Arc wire spraying, called TruMetal at Modulux, turns a prepared substrate into an architectural surface with a sprayed metal layer, visible texture, and metal depth that give the element a strong, clear presence.
The process uses metal wire, electric arc energy, and a controlled spraying method to build a metal layer on a reviewed substrate. At Modulux, the value is not only in the equipment. It is in the way the surface is assessed, prepared, finished, protected, and reviewed through an ordered sample when the project requires one.
TruMetal is used when an architectural element needs more than paint and needs the character of sprayed metal rather than a generic decorative coating. The selected metal, surface preparation, finish type, protection approach, use conditions, and ordered sample when required all shape the final recommendation.
Arc wire spraying is chosen when a project needs a sprayed metal layer across architectural surfaces, designed elements, and selected fabricated details.
The finish type can be based on zinc, aluminum-zinc, copper, brass, bronze, Corten, Rose Gold, and custom alloy directions when the project allows separate review and pre-agreed sourcing.
Every application begins with a technical and aesthetic review: substrate, size, geometry, heat sensitivity, exposure, touch level, protection, maintenance expectations, and a selected reference for the finish.
Arc wire spraying fits projects where the surface needs the character of sprayed metal, not just a painted metallic color. It is useful when designers want a metal layer, visible texture, tonal variation, and a finish type selected through the finish catalogue, the Modulux digital catalogue, or an ordered sample before production.
TruMetal can be reviewed for steel, aluminum, prepared fabricated metal, mineral boards, concrete, fiberglass, composites, and prepared wood-based panels. Suitability is not automatic. Large MDF or wood-based sheets, heat-sensitive forms, exterior exposure, coastal conditions, and demanding-use areas require technical review before recommendation.
It fits projects where the surface is central to the architectural result. Preparation, edge work, metal selection, protection review, and an ordered sample when required are part of the finish itself, not background work.
Arc wire spraying depends on what happens before the metal reaches the surface. The substrate must be reviewed, the geometry understood, edges and details checked, and the preparation method selected for the intended result.
The finish is then reviewed through the finish catalogue, the Modulux digital catalogue, or an ordered sample: selected metal, texture, tone, possible brushing or patina direction, protection approach, and maintenance expectations. A clear reference is what separates a controlled architectural surface from an improvised coating.
Arc wire spraying creates a sprayed metal layer on a prepared surface, giving the element metal depth, texture, and metal presence without describing it as solid metal.
Choosing arc wire spraying starts from the project, not from a catalogue alone. The first question is what the element needs to do visually and physically: interior or reviewed exterior use, touch level, cleaning expectations, size, geometry, substrate, and the desired metal appearance.
From there, the selected metal, preparation method, finish type, possible brushing or patina, protection approach, and selected reference are reviewed. Copper behaves differently from zinc. A public-space element needs a different conversation than a decorative wall plane. A large heat-sensitive panel needs a different review than a prepared fabricated metal detail.
This is why TruMetal is defined through review, the finish catalogue, or an ordered sample when required. The aim is not to force the same finish onto every object. The aim is to build the right surface for the project.
Arc wire spraying is a thermal spray process in which two metal wires are melted by an electric arc and atomized toward a prepared surface. At Modulux, this process is called TruMetal.
Talk to Modulux about arc wire spraying specification. Send the element type, substrate, dimensions, exposure, touch level, and the metal appearance you are considering, and the team will review whether TruMetal is the right way to build that surface.
