Your surface finish could be eating up 20–40% of your part cost — without you even knowing why.
We help OEMs and manufacturers identify the true cost drivers in surface finishing1, so you can keep performance high while cutting waste.
If your projects are going over budget, the problem may not be the raw material or machining — it could be the finishing process.
🎯 Why Finishing Costs Matter More Than You Think
In many industries — from automotive to medical devices — finishing costs2 can be the difference between a profitable job and a loss.
The wrong choice can cause:
- Unnecessary processing steps that add days to lead time
- Excess scrap or rework from coating defects
- Over-engineered finishes that don’t add value for the end customer
📊 Key Cost Drivers in Metal Surface Finishing
| Cost Driver | How It Impacts Price | Risk If Ignored | Our Advice |
|---|---|---|---|
| Material Compatibility | Some finishes require costly pretreatments for certain metals | Poor adhesion, corrosion failures | ✅ Choose finishes that match your base material |
| Coating Thickness | More microns = more material + longer cycle time | Wasted cost without performance gain | ⚠️ Use only the thickness needed for the environment |
| Part Geometry | Complex shapes require more masking, racking, or spraying passes | High labor & setup cost | ✅ Simplify geometry where possible for finishing |
| Batch Size | Small runs drive up setup cost per part | High cost per unit | ✅ Consolidate orders to hit economy of scale |
| Environmental Compliance | Hazardous chemicals need expensive waste treatment | Risk of fines, rework, and shipment rejection | ✅ Use RoHS/REACH-compliant finishes to avoid penalties |
| Surface Prep Requirements | Blasting, etching, or polishing adds labor & energy | Adhesion failure if skipped | ✅ Match prep method to finish type to avoid over-processing |
🔍 Hidden Costs Most Manufacturers Miss
- Masking & Demasking Labor — Can account for 10–30% of coating cost.
- Energy Consumption — Ovens, plating baths, and compressed air are major cost factors.
- Rework & Scrap Rates — A single defect can double the cost of that part.
- Over-Specifying Finishes — Adding corrosion resistance or wear layers that the customer never requested.
💡 How We Help You Reduce Finishing Costs
- Process Matching — We choose the lowest-cost finish that meets your specs
- Cycle Time Optimization — Minimize energy & labor in production runs
- Defect Prevention — Targeted prep and QC to avoid costly rework
- Compliance Assurance — Avoid fines, delays, and rejected shipments
🚀 Get a Free Cost Reduction Analysis
Upload your part drawing today, and in 24 hours we’ll:
✔ Identify hidden finishing cost drivers in your design
✔ Recommend lower-cost, compliant alternatives
✔ Provide an estimated cost-saving potential
👉 Start Your Cost Analysis Now
💼 Why 300+ OEMs Trust Us
We’ve helped clients:
- Cut powder coating costs by 28% through geometry simplification
- Switch from hexavalent chrome to eco-friendly finishes with zero failures
- Reduce masking labor by 40% on complex aerospace components
The right finish doesn’t just protect your part — it protects your budget.
