences if Not Fixed:**
– Runs, sags, and drips
– Poor edge durability (can crack or chip later)
– Aesthetic defects in visible parts
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## 🚀 **Quick Pro Tip:**
✔️ **Spray large flat areas first**
✔️ **Then reduce kV and powder flow**
✔️ **Spray edges last using a lighter pass**
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Would you like help **adjusting your gun settings** or **choosing powder designed for edge control**? Let me know your setup (manual or automatic) and part type!
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