By Eric Casebolt, The ChemQuest Group, Inc.
Although technology trends in areas such as powder coatings don’t shift dramatically from year to year—low-temperature cure and sustainability would top that list every time—it is always valuable to look at where powder coating manufacturers and raw material suppliers are actively pushing innovation. That is not to say that topics such as low-temperature-cure powder coatings are not being addressed, but this article will instead focus on areas where there appears to be significant, ongoing progress.
Of interest here are the areas where companies still catching up are asking a lot of questions at conferences, while those at the forefront of technology share just enough information to let everyone know they are the technology leaders. Three areas in particular continue to generate significant activity: improved aesthetics, dielectric powder coatings, and PFAS-free materials.
Improved Aesthetics
Improving aesthetics in powder coatings remains an active area of research, especially in architectural coatings, where powder coatings continue to compete with liquid coatings for market share. While powder coatings excel in several areas, such as single-coat, direct-to-metal applications, and environmental profile, they still lag behind liquid coating in some aesthetic categories, including smoothness, gloss range, and metallic finishes.
Smoothness is directly related to film build, so improving smoothness requires doing so at increasingly lower film builds. This is important because the single factor that most inhibits powder coatings in an as-applied cost comparison is the need to be applied at higher film build, which is required to achieve a smooth coating with adequate coverage and hiding. However, developing smoother powder coatings is not as straightforward as it may seem at first glance.
Modifying the binder by lowering the glass transition temperature (Tg) will result in improved flow, but it often creates challenges with powder processing and storage stability. As a result, formulators go well beyond working with lower Tg materials and consider options such as crystallinity, hybrid materials, and additives to improve processing and storage stability without negatively affecting flow during the curing cycle.
Gloss range is another area where powder coatings continue to improve. Gloss control in powder coatings is more complicated than it is in liquid coatings. Rather than relying on large-particle-size extender pigments to reduce gloss, powder coatings must use techniques such as controlled incompatibility and differential cure. Over the past several years, powder coating manufacturers have continued to develop methods of expanding the achievable gloss range, even in the extremely challenging AAMA 2605 space, and now rival the gloss range available with liquid coatings in most applications.
Finally, we are seeing continued improvement in metallic finishes. Powder coatings have historically struggled with the dispersion and orientation of metallic pigments needed to create a bright, uniform appearance. To address this challenge, the industry relies on a process known as metallic bonding, in which a polymer matrix, metallic pigment, and additives are combined using specialized mixing equipment prior to being dry-blended into the finished powder coating.
Many powder coating companies use third parties to perform this process, but those at the forefront of the technology conduct the metallic bonding in-house and keep the details of both the formulation and process very close to the vest. These companies understand that architects and brand owners are looking for a consistent, bright metallic appearance that creates a sense of depth, and they market their products accordingly.
As powder coating companies continue to improve smoothness, gloss range capability, and metallic appearance, they will increasingly take market share from liquid coatings in decorative applications over metal substrates. While a rising tide may lift all boats, the companies that can deliver superior aesthetics without sacrificing the durability and environmental profile that powder coatings are known for will ultimately rise to the top.
Continue reading in the July-August 2026 Issue of CoatingsTech.