Zircotec has further refined its process to allow ceramic to be plasma-sprayed onto the surface of carbon composite, glass-fibre composite and a range of plastic materials.  This coating provides protection against excess temperature, allowing these materials to be operated in environments where they might not otherwise be suitable.

The first stage after your part has arrived is masking.  We mask your parts to protect certain areas in the next stages of our process.  We mask all areas of each item that are required to be free from coating, so that there will be no problem with finish or fitting it once completed.  You can also request that we mask specific parts on the part depending on your requirements.

The next stages are surface preparation and bond coat application.  Surface preparation smoothes the surface of the parts in order to get the best results.  


The bond coat provides a metallic based layer for secure adhesion between the ceramic and the substrate.

Plasma Spray Ceramic

The Zircotec plasma spray  process is a derivative of the more general plasma-spray processing techniques.  Zircotec’s own in-house plasma-spray technology and our associated procedures were first developed within the UK nuclear industry, when Zircotec formed part of the UK Atomic Energy Authority.  These processes and procedures have been further developed and refined by Zircotec, resulting in the propriatory highly optimised plasma-spray process that we use today.

There are a large number of parameters that influence the interaction of the plasma-spray feedstock with the plasma jet and the substrate, and these parameters can result in very wide variations in the final product (e.g. feedstock type and composition, feed-rate, plasma gas composition and flow rate, energy input, torch geometry, nozzle design, nozzle offset distance and substrate cooling).  The Zircotec process ensures that these parameters are tightly controlled within pre-defined set points, thereby providing control over the quality of the final product.  By controlling these parameters we are able to control material properties to suit specific applications.

Optional Finish

The Zircotec technical team prefers to work alongside the customer to specify the coating arrangement that is most appropriate for the application.

All of our coatings are plasma applied.  Our Primary Black coating was devised as a lower cost derivative of our exhaust coating technology, this ceramic coating retains all of the quality and durability for which Zircotec’s coatings are renowned.  Balancing thermal performance with affordability, this ceramic coating will appeal to car and bike users who want the benefits of Zircotec’s plasma sprayed thermal barrier coatings, but who might not need the ultra high levels of thermal barrier performance offered by some of our other offerings.

Our Performance white which based on our core ThermoHold® formulation is only available from Zircotec.  It is the mainstay of Zircotec’s offerings to motorsport, delivering the ultimate in thermal barrier performance.  It is also used across a broad range of other applications.

Our Performance Colours range with similar levels of performance to our Performance WhiteTM exhaust coating, but with a surface finish that is robust and easily maintained, we have called this our Performance ColoursTM Range of ceramic coating.

Metal Spraying Service

Zircotec uses its plasma-spray process to provide metal coatings over different substrates.  These can be used to:

  • Replace material lost from a previously worn or corroded component.
  • Enhance aesthetics by providing a metal finish that is different to the underlying material thereby changing the appearance.
  • Provide a reflective coating that can help protect the underlying component from radiant heat, e.g. it is possible for Zircotec to provide a reflective aluminium or nickel surface.
  • Provide protection against corrosion, erosion and wear.  As an example, it is possible for Zircotec to spray hard metal surfaces such as tungsten or molybdenum.

To view our order process and get a quote for your parts visit here.