1. 01/17/15
Powder Coating and Printing onPowder Coating and Printing on
Metal with ElectrophotographicMetal with Electrophotographic
TechnologyTechnology
Eric Stelter, Patrick Lambert, Joseph Guth,Eric Stelter, Patrick Lambert, Joseph Guth,
Vern Lincoln, Bret Johnston, Michael FrauensVern Lincoln, Bret Johnston, Michael Frauens
NexPress Solutions, Inc.

2.  Protective coatings:
• Coils (rolls and sheeting), cans, architectural
panels
 Printing – in addition to one color, print
information & images:
• Cans
• New applications not in existence today - circuit
boards, window coverings, etc.
Idea:Idea: Apply powders electrographicallyApply powders electrographically
as an alternative to solvent coating,as an alternative to solvent coating,
conventional electrostatic sprayconventional electrostatic spray
powder coating, or printingpowder coating, or printing
Conventional electrostatic
spray powder coating
Conventional metal
decorating press
Conventional liquid coil coating

3. Value Proposition:Value Proposition: lower cost andlower cost and
equivalent or improved performance forequivalent or improved performance for
conventional coatings, nanocoatingsconventional coatings, nanocoatings
 Better uniformity, thinner coatings than
conventional powder coating
 Ability to prime, print colors, topcoat, and cure
in a single pass
 Higher coating speeds than used with liquids
 Reduced drying, curing, maintenance, capital
costs
 Reduced environmental costs (> $120M/yr in
US for can alone). Reduced VOC emissions
 Imaging for increased aesthetics/new
applications
Printed blinds
Printed cans

4. Substrate
N SS
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+ + +
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+
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+
+
+
+
+ + +
+
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- -
- - --
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- --
-
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- -
-
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-
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-- -
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Direct Application of Powder Coatings to MetalDirect Application of Powder Coatings to Metal
Substrate with Rotating Magnetic BrushSubstrate with Rotating Magnetic Brush
 Magnetic carrier particles form a
brush on the development roller.
 The powder (-) is attracted to the
carrier particles (+)
 The rotation of the outer roller and
the magnetic core impart motion to
the chains of developer
 Bias voltage applied to metallic
shell moves powder to substrate.

5. Printing on Metal with Electrophotography:Printing on Metal with Electrophotography:
NexPress 2100 imaging module (single color)NexPress 2100 imaging module (single color)
Primary chargerLED printhead
Cleaning station
Pre-clean erase
Pre-clean charger
Blanket
cylinder
Toning Station
Cleaning station
Transfer roller
Imaging
cylinderN s
N
N
N
N
N
N
s
s
s
s
ss
Transport web
Tack down
charger

6.  Nanoparticles for functional coatings can be
dispersed in powder material or applied to powder
particles as a surface treatment as shown at right
(patent pending)
 Small size of nanocoated, electrographically-applied
powder particles produces a high quality composite
material with good uniformity of nanoparticles after
fixing, fusing, or heat treating
 Composite coatings with multiple thin layers can be
made due to small size of electrographically-applied
powder particles
 Multiple layer coatings can be cured in a single pass
through an oven or curing system
Applications
include:
improved chip
and scratch
resistance,
chemical and
heat resistance
Application:Application: Nanocoatings and compositeNanocoatings and composite
coatings with significant performancecoatings with significant performance
improvements over conventional coatingsimprovements over conventional coatings

7. NexPress 2100NexPress 2100
4 Color Electrophotographic Press4 Color Electrophotographic Press
Image printed on metal
with NexPress 2100
and oven-cured

8. Conventional Coil Coating LineConventional Coil Coating Line
Source: www.coilcoating.org (National Coil Coating Association)
Length 30 to 50meters

9. The Magnetic Brush Coating Process:The Magnetic Brush Coating Process:
Experimental EquipmentExperimental Equipment
 Metallic substrate
 Coating apparatus
with magnetic rollers
and drive motors
 Power supplies for
bias voltage to roller
 Motors and motor
speed controllers
 Powder reservoir and
feed mechanism
 Powder: a
reprocessed and
modified commercial
polyester powder
paint

10.  Deposition of powder
with rotating magnetic
brush has exponential
behavior
 Extrapolation to high
speeds is
straightforward
 Powder area density
can be increased by
increasing bias
voltage applied to
magnetic brush
Deposition RatesDeposition Rates
Powder Area Density vs. Web Speed
(Log Plot)
1
10
100
0 1 2 3
Web Speed m/s
PowderAreaDensity
g/(sqm)
High Setpoints Black D1
Lower Setpoints Black D1
Expon. (High Setpoints Black
D1)
Expon. (Lower Setpoints
Black D1)

11. Why the market will want to use our capability forWhy the market will want to use our capability for
powder coating…powder coating…
Cost
…TCO curve
Environmental Advantages
… 30% of manufacturing
maintenance and plant capital
expenditures spent on
environmental control1
,
… accelerated effects if
adopted as MCAT
Featuring & Capability
… matte finishes, perforated
and textured surfaces, some
performance advantages.
1 http://www.coilcoating.org/why/consider.cfm?CFID=2217799&CFTOKEN=65542148
Key Coating Costs per Square Meter
$0.20
$0.25
$0.30
$0.35
$0.40
$0.45
$0.50
$0.55
$0.60
$0.65
$0.70
0.0 0.5 1.0 1.5 2.0
Process Speed (m/s)
Liquid - Low
Liquid - High
EP Powder
Thick trad. powder
25 microns of polyester topcoat plus 5 & 7 microns of primer

12. Business Opportunity DynamicsBusiness Opportunity Dynamics
(all not to scale)(all not to scale)
Coatings and Paint Market 2000
All "Paint" = 34B Euro
Powder Coatings
3.6B Euro
Global Coil
1.0B Euro
1000+ lines
Global Can
1.6B Euro
600+ lines
Wood
2.8B Euro
Plastics
.8 B Euro
Overprint
.4 B Euro
Current Target
For more details, contact Michael Frauens (585) 726-7507
Source: DSM Resins
 Growth of the Coil and the Powder markets historically exceeds GDP growth.
 Market share growth is due to environmental and workflow advantages.