E-coating and KTL processes subject masking components to immersion in electrodeposition baths, multi-stage rinsing, and elevated-temperature oven curing. Standard catalogue caps may not maintain a consistent seal under immersion pressure or resist the chemistry of pre-treatment stages, leading to coating ingress onto critical mating surfaces.

Our custom silicone masking caps for e-coating are moulded to your exact component geometry, designed for secure retention through all stages of the electrodeposition process, and manufactured from silicone grades that resist the chemistry of standard KTL pre-treatment and bath stages.

All custom caps are produced with a smooth inner surface to ensure consistent sealing against the masked component. For applications involving threaded studs or bolts, custom threaded silicone caps are available to provide a watertight seal and protect thread flanks through the full e-coating process.

Key properties and configurations:

• Temperature and chemistry rated: suitable for KTL curing temperatures and resistant to the alkaline pre-treatment and bath chemistry of standard e-coating processes
• Customisable hardness: Shore hardness selectable to match compression fit, retention under immersion, and sealing performance
• Any geometry: round, square, hexagonal, flanged, and complex non-standard profiles available to drawing or sample
• Reusable and durable: high-quality silicone construction supports repeated use across multiple e-coating cycles without loss of fit or sealing performance
• Colour-coded to specification: any silicone colour available to support operator identification and process control
• Economical for small series: custom tooling is viable even for smaller quantities where no standard masking cap provides a reliable fit

Lead time is typically 3 to 4 weeks from approved geometry.