1. + Beyond Powder Coating! Field Applied, Fully-Cured Powder Coating Technology

2. October 9-11, 2012 + Overview What is Polymer Thermal Spray (PTS)? PTS Fundamentals Benefits of a PTS Coating Background Flameless Technology Development PTS Specific Materials Field Repairable Coatings Current PTS Coating R&D Contracts Flameless PTS Application Video Summary

3. October 9-11, 2012 + What is Polymer Thermal Spray? Splats – unit building blocks of thermally sprayed coatings  Polymer rheology  Degree of melting  Impact velocity Define Coating Formation Process The deposition of semi-molten polymer particles onto a pre- heated surface whereby process heat causes the particles to flow and coalesce into a complete cohesive polymer coating.

4. October 9-11, 2012 + PTS Fundamentals Splat Formation Simulation Watch this video on YouTube

5. October 9-11, 2012 + PTS Fundamentals Traditional Powder Coating process enjoys the luxury of time - PTS must accomplish all coating steps in a single application process at industry acceptable coating deposition rates Primarily physical bonding to substrate Surface preparation – clean, roughen surface, degrease Pre-heat substrate for first-strike splat adhesion PTS coating deposition rate dependent on Coating properties – chemical and physical Substrate thermal absorption properties Process thermal energy capacity

6. October 9-11, 2012 + PTS Fundamentals Sufficient process thermal energy required for continuous application process Pre-heating ahead of deposition In-flight softening of particles to semi-molten state Immediate flow-out of first-strike splats to provide adhesion Accelerated temperature rise of material to begin coalescence Post-heating to flow material into uniform cohesive layer Post-heating to achieve complete cross-link cure All simultaneously occurring during normal spray application

7. October 9-11, 2012 + PTS Process Thermal Energy Process Heat Thermographic Analysis Watch this video on YouTube

8. October 9-11, 2012 + Benefits of PTS Applied Coatings No oven cure required No longer limited to oven size Flexible – Field portable or fixed manufacturing operation No Volatile Organic Compounds (VOC) or Hazardous Air Pollutants (HAP) Field repairable No overspray containment issues Standard surface preparation – No pre-treatments or primers Coated surface is immediately ready for service when cool Broad range of Thermoplastic and Thermoset materials Easy clean-up and color/material change

9. October 9-11, 2012 + Background – Historical Methods Historical adaptation of legacy processes Flame Spray Plasma Arc Spray HVOF Cold Spray Issues Designed for high-temperature, dense materials Not generally practical for field use Limited to a few select polymers Limited acceptance and use

10. October 9-11, 2012 + Background – Polymers vs. Flame Polymers Mild Hot Gas Polymers Flame Flameless PTS Technology Flame Spray Flameless PTS Coating Flame Spray Coating

11. October 9-11, 2012 + Flameless Technology Development Polymer particle heat and flow transport principles Temperature Degrees Celsius Particle Acceleration A Drag VpVp VgVg Convection Conduction Particle Heating (Cp = f(T)) PTS Nozzle

12. October 9-11, 2012 + Flameless Technology Development Particle heating during acceleration in hot air stream Polymer Particle Diameter: 300 μm Particle Surface Gas Temperature Particle Core Typical Spray Distance (5 kW System) PTS Nozzle

13. October 9-11, 2012 + Flameless Technology Development PTS required a total solution Completely novel application technology designed specifically for polymers No polymer degradation Apply a full range of materials Operational flexibility Polymer powder coating formulations specifically designed with properties to perform with PTS application Adhesion Flow and coalescence Application temperature / In-service temperature Robust chemistry – resistant to defect causing contaminants Cure rates – time and temperature

14. October 9-11, 2012 + Flameless Technology Development Electric heat source selected for initial development Closed-loop temperature control Polymer particles injected down-stream from heat source Later designs increased system thermal output from 5 kW to 15 kW to increase deposition rates for coating large surfaces 2 kW system developed for small area touch-up coating repairs Electric Heat Source System Three systems with output up to: 2 kW 5 kW 15 kW Electric 5 kW PTS Applicator

15. October 9-11, 2012 + Flameless Technology Development Transitioned from electric to combustion heat source to improve coating deposition rates Flameless design criteria maintained throughout substantial increases in thermal output capacity Flame locked down onto burner plate No polymer / flame interaction “Flameless” PTS System Only hot air contacts polymers Propane/Air Combustion High Output System 7– 30 kW Only a column of hot process air exits the front of the applicator Polymer powder is injected through shielded feed tube Watch this video on YouTube »

16. October 9-11, 2012 + PTS Specific Materials Development Thermoplastic Wide range of base resin selections Thermosetting Polyesters, Urethanes, Epoxies TGIC free formulation Hybrid Formulations Thermoplastic / Thermoset PE PMMA EVA EMAA EAA PAPP FLAMELESS PTS POLYESTERS POLYURETHANES EPOXIES

17. October 9-11, 2012 + PTS Specific Materials Development Engineered coating formulations Specific to PTS process requirements Coating properties enhanced for peak performance Unique coating creations possible Multi-component, in-flight materials blending (dry-blending) Coating formulations with large disparity in component size Spray method induced coating surface features

18. October 9-11, 2012 + Field Repairable Powder Coatings Repair and touch-up damaged powder coated surfaces with same powder coating material Repair both thermoset and thermoplastic coatings Strip and recoat not required Prepare damaged area similar to paint touch-up Repair in-service components Powder coat fasteners, brackets, welds, etc. after installation Damaged Coating Repaired Coating

19. October 9-11, 2012 + Current Coating Projects Amusement Park and Resort facility: Corrosion, wear and artistic creation coatings Pulp and Paper: Corrosion and specialized wear coatings Waste Water Facility: Containment and concrete corrosion protection U.S. DOT: Concrete highway barrier coating to mitigate tire climb induced vehicle rollover after impact U.S. Air Force: Friction reducing wear coating for C-130 aircraft skids for Arctic region operation U.S. Navy: Life extension of above waterline radar installations through PTS field applied coating repairs U.S. Dept. of Homeland Security: Energy absorbing foam for blast protection of infrastructure U.S. Army Research Laboratory: CARC compliant powder coating qualified to MIL-PRF-32348

20. October 9-11, 2012 + Flameless PTS Coating Application Watch this video on YouTube

21. October 9-11, 2012 + Summary PTS total solution - materials and equipment Continuous application process Powder coating is now out of the oven First commercial field repair powder coating process Beyond Powder Coating!

22. October 9-11, 2012 + Thank you for your attention For further information please visit Resodyn at: www.resodyncoatings.com Contact information: Kevin M. Lane Director, Resodyn Engineered Polymeric Systems 406-497-5288 kevin.lane@resodyncoatings.com