In short
Metallization by arc wire spraying builds a layer of real metal, such as copper, brass, bronze, zinc or Corten, on a piece made of steel, aluminum or another material. We polish, brush or patinate that layer, and we do all the work in our own production facility.
What is metallization by arc wire spraying?
It's a method from the thermal spray family, and it's the heart of our arc wire spraying service. The spray gun takes two metal wires, an electric arc melts them, and compressed air throws the molten metal onto the piece in fine droplets. Each droplet flattens as it lands and grips the prepared surface and the droplets before it, so pass after pass a layer of the metal you chose builds up.
That layer is real metal, not paint in a metallic color and not metal powder in a binder. Sprayed copper is copper, so we polish it, brush it and give it a patina the way we would any copper. The piece underneath stays what it was built from, and only the surface changes. Because it is real metal, it also changes with the air if left bare, so we seal it once the finish is right.
Why spray metal instead of building the piece from solid metal?
Because solid metal isn't always the right material for the body of a piece. Solid brass or bronze is expensive and heavy, and it doesn't always suit the structural job. A large cladding panel, a frame or a sculpture first has to stand steady and connect properly. Spraying splits the two jobs. The body is built from steel or aluminum, whatever the structure needs, and the metal you see and touch is sprayed on top.
It also gives you more design freedom. The metal goes on after the piece is built, so curves, rounded corners and large surfaces all take the same metal. Nobody has to bend a brass sheet around a curve or find a bronze casting in the size on the drawing.
Joined parts are where you see it most. A frame welded from several sections gets one layer that runs across the welds too, and the eye sees one piece in one finish. A wall built from many panels gets the same metal on every one of them. And when the design changes its metal, the same steel frame can come out copper, brass or Corten.
Which metals can be sprayed, and onto what?
Zinc, aluminum-zinc, copper, brass, bronze, Corten and rose gold, and more. If your design needs something else, we import a custom alloy for the project, with a minimum order we agree in advance.
We spray mostly onto steel, aluminum and pieces already fabricated from metal, and also onto concrete, mineral boards, fiberglass and composites. Before we spray, we check every piece, its material, shape, edges and joints, and prepare the surface so the metal grips it well.
Spraying is a hot process, so for MDF and wood pieces we usually choose Liquid Metal Coating – MetaliQ. And if the piece is already solid brass, bronze or copper, it needs no spraying. We finish it directly, through Metal Finishes on Solid Metals.
Which finishes can sprayed metal take?
Sprayed metal comes out of the gun with a texture of its own, and that's where the finishing starts. We brush it, polish it or give it a patina. Any sprayed metal can be polished to a mirror, from copper to zinc, and sprayed copper, brass and bronze also take a patina. Brushed, sprayed metal shows fine lines that catch light from the side. Polished, it turns smooth and bright.
Finally we seal the finish with a ceramic clear coat chosen for the metal, the finish type and the place where the piece will stand. Several finishes in our collection are also made by spraying. In copper these are Polished Copper, Copper Tiffany Patina and Smoked Patina Copper, in zinc Brushed Zinc, Blackened Zinc and Acid Patina Zinc, and in steel Corten Steel and Rust. That isn't the whole list. We make many more finishes to order, by spraying and as a liquid metal coating. And if you are weighing finish types, we wrote a guide to architectural metal finishes.
Where does arc wire spraying work best?
In hotels, offices and restaurants, and at home too. Feature walls and wall cladding, furniture, sculptures and pieces for public spaces, anywhere you want the metal to be the first thing people notice. In hotel and office lobbies it gives the space depth and warmth.
Two of our projects show it well. A mirror zinc sculpture in a private garden was sprayed with zinc and polished until it reflects the trees and the sky. The Maccabiah torch was sprayed with metal in a rose gold tone and polished to a mirror, so it shines in every photo.
Maccabiah Torch in Rose Gold Tone
- Technology:
- Arc Wire Spraying – TruMetal
How does a metal spraying project run?
Send us drawings or photos, and tell us what the piece is made of and where it will stand. We suggest the metal, the finish and the clear coat, and you choose from our finish catalogue or ask for a sample. From sample approval to finished pieces usually takes 2 to 4 weeks.
We make everything in our own production facility. Since 2017, more than 1,000 projects in Israel and around the world.
The best way to decide is to hold the finish in your hand. Pick samples from our sample set, or ask for a sample made for your project, and see how the metal looks in your own light.
