Cost vs. Performance: A Guide to Maximize Your ROI in Aerospace Surface Finishing Applications

Aircraft manufacturers face constant pressure to balance performance, compliance, and cost. In an industry where every gram and micron matters, selecting the right aerospace finishing process can have a measurable impact on quality, reliability, and profitability. At National Aerospace Processing (NAP), we help Tier 1 and 2 aerospace OEMs optimize total cost of ownership without compromising performance or schedule through advanced metal finishing services that support the full range of aerospace surface finishing applications. 

Below, we’ve outlined key factors that influence ROI in aerospace treatments and how to determine which finish delivers the best overall value for your application.

Key Factors in Evaluating Surface Finishing ROI

When comparing aerospace finishing options, upfront cost alone doesn’t define value. The best ROI comes from aligning process, performance, and production goals:

  • Material compatibility: Different metals respond best to specific finishes. Aluminum components often require Anodizing or ChemFilm for corrosion protection, while stainless steel parts benefit from Passivation to restore a protective oxide layer. 
  • Operating environment: A part’s function and installation location determine its exposure to heat, moisture, and chemicals – assessing the operating environment is key in selecting a coating that ensures lasting protection and reliability.
  • Compliance and quality: Meeting MIL, AMS, and OEM specs helps prevent work delays, and quality issues. NADCAP-certified processes ensure consistency, reduce risk, and protect ROI across all surface finishing treatments.
  • Production efficiency: Fast, certified turnaround reduces downtime and inventory costs, helping programs stay on schedule and within budget.
  • Lifecycle value: The right surface treatment minimizes rework, extends service life, and reduces total cost of ownership over time.

Comparing Common Aerospace Surface Finishing Applications

Anodizing

Anodizing creates a protective oxide layer on aluminum, improving corrosion and wear resistance while enhancing paint adhesion. It’s ideal for housings, brackets, and structural parts. With a moderate upfront cost, it delivers strong long-term ROI by minimizing corrosion-related downtime and rework.

ChemFilm (Chemical Conversion Coating)

ChemFilm coating forms a conductive, corrosion-resistant layer on aluminum and is often used on connectors, enclosures, and fasteners. It’s a cost-effective option where conductivity and paint adhesion are critical, offering excellent protection without the added step of anodizing.

Passivation

Passivation removes contaminants from stainless steel and restores its natural oxide film, preventing rust and extending part-life. Common in fittings, valves, and hydraulic components, the passivation process is low-cost but delivers high value for corrosion resistance and dimensional precision.

Wet Painting (Prime & Topcoat)

Wet painting protects surfaces, seals finishes, and ensures compliance with MIL and OEM specifications. Used on both interior and exterior aircraft components, it pairs effectively with ChemFilm or anodizing to improve coating cohesion and longevity. Proper preparation and application extend repaint internals, reducing long-term maintenance costs.

For a broader view of available processes, learn more about types of aircraft surface enhancements.

Calculating the True ROI of Your Surface Treatment

Initial process cost is only part of the equation. The right finish prevents corrosion, strengthens fatigue resistance, and reduces rework – cutting maintenance and extending part service life. Cheaper or non-certified processes might lower upfront expenses but often increase long-term costs through failures and downtime. NAP’s integrated surface treatment capabilities help you  achieve dependable results faster and with measurable return.

Strengthen Your Supply Chain with Certified Aircraft Metal Finishing

Enhance performance, reliability, and long-term value with NAP’s NADCAP-certified metal finishing services. Trusted by Tier 1 and 2 aerospace manufacturers across the nation, we deliver precision finishes that meet the highest quality and compliance standards. Request a quote to see how NAP can help your aircraft components meet spec, stay on schedule, and perform for the long haul.