Plasma Spray Masking

Process improvement for time and cost savings - Masking for this extremely hot coating process presents some unique challenges. Often applied to high cost components masking effectiveness is critical to avoid costly failures. PTFE Group engineers masking materials that are highly effective and resist the extreme heat and abrasion in this environment. They are highly  conformable, easy to apply, and remove cleanly and easily. This translates to more effective masking that leads to significant time and cost savings.

Plasma Spray Coating is an extremely hot yet highly precise method of applying protective coatings to high value items such as jet engine components. With a jet spray temperature that typically exceeds 8000° C, plasma spray is used to apply coating materials with high melting points such as pure ceramic coatings which offer protection from heat, abrasion and corrosion. 

The Need for Effective Masking
Plasma spray coatings are often intended for specific areas of item being sprayed. Non-target items must be masked to prevent contact with the coating spray and must be masked with a durable masking material that will stand up to the extreme abrasion and heat of both the surface preparation (grit blasting) and thermal spray processes.

Engineered for Performance and Efficiency

  • Heat Resistance – PTFE Group masking materials are engineered to resist the extreme temperatures of thermal spray coating processes including plasma spray, reducing the chance of product failure.
  • Abrasion Resistance – The coatings and thicknesses used are engineered to resist the abrasive forces of both the grit blast and plasma spray coating processes.
  • Conformable – PTFE Group masking materials are easy to work with and conform well to surface contours in more complex masking applications - reducing masking time and eliminating the need for re-work.
  • Adhesion – Performance tested adhesives holds firmly both to metal and other surface materials (including tape surface), and to tape material (to prevent flagging) thereby reducing the chance of product failure.
  • Clean Release – Despite high adhesion, PTFE Group tapes are designed to remove cleanly with no adhesive residue, eliminating the need for additional post-spray clean-up.

Recommended Materials


  • GBI 170-10s YL - A reliable masking tape for most standard plasma spray applications.
  • GBI 170-10s Green - For applications that involve higher abrasion. This tape produces cleaner coating lines and may be used with fewer layers (and less quantity) than standard tapes.
  • GBI 170-10s Red - Recommended for applications involving higher temperatures. This tape resists burning / scorching which leaves cleaner coating lines and less residue from any scorching that may occur.
  • GBI 170-14C - A premium masking solution for applications involving the harshest conditions including high abrasion and high temperatures. This tape can be applied in fewer layers (less quantity) which results in faster masking, less waste and overall savings in terms of time and cost.


  • HVMC - High Velocity Masking Compound is highly effective for masking small details, providing additional barrier protection over other masking materials, and creating reusable masking moulds, plugs, caps, & sleeves.


  • S/W 35 Thermal Spray Masking Blanket - (silicone coated glass fabric) can be deployed as a secondary masking material to protect against overspray. This material can be reused for many cycles.