E-coating and KTL processes expose masking components to immersion in electrodeposition baths, rinsing stages, and oven curing at elevated temperatures. Standard catalogue plugs may not provide a consistent seal under these conditions, leading to coating ingress into critical bores or thread damage during removal.

Our custom silicone masking plugs for e-coating are moulded to your exact geometry, designed for secure retention through immersion and curing, and manufactured from silicone grades that resist the alkaline and acidic chemistry of electrodeposition pre-treatment and bath stages.

All custom plugs are produced with a smooth outer surface to ensure consistent sealing against the masked surface. For applications involving threaded openings, custom threaded silicone plugs are available to provide a watertight seal and protect thread geometry 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 pressure, and sealing performance
• Any geometry: tapered, straight, flanged, pull-through, threaded, 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 degradation 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 plug provides a reliable fit for your component

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