The Silicone Shield project aims to improve the masking stage in thermal spraying by replacing manual methods with digitally designed, 3D‑printed silicone masks. Thermal spraying is widely used to enhance component performance, but masking remains labor‑intensive, slow, and inconsistent. By integrating 3D scanning, CAD design, and additive manufacturing, the project introduces a more precise and automated approach for handling complex geometries.

The goal is to develop suitable 3D printable silicone materials and optimized mask designs that can be reused and perform reliably across different spraying techniques. Expected outcomes include validated material compositions, efficient digital workflows, and functional prototypes that reduce preparation time, improve reproducibility, and enhance coating quality. This also enables faster production cycles and supports customization in industrial processes.

The project strongly contributes to the circular economy by reducing waste from single‑use masking materials and enabling reusable tooling. Combined with thermal spraying’s role in repairing and extending product lifetimes, this approach supports more resource‑efficient, sustainable manufacturing systems.

This project is partially funded by KIEM HighTech. Image from Plasma Service