Consulting and engineering services for thermal spraying and coating development
Thermal Spray Innovations FlexCo
Bruck an der Grossglocknerstrasse · Klagenfurt am WörtherseeNew on Amplifa
About Thermal Spray Innovations
Thermal Spray Innovations FlexCo is an Austrian consulting company founded in 2020, headquartered in Bruck an der Grossglocknerstrasse (Salzburg) with its registered office in Klagenfurt am Wörthersee. The company offers specialized services in the field of thermal spray, in particular support in the development of thermally sprayed coatings, expertise in Suspension Plasma Spray (SPS) as well as training, teaching and troubleshooting. The service portfolio includes parameter development with Design of Experiments (DoE), bond coat development with plasma, HVOF and HVAF processes, technical reports and state-of-the-art analyses, support with equipment selection, and the brokerage of Furnace Cycling Test (FCT) test rigs from the Swedish manufacturer Entech AB. For external spray capacity, there is a partnership with PTC Innovation in Sweden with access to the spray facilities of University West (plasma, HVAF, flame spraying) as well as support in coating evaluation. Customers come from aerospace, industrial gas turbines, coating companies and research institutes, including Siemens Turbomachinery, MTU, University West, IPP Prague and Treibacher Industrie. Managing director and founder is Nicholas Curry.
- Site
- Bruck an der Grossglocknerstrasse
- Processes
- Coating Development (thermal spraying), Suspension Plasma Spray (SPS), Plasma Spraying (High Power), Plasma Spraying (Legacy Systems, F4-Type, 3MB/9MB), High Velocity Air Fuel Spraying (HVAF), HVOF, Flame Spraying, Furnace Cycling Test (FCT) for Thermal/Environmental Barrier Coatings
- Materials
- TBC powders (porous thermal barrier coatings), Abradable powders, Environmental Barrier Coating materials, Bond coat materials, Ceramic suspensions (e.g. ethanol-based, d50 0.5–0.7 µm, 20–25 wt.%), Superalloy test coupon, Suspension Plasma Spray, High Power Plasma Spray (Northwest Mettech Axial III)
- Founded
- 2020
- Employees
- 1
- Industries
- Aerospace, Industrial gas turbines (IGT), OEM coating companies, Research institutes and universities, Powder manufacturers, Aerospace
- 01
Feedstock/powder selection
- 02
Parameter development (DoE)
- 03
Process support plasma/HVOF/HVAF/SPS
- 04
Coating evaluation (partner)
- 05
Reports and training
Processes and Materials
Suspension Plasma Spray
Spraying of ceramic suspensions (e.g. ethanol-based, d50 0.5–0.7 µm, 20–25 wt.%) for columnar coating structures.
High Power Plasma Spray (Northwest Mettech Axial III)
High-energy plasma process for TBC, EBC, abradable and bond coat parameter development.
High Power Plasma (Progressive Surface 100HE)
High-power plasma system with extensive experience in parameter development.
Legacy Plasma Systems (F4-Type, 3MB/9MB)
Experience with classic plasma systems, among other things for bond coat development.
HVAF (UniqueCoat M3)
High Velocity Air Fuel process for dense bond coats.
HVOF
High-velocity flame spraying for bond coat development.
TBC/Abradable/EBC Powders
Development of thermally sprayed materials for porous coatings (TBC, abradables) and dense segmented TBC or EBC coatings.
Furnace Cycling Test (Entech AB EEF 20-16 / EEF 40-16)
Test rigs for cyclic furnace testing of thermal and environmental barrier coatings, test plates up to 400 x 400 mm.
Locations
Bruck an der Grossglocknerstrasse
ATHeadquarters / Consulting
Klagenfurt am Wörthersee
ATRegistered office (Schloßweg 6)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Coating Development (thermal spraying)Surface | – | – | – | – | – |
| Suspension Plasma Spray (SPS)Surface | – | – | – | – | Ceramic suspensions |
| Plasma Spraying (High Power)Surface | – | – | – | – | TBC ceramics, Environmental Barrier Coatings, Abradables, Bond Coats |
| Plasma Spraying (Legacy Systems, F4-Type, 3MB/9MB)Surface | – | – | – | – | Bond Coats |
| High Velocity Air Fuel Spraying (HVAF)Surface | – | – | – | – | Bond Coats |
| HVOFSurface | – | – | – | – | Bond Coats |
| Flame SprayingSurface | – | – | – | – | – |
| Furnace Cycling Test (FCT) for Thermal/Environmental Barrier CoatingsTesting | – | – | – | – | Superalloy test coupons |
| Coating evaluation/characterization (via partner PTC Innovation)Testing | – | – | – | – | – |
| Training, Teaching, Seminars, TroubleshootingEngineering | – | – | – | – | – |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| High Power Plasma Spray Gun (axial) | Northwest Mettech Axial III | – | – | – | – |
| High Power Plasma System | Progressive Surface 100HE | – | – | – | – |
| Plasma Spray Gun | F4-MB / F4-Type | – | – | – | – |
| Plasma System (Legacy) | 3MB/9MB Type | – | – | – | – |
| HVAF System | UniqueCoat M3 | – | – | – | – |
| Furnace Cycling Test Rig | Entech AB EEF 20-16 (Standard) | – | – | – | – |
| Furnace Cycling Test Rig (XL) | Entech AB EEF 40-16 (Test plate 400 mm x 400 mm) | – | – | – | – |
Additional services
Reference customers
History
- 2020
Foundation of Thermal Spray Innovations by Nicholas Curry (sole proprietorship/FlexCo).
- 2025
Registration of Thermal Spray Innovations FlexCo in the Austrian commercial register (FN 654545 t, Klagenfurt am Wörthersee, effective date 24.06.2025).