Trusted by the world’s leading manufacturers in aerospace, defense, and energy. Every job NADCAP accredited, fully documented, and delivered to schedule.
New England Plasma engineers precision coated surfaces for high-demand aerospace and defense components. Technical excellence is the baseline — but what sets us apart is how we work. Experienced people, clear communication, and personal ownership on every job, from first article through full production. Quality you can trust, at the scale your program requires.
In-house coating. In-house grinding. In-house testing. Complete documentation.
Surface engineering for turbine engines, compressors, and airframe components. Applied to OEM specification for leading engine manufacturers worldwide.
ITAR-compliant surface treatment for defense aviation, rotorcraft, and weapons system components. Full documentation and traceability for defense program requirements.
Thermal spray coatings for power generation turbines, compressors, and high-demand energy components — including next-generation applications serving data centers and AI infrastructure.
New England Plasma is equipped and organized to support the repeat production volumes that prime aerospace and defense programs require. We coat components on program schedules — consistently, to specification, with complete documentation on every lot.
Program managers and supply chain teams can count on the same process, the same quality system, and the same results whether we’re processing ten components or ten thousand.
The same process, the same team, the same results — lot after lot.
Production planning built around your program schedule. Consistent turnaround, every lot.
Every lot documented and certified — process records, inspection data, and certifications with every shipment.
Not every job fits a standard process. New England Plasma has the technical depth to take on complex, one-of-a-kind challenges — components with unusual geometries, demanding specifications, or coating requirements that need a custom approach.
When a part has been turned away somewhere else, or when a program requires something that hasn’t been done before, we figure it out. We also maintain strong relationships with a network of trusted specialists — allowing us to coordinate additional services and provide a more complete solution for our customers.
Complex, first-time, or unusual applications handled with the same rigor as production work.
Strong relationships with trusted specialists allow NEP to coordinate broader services and act as a more complete solution for customers.
We start with the challenge, not the process. If we haven’t solved it before, we’ll figure it out.
Turbine blades, landing gear, compressor seals, defense systems, space propulsion. Whatever the application, we handle the complete surface engineering process in-house — coating, grinding, and metallurgical testing under one NADCAP-accredited quality system. Every job certified before it ships.
Worn, damaged, or out-of-tolerance components restored to original specification. Thermal spray buildup, precision grinding, and full certification — under one roof.
Plasma Spray, HVOF, Twin Wire Arc, Combustion Spray, Abradable Coatings, and HVAS — each applied to the exact specification your program demands, under our NADCAP-accredited quality system.
Pre-spray preparation, post-spray grinding, and precision finishing — all in-house. One facility, one quality system, one point of accountability.
In-house metallographic evaluation, microstructural analysis, hardness testing, and dimensional inspection. Every job documented and certified before it ships.
Every job begins with the specification. We review the requirement before quoting and flag anything that needs clarification upfront.
Applied to print, under our NADCAP-accredited quality system. Process parameters documented throughout.
Post-spray grinding and precision finishing completed in-house, to tolerance. No second vendor.
Metallurgical evaluation, inspection, and complete documentation package assembled before anything ships.
New England Plasma holds approvals from major aerospace and defense OEMs. View our current approved supplier list by part number and specification.
Tell us about the component, the specification, and the program requirements.
Four things drive the way we work. They haven’t changed.
Most of our clients have been with us for years — some for decades. That’s not something we take for granted. The people handling your job already know your standards, your preferences, and what matters most to you. You have a contact who picks up the phone and follows through. We think that’s what a real working relationship looks like.
If a part has been turned away somewhere else, that’s usually when we get the call. Unusual geometries, demanding specifications, tight tolerances — these aren’t exceptions for us. We don’t look for reasons to say no. We look at what the part needs and figure out the best path to get there.
Good coatings don’t happen by accident. Every material choice, every process parameter, every step in surface preparation affects the final result. Our team knows this work at a deep level. We don’t sign off until the results match the specification. Not approximately. Exactly.
We were early adopters of chrome replacement through thermal spray — eliminating hexavalent chromium without sacrificing performance. We hold REACh compliance and have been recognized with Green Circle Awards from the State of Connecticut for our environmental practices.
Walk through how we manage a job from quote to certified delivery.
When you send a component to New England Plasma, here’s exactly what happens to it.
Every job starts with a conversation. Tell us about the component — the material, the application, the environment it will operate in, and any specifications or OEM requirements.
Once approved, your job enters our production schedule. We confirm lead time, discuss any special handling requirements, and coordinate pickup or delivery.
Parts are inspected before anything begins. We document the condition of every component on intake so there’s a clear record from day one.
Proper preparation is as important as the coating itself. Every step follows the process specification exactly — no shortcuts.
Our technicians follow the specification exactly, documenting every parameter throughout the process.
Post-spray grinding is done here, in the same facility. Tolerances are verified before the job advances.
Every job goes through our metallography lab. Coating thickness, adhesion, porosity, and microstructure are evaluated and documented.
You receive full documentation with every job. Nothing ships without a complete package.
Parts ship with documentation included. The same contact who managed your job is still your contact.
Each stage of your job is handled by the specialist responsible for that process. As the component moves through our facility, it is tracked digitally — visible on screens throughout the shop floor and office so every department knows exactly where every order stands.
NADCAP accreditation, FAA and EASA approvals, ITAR compliance, and documentation practices that hold up to audit.
Tell us about the application. We’ll take it from there.
This page will cover company history, founding, key milestones, and the evolution from R&D to production-scale aerospace supplier.
You know your component better than anyone. Choose the performance requirement you’re solving for and we’ll show you exactly how we approach it.
Parts exposed to moisture, chemicals, salt air, or oxidizing environments break down from the outside in. Thermal spray coatings create a dense, well-adhered barrier between the substrate and whatever it’s operating in — extending service life without changing part geometry.
Surfaces that operate under friction, abrasion, or erosion wear down over time. HVOF-applied tungsten carbide and chromium carbide coatings deliver hardness levels that outperform many hard-faced or plated alternatives — extending component life significantly.
Components in or near combustion environments are exposed to temperatures that exceed the limits of the base material. Thermal barrier coatings (TBCs) insulate the substrate, protecting against thermal fatigue. Yttria-stabilized zirconia (YSZ) is the industry standard material.
MCrAlY alloys and other high-temperature metallic coatings protect the surface from oxidation, scaling, and degradation at elevated temperatures. Used extensively on hot-section aerospace components.
Alumina (aluminum oxide) applied by Plasma Spray produces a dense ceramic layer with high dielectric strength and good thermal stability. Used to electrically insulate metal components in generators, motors, and electronic assemblies.
Hard chrome plating is one of the most heavily regulated industrial processes in use today — hexavalent chromium is a known carcinogen. HVOF-applied tungsten carbide and chromium carbide coatings match or exceed the hardness, wear resistance, and corrosion resistance of hard chrome without the hexavalent chromium. New England Plasma has been performing chrome replacement work for aerospace and defense programs for years and holds REACh compliance.
Thermal spray can build up a worn or undersized surface, which is then precision-ground back to the original dimension and finish specification. New England Plasma handles both the coating buildup and the post-spray grinding in-house — one job, one point of accountability.
Tell us about the component and what it needs to do. We’ll figure out the right approach.
New England Plasma operates four thermal spray processes in-house. Each is selected based on the component, material, specification, and performance requirement.
Air Plasma Spray uses a controlled plasma arc operating above 15,000°C to heat and accelerate ceramic or metallic powder onto the component surface. It is the only practical thermal spray method capable of depositing ceramics and refractory materials — making it the standard process for thermal barrier coatings, dielectric applications, and abradable seal coatings in aerospace and defense.
APS is applied across a broad range of critical components: from thermal barrier coatings on turbine blades, vanes, and combustors, to abradable seal coatings for clearance control in compressors, to dielectric coatings for electrical insulation in aerospace and industrial equipment. New England Plasma applies APS to AMS, OEM, and customer specifications under our NADCAP-accredited quality system.
Common applications
Materials: Yttria-stabilized zirconia (YSZ), alumina, MCrAlY alloys, chromium carbide, tungsten carbide
NADCAP Accredited
All plasma spray work is performed under our NADCAP-accredited quality system with complete process documentation and certification on every job.
HVOF uses the combustion of fuel and oxygen to accelerate coating particles to 300–600 meters per second before surface impact. The result is an exceptionally dense, well-adhered coating with compressive residual stress — the preferred process for demanding wear and corrosion applications, and the established alternative to hard chrome plating in aerospace and defense programs.
HVOF-applied tungsten carbide and chromium carbide coatings consistently outperform hard chrome in wear resistance, bond strength, and corrosion performance — without hexavalent chromium. New England Plasma has been performing HVOF chrome replacement for aerospace and defense programs for years, qualified under AMS 2447 and accepted by major OEMs for landing gear, actuators, and hydraulic system components.
Common applications
Materials: Tungsten carbide cobalt (WC-Co), WC-CoCr, chromium carbide nickel chrome (CrC-NiCr)
AMS 2447 Qualified — Hard Chrome Replacement
REACh compliant. Accepted by major aerospace OEMs for flight-critical component applications including landing gear and actuator systems.
Twin Wire Arc Spray melts two electrically charged wire feedstocks by creating an arc between them, then uses a compressed gas stream to atomize and propel the molten material onto the component surface. It is a high-deposition-rate process well suited for metallic coatings — particularly corrosion protection, dimensional restoration, and bond coat applications on larger or heavier components.
Wire arc is widely used in MRO operations for restoring worn components — bearing journals, shafts, compressor housings, and seal surfaces — back to serviceable dimensions. It is also effective for applying zinc and aluminum corrosion-protective coatings on structural components and equipment operating in aggressive environments.
Common applications
Materials: Zinc, aluminum, zinc-aluminum alloys, stainless steel, carbon steel
Flame spray uses the combustion of fuel gas and oxygen to melt and propel coating material in powder or wire form. While it operates at lower particle velocities than HVOF or plasma spray, it is a reliable and cost-effective solution for applications where maximum coating density is not the primary requirement, or where the substrate is sensitive to the higher heat input of more energetic processes.
Flame spray is widely used in MRO and industrial settings for restoring worn components such as pump sleeves, shafts, and machinery parts, as well as applying corrosion protection coatings on structural components. For the right application, it delivers consistent performance at a lower operating cost than higher-energy processes.
Common applications
Materials: Zinc, aluminum, bronze, Babbitt, various powder and wire feedstocks
Aerospace · Defense · Power Generation · Energy
Every thermal spray process is available for production volumes and one-off applications. NADCAP, FAA, EASA, and ITAR qualified.
Most components require more than coating alone. New England Plasma handles surface preparation, thermal spray, precision grinding, and metallurgical testing in-house — so your component is complete and certified before it leaves our facility.
Pre-spray preparation and post-spray grinding in-house. No second vendor, no split accountability.
In-house coating evaluation, microstructural analysis, and certification on every job.
Worn or damaged components restored to original specification using thermal spray and precision grinding.
Tell us about the component and the specification. We’ll recommend the right process and explain why.
Pre-spray preparation, post-spray grinding, and precision finishing — all performed in-house. Your component doesn’t need a second vendor.
Most thermal spray operations send components out for machining and grinding. We don’t. Pre-spray surface preparation, post-spray grinding, and precision finishing are all performed in-house at New England Plasma — by the same team, in the same facility, under the same quality system.
All machining is performed in-house to ensure every component meets NEP’s high standards, quality thresholds, and customer specifications. CMM inspection and surface finish measurement are used to verify every part before it advances to the next stage.
Pre-spray preparation performed to specification before any coating is applied. Masking and fixturing protects areas not receiving coating. The condition of every component is documented on intake.
After coating, components requiring tight dimensional tolerances are precision-ground in-house. CMM inspection and surface finish measurement verify every part meets specification before it advances.
CMM inspection and surface finish measurement used at every stage. NEP’s in-house machining capability ensures components meet our quality standards, customer specifications, and program requirements.
When coating and grinding are performed in the same facility under the same quality system, tolerance stack-up is managed by one team. There’s no handoff between shops, no re-inspection on arrival, and no question about what happened between operations. The job is documented end-to-end — and so is accountability.
For aerospace and defense programs where dimensional accuracy and documentation traceability are non-negotiable, that’s not a convenience. It’s a requirement.
Grinding parameters set with direct knowledge of the coating applied — no assumptions, no surprises.
No freight between vendors. No scheduling across operations. One facility, one timeline.
Every step documented under the same quality system, from incoming inspection through final measurement.
One point of contact manages the entire job. One team responsible for the result.
Tell us about the component and specification. We’ll take it from there.
A coating is only as good as the evidence behind it. Our in-house lab verifies every coating meets specification before it leaves our facility.
Aerospace and defense components don’t just need to be coated correctly — they need to be proven correct. Our metallography lab evaluates coating microstructure, thickness, adhesion, porosity, and hardness on every job that requires it.
Having the lab in-house means we catch issues before they become your problem.
The most rigorous quality certification available for aerospace special processes. Not self-certified — earned through independent audit and maintained through ongoing surveillance.
Every job that leaves New England Plasma ships with complete documentation — process records, inspection results, and certifications to applicable standards. If your quality department has questions after delivery, the documentation is there — and so are we.
Quality isn’t a department at New England Plasma. It’s how every job is run.
Our quality system is structured around the requirements of aerospace and defense manufacturing — the most demanding standards in any industry. Process controls, documentation practices, inspection protocols, and personnel qualification standards are all maintained to aerospace requirements, regardless of whether a given job formally requires them.
Every thermal spray process is performed to written procedure. Process parameters — temperatures, velocities, standoff distances, feed rates — are specified, monitored, and recorded for every job.
Early adopters of chrome replacement through thermal spray. REACh compliant. Recognized with Green Circle Awards from the State of Connecticut.
We’ll provide whatever your quality department needs.
Independently verified and current. Certificate documents available to download below.
NADCAP — the National Aerospace and Defense Contractors Accreditation Program — is the premier quality accreditation for special processes in aerospace and defense manufacturing. It requires an independent, in-depth audit of processes, procedures, equipment, personnel, and documentation. Not self-certified and cannot be purchased.
New England Plasma holds Federal Aviation Administration (FAA) approval for applicable thermal spray processes. FAA approval is required for work performed on FAA-certified aircraft components and assemblies.
European Union Aviation Safety Agency (EASA) approval — the European equivalent of FAA certification. Qualifies NEP for work on aircraft components destined for European-registered aircraft. Held by a limited number of thermal spray operations in the Northeast.
Registered with the U.S. Department of State Directorate of Defense Trade Controls (DDTC) and compliant with the International Traffic in Arms Regulations. Current registration. Handling procedures meet ITAR requirements.
New England Plasma holds approvals from major aerospace OEMs. Listed on our Approvals page by part number and specification.
New England Plasma holds OEM approvals from major aerospace and defense manufacturers.
Current approvals are listed below by part number and component type. Contact us to verify approved supplier status for your specific program.
| Prime | Company | Specification |
|---|---|---|
| [Prime OEM] | [Company] | AMS XXXX |
| [Prime OEM] | [Company] | AMS XXXX |
| Full list to be provided by NEP team | ||
Our approvals list is updated as new qualifications are added. If your program requires a specific OEM approval we don’t currently hold, contact us — we can discuss qualification pathways and timelines.
Common questions about working with New England Plasma.
Reach out directly. We’ll give you a straight answer.
Technical question, program inquiry, or careers — reach out below.
Or call: (860) 928-6561
Use our Request a Quote form for the fastest response.
Tell us about the component and program requirements.
Tell us about the component. The more detail you provide, the faster and more accurate your quote will be.
Time-sensitive? Call us at (860) 928-6561
When a component is worn, damaged, or out of tolerance — it doesn’t always need to be replaced. New England Plasma restores components to original specification, fully certified.
High-value aerospace and defense components are precision-engineered and expensive to replace. When a component wears beyond tolerance, corrodes, or sustains surface damage, thermal spray restoration is often the fastest, most cost-effective path back to serviceable condition — without compromising the original design intent.
New England Plasma manages the complete restoration process in-house: thermal spray buildup to restore lost material, precision grinding to return the component to original dimensions, and metallurgical testing to certify it meets specification before it ships. One facility, one quality system, full documentation.
Incoming inspection documents the component’s condition. We assess the damage, confirm restorability, and recommend the right process before anything begins.
The worn surface is cleaned, profiled, and prepared to the required specification. Masking protects areas not receiving coating.
Thermal spray applied to build the surface back to above the required dimension. Process parameters documented throughout.
Precision ground to original dimension and surface finish. Metallurgical testing confirms the restoration meets specification. Full documentation package with every shipment.
Tell us about the component and what happened to it. We’ll assess restorability and recommend the right approach.