Interfacial interactions between air and coatings formulations can create manufacturing challenges and compromise the performance of the coating through surface defects. Interactions with the air can lead to the formation of flaws in the surface such as poor wetting, cracking, bubbles, craters, orange peel, fish eyes, blistering, voids, pinholes, or uneven coating layers. These defects reduce the quality of the coating application, cosmetically or more substantially, and can negatively impact the overall performance of the coating. This presentation will discuss air entrapment and its stabilization within coatings due to unfavorable air/liquid interactions during production and application.

Defoamers are essential tools in addressing foam-related issues at the air/liquid interface in coating formulations. Defoaming additives used to correct these issues by breaking down or preventing the formation of bubbles will be examined, along with potential repercussions of under or overuse. Achieving the right balance is crucial to maintaining the desired coating properties without introducing unintended side effects. Guidelines for selecting the appropriate chemistry, dosage, and point of addition will be reviewed with the goal of creating ideal defoaming for production, storage, application, and film formation without creating surface defects. Finally, current compliance challenges for defoamers in different coating markets will be discussed along with green formulation strategies and additives that meet these challenges, some with substantial bio-based renewable content or other sustainability benefits.

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