The Challenges of Coating Complex Metal Parts and How We Solve Them
Coating a flat, simple part is one thing. But when the geometry gets complicated, everything changes—from how a part is handled to how the coating is applied. At Giering Metal Finishing, we understand the unique challenges that come with finishing complex components, and we’ve built our process around solving those challenges before they become problems.
Why Complex Parts Require a Different Approach
When we talk about complex parts, we’re often referring to:

- Irregular or intricate geometries
- Deep recesses or hidden cavities
- Tight tolerances or critical surfaces
- Unusual weight distribution or size
- Limited options for racking or grounding
Each of these factors impacts how the part can be handled during finishing, especially in processes like powder coating, electrocoating, or liquid painting. If the part can’t be positioned properly, it can lead to uneven coverage, grounding issues, or finish defects.
Racking and Grounding: Two Key Considerations
Every part must be securely racked or suspended during finishing. That means we need to account for:
- Stability during the entire process
- Access to all surfaces that require coating
- Electrical grounding, especially for powder and e-coating
- Minimizing rack marks or damage to finished surfaces
If a part is racked incorrectly, we risk poor coverage in critical areas—or worse, a part that can't be properly grounded, which is essential for any electrostatic application.
Our Solution: Engineering Comes First
The key to coating complex parts successfully is planning. At Giering, we take an engineering-first approach to every challenging job.
Before production begins, we:
- Review part geometry and coating requirements
- Design or adapt custom racking solutions
- Determine optimal grounding points
- Identify any masking needs for critical areas
- Test and adjust our process using sample parts or panels
This proactive approach helps us avoid rework, eliminate guesswork, and give our customers confidence that their parts will be coated correctly the first time.
Trusted by Manufacturers with Complex Needs
We’ve helped customers across industries—automotive, aerospace, defense, medical, and industrial—solve their most difficult coating challenges. Whether it’s a delicate aluminum casting, a precision-machined bracket, or a large-scale welded assembly, our team has the experience and tooling to get it done right.
Need Help Coating a Complex Part?
If your part requires more than a basic finish—and you need a team that knows how to engineer around geometry, grounding, and access—Giering Metal Finishing is ready to help.
