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I have had some personal experience with projects where we set up bulk application systems. We were applying standard cathodic epoxy E-coat materials. Those projects encountered several challenges. For example, all of the parts must be in electrical contact in order to have the paint electrodeposited on them. The contact points would leave bare spots. Also, where the parts were in contact they would stick to each other when the coating was cured. The parts were tumbled in a rotating barrel to prevent them from sticking together. As a result of the tumbling action the coating film was damaged by abrasive contact with other parts before the coating was cured. If the quality requirements for the part will allow some of these deviations from the norm, then a bulk method could be worth looking into.

Some castings with rough surfaces and somewhat complex configurations can be successfully E-coated in bulk by placing them in basket carriers on the conveyor. One technique I have witnessed utilized a tilting mechanism to tilt the basket carriers back and forth. The tilting action was to cause the parts to move slightly so they will not always have the same contact points. This reduces areas of coating voids. In one of the applications I observed, the surface was course enough to obtain an acceptable film consistency with virtually no visible bare spots.

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