Masking for Thermal Spray Coating

Thermal spray processes — including plasma spray, HVOF (high-velocity oxygen fuel), arc spray, and flame spray — deposit metallic, ceramic, or carbide coatings by propelling molten or semi-molten particles at high velocity onto a substrate. The masking challenge is unique: materials must withstand not just elevated surface temperatures but also the mechanical impact of high-velocity particles, while maintaining a clean, sharp coating boundary.

At Masking Supply, we supply high-temperature masking tapes, custom silicone shapes, and precision die-cuts suited to thermal spray environments. For complex part geometries or production applications, we engineer custom masking solutions from your part drawings.

Masking Products for Thermal Spray

  • Glass cloth masking tape roll for high-temperature thermal spray and powder coating

    Glass Cloth Masking Tape

    Rated to 260 °C (500 °F). Woven glass fibre backing resists particle impact and surface heat. The standard masking tape for plasma spray and flame spray applications.

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  • Polyimide masking tape for powder coating, PCB manufacturing, and electronics, temperature-resistant up to 260°C

    Polyimide (Kapton) Tape

    Rated to 260 °C (500 °F) with excellent dimensional stability. Used for precision masking boundaries where a thin, conformable tape is required.

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  • Dual-flanged silicone pull plug for masking weld nuts and through holes, temperature-resistant up to 250°C

    Silicone Masking Plugs

    Protect threaded holes, bores, and recesses from coating deposition during thermal spray. Silicone withstands surface heat and can be removed cleanly after spraying.

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  • Silicone flanged cap for masking in powder coating and painting, temperature-resistant up to 250°C

    Silicone Masking Caps

    For studs, bolts, and protruding features that must remain uncoated. Rated to 250 °C (482 °F). Multiple sizes available.

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  • Custom Silicone Masking Parts

    Engineered-to-drawing silicone shapes for complex thermal spray geometries — turbine components, shafts, and industrial parts. Cost-effective from 1,000–2,000 pieces.

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  • Custom silicone die-cuts in round shape manufactured by maskingsupply.com

    Custom Die-Cut Shapes

    Pre-cut glass cloth or polyimide tape in custom profiles for precise coating boundaries on complex part surfaces. Eliminates hand-cutting and improves repeatability.

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Custom silicone plug with cut-out for hanging solution made by maskingsupply.com

Need a Custom Masking Solution for Thermal Spray?

Thermal spray components often have complex geometries that standard masking products cannot cover precisely. We engineer custom silicone masking shapes and precision die-cuts from your part drawings. Custom solutions are typically cost-effective from 1,000 pieces.

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Thermal Spray Masking Resources

Masking for Plasma & Thermal Spray: Complete Guide

Material selection, application techniques, and best practices for thermal spray masking.
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Temperature Resistance Chart

Full material comparison chart for masking tapes, plugs, and caps across all processes.
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Silicone Rubber for Masking

Why silicone is the preferred material for high-temperature masking applications.
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How to Mask Complex Geometries

Techniques for masking parts with complex profiles in thermal spray applications.
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Custom Masking Solutions

When standard products aren’t enough — how custom masking is engineered for demanding applications.
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Masking Die-Cuts: Standard and Custom Shapes

How precision die-cuts improve repeatability and reduce labour in thermal spray production.
Read Article 

Not sure which masking product is right for your thermal spray process?

Our masking specialists will help you select the right tapes and custom shapes — or engineer a precision masking solution for your specific component geometry and spray process.

Contact our Experts