Powder coating is a dry finishing process commonly applied to metal lightsaber hilts and hilt components. Along with anodizing, powder coating is one of the most common methods of applying a color to a lightsaber hilt.
The coating is usually applied electrostatically as a dry powder and cured with heat. Powder coating is available in a range of colors and textures. The dense and durable coating can be protective, decorative or both.
Some sabersmiths and custom saber companies, including The Custom Saber Shop and Saberforge, offer powder coating as a service or an add-on. Adding a powder coating service may delay the shipment of the lightsaber order. Shadowcrest Design frequently pairs powder coating with acid etchings as well.
The powder coating process was originally invented in the 1940s and is commonly used with household appliances, cars, bicycle parts, etc.
Cover Image Credit: The Custom Saber Shop
Image shows a powder coated lightsaber hilt body (left) and pommel (right).