E-Coating
Corrosion Resistant, Complete Coverage, Cost Effective
E-coating, also known as electrocoating, immerses metal parts in a charged liquid coating bath. An electrical current draws the coating evenly onto the entire surface—even complex shapes, recessed areas, and hard-to-reach spaces—before the parts are cured in an oven.
At Great Dane, we e-coat complex parts and high-volume production runs while maintaining a sub-1% rework rate. The process provides consistent coverage and a durable, corrosion-resistant finish. After coating, the parts are heated to a specific temperature to cross-link and fully cure the material, creating a protective finish designed to provide long-lasting corrosion protection.
E-COATING SPECIALISTS
E-Coating Services
Great Dane specializes in electrocoating a wide variety of metal substrates, providing uniform coverage and dependable corrosion protection—even on complex parts, recessed areas, and hard-to-reach surfaces where a spray application wouldn't reach.
We understand that every project is different, which is why our dedicated e-coating facility in Pennsylvania is equipped to handle everything from small components to large assemblies. Since bringing the facility online in 2019, our team has provided e-coating services to manufacturers throughout the Eastern United States.
Our e-coating process delivers consistent, durable coverage across every part, helping protect metal surfaces from corrosion and wear while maintaining a clean, uniform finish.
E-Coating
- Axalta AquaEC 6000 series coatings
- Sub-1% rework rate on production runs
- Fast 5-day turnaround on most orders
- Capable of handling a wide range of part sizes and configurations
For projects requiring additional durability and protection, Great Dane also operates a separate Powder Coating facility. This allows us to combine e-coating and powder coating under one roof, applying powder over an e-coat primer when a tougher, dual-layer corrosion-resistant finish is required.
What are the advantages of e-coating?
Choosing e-coating offers several benefits compared to other coating methods:
Even coverage on complex shapes: E-coating reaches recessed areas, seams, and interior surfaces that spray methods miss.
Thin, uniform film: The immersion process builds a consistent, protective layer without adding bulk or weight.
Enhanced corrosion protection: E-coat resists rust and also works well as a primer under other finishes.
Environmentally friendly process: The water-based bath avoids flammability issues and produces very little waste.
Precise film thickness control: Adjusting the electric current sets a predictable, repeatable coating thickness.
High material efficiency: Nearly all of the coating material is used, which keeps waste and cost low.
Ideal for high-volume runs: Automation and consistency make e-coat well suited to large production orders.
HOW IT WORKS
How does e-coating work?
E-coating immerses a metal part in a charged bath, then bakes it into a thin, even film. The result protects complex parts inside and out.
Our electrocoat system runs an eight-stage zinc phosphate pretreatment, then the electrocoat application. Racked parts enter a charged bath of Axalta AquaEC 6000 series coating. An automatic voltage control system works with the direct power source to deliver uniform film thickness regardless of the square footage being coated. The current reaches every conductive surface, including recessed areas and seams. A post-rinse removes the excess, then a curing oven sets the film. E-coat works as a primer, as a top coat, or as both, and it pairs with other coatings including powder.
Ready to put e-coating to work?
Great Dane e-coats parts for manufacturers across many fields. From automotive and construction to energy, HVAC, and more, see the full range on our Industries Served page. Whatever your parts and finish needs, our team helps you get them right.
Want more than corrosion protection? We also offer Custom Coating services like masking, custom handling, and packaging, along with powder coating for a tougher topcoat. And if you want to see exactly how we finish your parts start to finish, walk through our process step by step.
When you are ready, request a quote and tell us about your job. We will recommend the right approach and turn around a price you can count on.