Large-scale automated ultrasonic cleaning targets high standards of aluminium surface-cleanliness and quality bonding.

Powdertech Surface Science has upgraded its aluminium cleaning capability with the installation of a large ultrasonic cleaning system at its facility in Bicester, Oxfordshire.

The investment gives Powdertech’s customers access to high-capacity, repeatable ultrasonic cleaning for high-volume and complex aluminium components, achieving surface cleanliness levels of 56 Dynes and above.

Ultrasonic cleaning has been added to Powdertech’s 4-meter, 4,800-litre tanks, adding an improved ability to remove contaminants from surfaces, cavities and difficult-to-reach areas to help improve coating adhesion, structural bonding and long-term reliability of finished aluminium components in medical and precision-engineering sectors.

Jimmy Phillips, Head of Sales and Marketing at Powdertech Surface Science, said, “We know our customers are seeing more demanding cleaning specifications that calls for testing to higher Dyne levels, with this new system, we can offer them measurably cleaner aluminium at scale.

''We see this as an investment in better aluminium bonding for our customers, and their customers.

''We think this is the biggest ultrasonic cleaning system of its kind from a specialist provider in the UK. It gives us the capacity and control to deliver consistently high standards of cleaning on thousands of parts a day, strengthening the value we can bring to customers with increasingly demanding aluminium applications.''

Powdertech has been providing powder coating and aluminium cleaning and passivation services to the automotive industry for over 25 years.

In recent years, the company has become a key part of the UK EV supply chain.

Aluminium ultrasonic cleaning tank at Powdertech's Bicester facility.

Why is precision aluminium cleaning becoming increasingly important?

As lightweight materials, advanced coatings and structural adhesives become more widely used across various industries, the need for exceptionally clean component surfaces is increasing.

Standards such as ISO 16232 are also placing greater emphasis on controlling particulate contamination, helping manufacturers achieve strong adhesion, reliable bonding and consistent product performance.

For customers handling intricate or high-value aluminium components, even small amounts of contamination can affect function, coating adhesion or long-term reliability. This makes achieving consistent, repeatable cleanliness increasingly important.

How does ultrasonic cleaning support precision cleaning?

Ultrasonic cleaning uses high-frequency sound waves (typically ranging from 20 kHz to 400 kHz) that produce microscopic bubbles in a liquid cleaning solution. These bubbles when bursts provide a rapid, non-abrasive method for deep cleaning aluminium components.

Ultrasonic cleaning is particularly effective for parts with cavities, recesses and complex geometries that are difficult to clean consistently using standard methods. The process is energy-efficient and environmentally friendly, requiring no harsh chemicals.

Powdertech has two automated up to 15-stage cleaning and pretreatment lines for aluminium components, offering best-in-class optimised TiZr passivation using the Gardobond and Gardoclean systems. 

Ultrasonic cleaning system generators.

Investing in the future of advanced manufacturing services.  

Jimmy Phillips said: “The installation of our ultrasonic cleaning line builds on our established expertise in advanced aluminium powder coating and pre-treatment, enabling customers to access an even broader range of specialist manufacturing services from a single, trusted supplier.

''We expect demand for cleaner, more reliable and higher-performing aluminium components will increase, particularly within the automotive and other precision-engineered sectors.

''This investment ensures that we are well positioned to support both today's production requirements and the manufacturing challenges of the future.”

About Powdertech Surface Science 

With over 40 years of experience, Powdertech Surface Science is the most technically advanced provider of aluminium powder coating and chrome-free pre-treatments in the UK.  

Established in 1984, with a clear aim to provide high-quality professional chemical pre-treatment, powder coating, and bonding services to specialist niche market sectors and leading-edge manufacturers in automotive, aerospace, medical, battery electric vehicles (BEVs), and other specialised industries.