How to make good texture powder

Common textured powders include wrinkled, artistic patterns, hammered, sanded, and water-wave texture types. Compared to flat powders, textured powders are more challenging to produce. The key raw material for creating textured powders is the texture agent, which, along with equipment, formulation, and process parameters, plays a significant role. The technician's skills and experience are also crucial. This article shares some production techniques for textured powders to facilitate discussion among industry peers.

1. Wrinkles

Wrinkles are a high-volume and widely distributed variety in texture powder coatings. Initially used on electrical cabinets and instrument panels, their uneven surfaces scatter light to reduce glare and eye fatigue. They are now also applied on file cabinets and security doors.

Requirements:

Strong three-dimensional effect

Uniform wrinkle distribution

No base exposure

Customizable wrinkle sizes (large wrinkles are harder to spray and control)

Large Wrinkle Technique:

Minimal filler content

Coarse floating agents with graded particle sizes (coarse agents create prominent wrinkles, fine agents eliminate pinholing)

Special-effect floating agents may be used

Small Wrinkle Techniques:

High-filler method (50%+ filler content):

Added light calcium carbonate to reduce costs (common in industry)

Low-filler method:

Accelerators enhance fine wrinkles

Increased fine floating agents (external mixing) improve spray coverage or mechanical properties (e.g., pre-coated panels requiring bending)

External vs. Internal Mixing:

External mixing (post-additive):

Adjustable texture, strong 3D effect (dominant in China)

Drawback: Recycled powder texture varies

Internal mixing:

Consistent texture in recycled powder

Less 3D effect, more technically challenging

Key Additives:

Accelerators, organic bentonite, and light calcium carbonate play significant roles.

Other Factors:

High softening point epoxy/polyester improves wrinkle formation.

Poorly extruding screws enhance texture (some manufacturers use dedicated screws).

Lower extrusion temperature (10°C below flat powder).

Coarser powder (140 mesh max), reduced secondary grinding speed.

Table 1：Gray Wrinkle Reference Formula（External Mix 101B Floating Agent）

Additional Notes:

(1) ‌Add 0.05% 2-Methylimidazole‌ to the formula. This ‌accelerator‌ enhances ‌three-dimensional texture‌ and aids in ‌wrinkle formation‌ when curing at lower temperatures ("cold oven out-wrinkle").

(2) ‌‌Large-pattern base powder‌ can achieve ‌fine wrinkles‌ by increasing the ‌floating flower agent‌ dosage. ‌Small-pattern base powder‌ is difficult to adjust into larger textures.

(3) ‌For ‌thick workpieces (e.g., castings)‌, use ‌104B Super Effect Floating Flower Agent‌ to ensure uniform texture. ‌Matte wrinkles‌ (difficult to form) can also benefit from ‌104B Super Effect Floating Flower Agent‌.

‌Figure 1: Wrinkle Magnification‌
(The raised areas are more pronounced, while the recessed areas are deeper but do not expose the substrate.)

2. ‌Artistic Patterns‌

Artistic patterns refer to coatings that form ‌floral or decorative designs‌ using ‌floating colored pigments or metallic pigments‌. In the market, ‌floating aluminum silver powder and copper gold powder‌ are more common, while ‌floating colored pigments‌ are less frequently used. The ‌base powder formulation‌ is similar to that of ‌wrinkle coatings‌, with two methods: ‌external mixing‌ and ‌internal extrusion‌, followed by ‌external mixing (post-addition) of pigments‌.

‌Black Base with Silver Patterns‌: This is a ‌common variety‌, where the silver patterns appear in two forms:

1. One is ‌silky or strip-like patterns‌, the other one is ‌large, interconnected patches with a cracked appearance‌ (some refer to this as ‌"turtle shell" or "cracked" patterns‌, resembling the texture of a turtle’s shell). ‌Reference formula:‌
   ‌Table 2: Black Base with Silver Patterns – Reference Formula:

Note:‌ The formulations for various colored patterns are similar. For example, a ‌white base with floating green (or blue) large turtle shell/crack patterns‌ can refer to the first formula. Generally, ‌large patterns work better with internally mixed wrinkle agents‌, while ‌externally mixed floating flower agents are less effective for achieving large designs‌.

‌Figure 2: Enlarged view of black base with silver floral patterns

‌Figure 2-1: Enlarged view of floating silver turtle shell (crack) texture

‌Black Base with Gold Floral Patterns (Floating Copper-Gold Powder)‌

‌Description:‌ ‌"Black base with gold floral patterns"‌ refers to designs using ‌floating copper-gold powder‌ on a black background. ‌Copper-gold powder‌ comes in three variants: ‌Blue-green (brass tone)‌, ‌Blue-red‌, and ‌Red.‌

‌Red and blue-red‌ variants may oxidize and turn black under ‌high temperatures‌ or prolonged ‌sun/rain exposure‌, leading to ‌customer complaints and claims‌.

Replace ‌red copper-gold powder‌ with ‌pearl pigments‌ to avoid discoloration.

‌Blue-green (brass tone)‌ remains stable and can be used directly.

The pattern may appear as ‌"sesame seed-sized dots"‌ or ‌"filament-like streaks"‌.

‌Formulation:‌ Similar to ‌black base with silver floral patterns‌.

‌Figure 2-2: Close-up of black base with gold floral patterns (floating blue-green copper-gold powder)

3. Hammer Texture‌

‌Application:‌
Hammer texture powder is commonly used on ‌security doors‌ and ‌safes‌.

‌Note on Terminology:‌

• The names of textures (e.g., ‌wrinkle, hammer, cotton-like patterns‌) may differ between ‌industry insiders and outsiders‌, as well as between ‌domestic and international markets‌.
• In our industry, we typically refer to ‌silver powder mixed internally‌ to create textured effects as ‌hammer texture‌, distinguishing it by the ‌internal incorporation of silver powder‌.

‌Methods:‌
There are two main approaches:

1. ‌External mixing of floating flower agents‌
2. ‌Internal mixing of texture agents‌ (more commonly used)

‌Reference Formula:‌
‌Table 3: Reference Formula for Hammer Texture Powder

Notes:

(1) In hammer pattern coatings, polyester selection is critical. Suitable polyesters easily achieve hammering effects while allowing higher filler content, whereas unsuitable polyesters yield poor results regardless of adjustments. This refers to compatibility, not quality—always choose the right polyester for hammer patterns.

(2) Omitting hammering agent from the formula and externally blending floating agent (e.g., external floating agent) after base powder application can also create hammer patterns. This method enhances 3D effects but reduces pattern size.

(3) For strong transparency in hammer patterns, reduce or omit fillers, balancing cost and pricing.

(4) Similar to wrinkle effects, inferior extrusion effect often improves hammer patterns.

(5) Apply hammer patterns at moderate thickness. Leveling agent (gloss enhancer) addresses pinholes/mottling as needed, while surface conditioning agent enlarges the pattern.

‌Figure 3:‌ Silver-gray hammer pattern magnification (note the transparent metallic silver effect in the base, distinguishing it from wrinkles).

‌Figure 3-1:‌ Blue hammer pattern magnification (the base color distinctly shows a transparent metallic silver effect, which differentiates it from wrinkles).

‌

‌4. Sand Pattern‌
Sand pattern is the second largest textured powder variety after wrinkle patterns, with aluminum profiles being the primary application. It is relatively easy to produce and can be applied thinly (film thickness: 40-50μm). Common challenges include achieving fine/smooth surfaces, scratch resistance, and extrusion/calendering.

‌Key Solutions:‌

1. ‌Fine/Smooth Texture‌
   • Select appropriate sand pattern agents and grind the powder thoroughly for smoother results.
2. ‌Scratch Resistance‌
   • Add wax powder (e.g., expensive fluorinated wax) or L503 hardener (proven effective in practice).
3. ‌Extrusion/Calendering Issues‌
   • For dry materials, a practical trick is adding water during mixing—vaporization during extrusion softens the material.

‌Material Adjustments:‌

• ‌Organic bentonite‌ (0.5-2%) adjusts texture coarseness and reduces gloss. Imported types enhance smoothness.
• Small amounts of promoters can increase texture roughness.

‌Recycling Application:‌
Sand patterns serve as ideal recycling solutions for mixed waste powders (e.g., reclaimed powders) when color consistency is not critical.

‌Table 4:‌ Black sand pattern reference formula

Notes:

The coarse texture is achieved by utilizing the high viscosity of pure polyester combined with coarse sand pattern agents, resulting in a rough but non-abrasive surface. For fine sand patterns, use sieves with 200 mesh or finer, and grind the powder as thoroughly as possible to ensure a smooth finish.

‌Figure:‌ Sand pattern magnification (the enlarged view clearly shows the rough and uneven texture).

5. Water Pattern Powder (Mianmian Powder)‌
Water pattern powder, also known as mianmian pattern, is a less common variety. Most powder manufacturers produce it in limited quantities, with indoor types being more prevalent than outdoor polyurethane varieties.

‌Production Characteristics:‌

• ‌Small patterns‌ are easier to produce and spray, while ‌large patterns‌ are more challenging.
• Indoor water patterns are generally easier to produce than outdoor types.

• ‌Key factors for stability:‌
  • Selecting appropriate epoxy resin (indoor) or polyester (outdoor).
  • Using high-quality, stable water pattern agents.
  • Grinding the powder coarsely (passing 120 mesh sieve).

‌Table 5:‌ Indoor black water pattern reference formula

Notes:

‌1. L107 Water Pattern Agent‌
L107 is a strong curing accelerator. The curing of epoxy dicyandiamide is relatively slow, but under the strong promotion of L107, shrinkage creates water patterns (ripple effects). ‌Note:‌

• Smaller L107 dosage results in ‌larger patterns‌, while ‌less filler‌ also increases pattern size.

‌2. Large Pattern Modification‌
For large water patterns, external mix floating agents or crackle agents are typically added to modify the texture into ‌radial or snowflake patterns‌. These patterns are beneficial for spraying. ‌Key point:‌

• Apply the powder ‌thickly‌ (thin layers may appear shiny).

‌3. Formula Optimization‌

• Adding leveling agents eliminates ‌tear marks or pinholes‌.
• Using ultra-fine dicyandiamide instead of standard types may improve results.

‌4. Safety Precautions‌
L107 irritates the ‌eyes and respiratory system‌. Ensure:

• ‌Ventilation‌ and ‌labor protection‌ during use.
• Symptoms usually resolve within ‌one week‌ after exposure.

‌5. Application Scope‌
L107 can also be used in:

• Epoxy-polyester hybrid and pure polyester systems, producing ‌wrinkle or sand effects‌.
• ‌External mixing‌ creates a rougher appearance.

‌Figure 5:‌ Indoor water pattern magnification (base powder applied first, then mixed with floating agent).

Table 6：Outdoor Water Pattern Reference Formula：

Notes：

‌1. Outdoor Water Pattern Characteristics‌
Outdoor water patterns can create ‌much larger crackle effects‌ than indoor patterns, such as:

• ‌10 mm square cracks‌
• ‌6 mm diameter cracks‌
• The raised ‌vein patterns‌ are significantly more pronounced.

‌2. Resin Selection for Outdoor Patterns‌
Similar to indoor applications, ‌resin choice‌ is critical:

• Recommended resins: ‌Chanxie 1000H‌, ‌Qingtian 7805‌.

• ‌Filler ratio‌ affects pattern size:
  • ‌Less filler‌ → ‌Larger patterns‌
  • ‌More filler‌ → ‌Smaller patterns‌

‌3. Formula Structure Comparison‌

‌Figure 6:‌ Outdoor water pattern magnification.

Dot Pattern (Marble Pattern) and Ice Pattern‌
In addition to the less commonly used ‌dot pattern‌ (also called marble pattern) and ‌ice pattern‌, as shown below:

‌Figure 7:‌ Dot pattern magnification (First, use a special effect floating agent to create dot powder and base powder. Then mix the dot powder with the base powder. The dot powder will diffuse into individual flower-like dots. However, the dot powder is difficult to stabilize the pattern during actual spraying.)

Figure 7-1:‌ Ice pattern magnification (Ice patterns can be created by reacting epoxy with acrylic resin, such as our acrylic resins with acid values of 80 and 150, along with promoters and surfactants. Ice patterns originated abroad and are relatively rare in China. They feature textured patterns on a flat surface, typically with a matte or semi-matte finish.)

‌

‌Conclusion:‌
Producing textured powder is ‌not difficult‌, but the challenges lie in achieving ‌stable quality‌ and ensuring ‌stable performance in customer applications‌. In China, some powder manufacturers specialize in textured powders or specific textures, reaching a certain production volume. The ‌profitability of textured powder‌ is significantly higher than that of ordinary flat powder. Manufacturers with large-scale textured powder production generally perform well. Therefore, mastering textured powder production is a ‌promising business path‌.