Plasma polymer composite coating: the advantages and disadvantages

Plasma-sprayed coatings are highly flexible and are a popular choice across various industries. They have many advantages over other coating types.

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Firstly, they can provide a coating that is resistant to wear, corrosion, heat, electricity, and oxidisation. These are very useful properties to have and can prove crucial in some scenarios.

Secondly, the bonds that are created are strong and can be either mechanical, semi-fused or metallurgically fused

Thirdly, the substrate that can be coated using this process can be any type of metal, ceramic, plastic, or even wood.

Fourthly, the coating itself can be made of a wide variety of materials. Metals like stainless steel can provide corrosion resistance, whilst ceramics such as zirconia or alumina can offer wear resistance and high-temperature stability.

Another advantage is that it can be sprayed onto a removable substrate, enabling free-standing parts to be made. Additionally, because the substrate is not heated above 250 degrees Fahrenheit, there will be no distortion.

Polymer composite coatings

The use of polymer composites in the plasma spray process creates coatings that are tough, durable, and have enhanced-release properties. These composites can be tailored to suit individual specific applications.

Plasma polymer composite coatings provide significantly longer non-stick life than conventional polymer coatings and are more scratch and wear-resistant. They also offer enhanced lubricity, a lower friction coefficient, and superb adhesion to both metallic and plastic surfaces.


There are numerous applications for polymer composite coatings including food moulds, confectionery, medical wear, and packaging.

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Potential solution?

If you feel that plasma polymer composite coatings could be the solution you are looking for and would like to know more, there are several specialist firms such as who have excellent online resources for you to take a look at.

Plasma polymer coating – disadvantages

Whilst there are some great advantages to plasma polymer coatings, there are also a few potential downsides to be aware of. These coatings have a fairly low resistance to abrasion, they tend to be fairly thin, and they can be more expensive than other options.

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