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The Benefits Of Hybrid Crosslinked Polymer Coatings

Manipulating macromolecules to protect our industrial machines and materials.


In 1953, when German chemist Hermann Staudinger won the Chemistry Nobel Prize for demonstrating that polymers are long-chain (giant) macromolecules, the foundation was laid for the plastics industry. Longchain polymers could be organized to create very strong long-lasting materials that eventually found their way into every industrial sector.

In the 1950s, when aerospace industry engineers were looking for strong materials that were cost-effective and chemically and environmentally resistant, they found that many polymeric materials had serious limitations.

Eventually, it became possible to crosslink polymers; this allowed for blends that could encompass multiple benefits in one polymer material, whilst overcoming some of the limitations. Here are the major types of polymers and some of their advantages and disadvantages:

  1. Epoxies – Good bond strength, strong, chemically resistant, but can crack and chip. Other disadvantages include long cure time and strong toxic fumes.

  2. Phenolics - consistent, high-grade protection against corrosion, scratches, and cracks. However, they are highly flammable, lack toughness, and are difficult to apply.

  3. Polyester – Impact and scratch resistant, provides good flexibility and good chemical resistance. However, it has a limited shelf-life of about 6 months to 1 year.


If a company is finding it difficult to find a coating that delivers all its required properties, hybrid coatings (also known as composite coatings or custom blends) may be the answer. A polymer hybrid blend enables aerospace firms to combine multiple polymer types with others to address any performance limitations. Essentially, the combination becomes a super-coating that offers dual benefits of strength and flexibility, as well as adhering to multiple substrate types. It can also be blended to be chemically resistant and longlasting.

Crosslinking polymers and blending them with additives or new nanotechnologies in just the right formulation requires enormous investments in research and development. Customized formula blends are difficult to create at a consistent, high-grade performance level. Elements must be linked together consistently with every batch and coating manufacturers must be able to successfully scale up the batches to meet industry needs.


Filling in the performance gaps between polymers is just one benefit of using hybrid coatings. When crosslinking different polymer types, coating engineers can also create specialized technological features, such as:

  1. High-performing thin films –Thin films help grounded aircraft get back into service sooner. They eliminate the need for thick epoxies that need to be removed so that parts can be inspected. This benefit is especially meaningful in aerospace, when getting an AOG (grounded aircraft) back to service means high-value time and cost savings.

  2. Self-leveling capabilities – When coatings are formulated, chemists think about the coatings’ flow out and viscosity needs. Hybrids enable customizable flow and viscosities, which enable the coating to achieve a specific uniform thickness over the substrate to which it is being applied.

  3. Pinhole resolution - Pinholes are often caused by air or solvent vapor release from the film when the coating is too viscous to flow back and repair voids. Hybrid coatings are highly customizable, can suspend an additive, and/or yield just the right viscosity to allow for pinhole resolution before the coating becomes tack-free.

  4. Additives suspended in polymers – Some polymer hybrid blends are capable of suspending nanoparticles in their formulas so that the coating can protect materials in a specific way. For instance, one could add a fire retardant, a stabilizer to prolong the shelf-life, UV absorbers, or antioxidants to prolong substrate service life. Antimicrobial additives could also be added to help protect high-touch surfaces from harmful organisms.


Protecting people, critical assets and the environment is a core focus for Nycote Laboratories Corporation. Our proprietary crosslinked polymer hybrid coatings keep people and aircraft safe from a wide variety of harsh conditions and substances. Each coating product is thoughtfully developed to meet mission-critical applications and adds value in the following ways:

  • Superiorly bonds to a multitude of substrate types (metal, plastics, textiles).

  • Prevents all types of corrosion on metal and plastics.

  • Reduces conductivity and friction.

  • Simple to apply by spray, brush, dip, or roll-on. Expensive equipment is not required to apply the coatings to the substrate.

  • The formulations are all transparent, lightweight, thin polymer nylon & epoxy with self-leveling features to a thickness of 8 to 10µ, or .04 to .06 ml.

  • Conformal electronic formulation to protect circuitry.

  • Protects against impact, abrasion, and wear.

  • Specialty safe antimicrobial and antiviral additives protect high-touch surfaces from SARSCov2 and other viruses, E. Coli, Staphylococcus, and other bacteria, and fungus.

  • Specialty coating with an additive that provides an optical fingerprint to prevent tampering and theft of customer assets. Protects your supply-chain and your IP.



Nycote® Laboratories Corporation
12750 Raymer Street, Suite A3
Los Angeles, CA 91605

Topics: Products