M5™ Mass-Flow-Controlled HVAF System.
The M5 HVAF System is Uniquecoat’s flagship platform, combining the next-generation, high-thermal-efficiency M5 spray gun, the ULTRACOAT-M5 control center, and the GDU-M5 gas distribution unit with independent mass-flow control of all process gases into a fully integrated system.
The M5 HVAF System, built around fully independent mass-flow control of all process gases, provides advanced process control, high operating efficiency, broad powder-size versatility, and exceptional coating quality and repeatability. This highly flexible platform enables users to produce dense, virtually non-porous coatings with high deposition efficiency using standard HVOF-grade WC- and CrC-based powders, as well as metals and alloys.
In addition, the M5 System is ideally suited for producing impermeable Flash Carbide coatings from ultra-fine HVAF powders without requiring hydrogen, while hydrogen-assisted operation remains available when desired. These coatings exhibit extremely low as-sprayed surface roughness (Ra 1.1–1.3 µm) while remaining impermeable, enabling effective corrosion protection at significantly reduced coating thicknesses.
Uniquecoat M5 HVAF System
Key Features
1. Full Mass-Flow Control of All Process Gases
The M5 HVAF is the only HVAF platform featuring fully independent mass-flow control of all process gases in both single-stage and dual-stage combustion modes. This capability enables:
● One-Touch Startup — Automatic ignition at full operating flow rates eliminates the trial-and-error adjustments typical of pressure-controlled systems; no startup ramp is required.
● Stable Gas Delivery — All gas flow rates are maintained precisely at defined setpoints throughout the entire spray process.
● Highly Reproducible Results — Stored gas-parameter recipes can be recalled for repeat jobs, ensuring consistent coating quality and deposition efficiency across production runs.
● Consistent Results Across Multiple Systems — Process recipes transferred between M5 HVAF units deliver uniform coating performance across all compatible Uniquecoat systems, a capability not achievable with pressure-controlled designs.
2. High-Thermal-Efficiency M5 Combustor and Dual-Stage Combustion with Independent Stage Control
● High Thermal Efficiency — The optimized combustor design improves the completeness of fuel combustion and enhances heat transfer to powder particles, maximizing particle heating while reducing overall fuel consumption.
● Dual-Stage HVAF Combustion — Secondary combustion within the extended nozzle increases total jet energy, improving particle heating and enabling the formation of dense, low-porosity coatings with high deposition efficiency.
● Independent Stage Control — Primary and secondary combustion zones are regulated independently, allowing precise adjustment of jet temperature and energy distribution. This enables particles to reach optimal temperature and velocity, ensuring optimal coating results across a wide range of powder materials.
M5 HVAF System — Main Components
The M5 HVAF System integrates three core modules — the M5 HVAF Gun, GDU-M5 Gas Distribution Unit, and ULTRACOAT-M5 Control Center — working together for precise combustion control, stable operation, and exceptional coating quality.
You can also add a high quality Uniquecoat gravimetric or volumetric powder feeder to your M5 HVAF system
The system operates on standard LPG fuels (propane or propylene) supplied at 145 psi and up to 0.5 kg/min flow. For consistent gas delivery, use an electric LPG vaporizer and, if needed, an LPG pump to maintain proper pressure under low-temperature conditions. Both units are available from Uniquecoat.
ULTRACOAT-M5 HVAF Control Center
The ULTRACOAT-M5 control center unifies all HVAF system functions into a single, intuitive, operator friendly platform.
Built around MFC-controlled gas delivery, it ensures maximum process stability, repeatability, and operational safety during every coating run.
● Intuitive Touchscreen HMI – large, responsive display for rapid parameter adjustments and clear real-time status feedback.
● Unlimited Recipe Library – store, recall, and share coating profiles instantly for repeatable process setups.
continuous oversight of all critical parameters with automatic shutdown in case of out-of-spec conditions.
● SprayView™ Video Integration – live high-resolution spray plume visualization for immediate process diagnostics.
● Unified System Control – manages MFCs, powder feeders, gas flows, robots, compressors, and auxiliary devices from a single interface.
● AutoSpray™ Automation Suite – enables one-button job startup, full sequence control, and automatic end-of-cycle data logging.
● Secure Remote Access – provides internet-enabled diagnostics, software updates, and remote technical support.
M5 HVAF Gun
The M5 is Uniquecoat’s new core HVAF platform, representing a major step forward in combustion efficiency, process control, and coating performance. The gun features interchangeable nozzles, allowing operation in both single-stage and dual-stage combustion modes for unmatched versatility.
● High-Efficiency Combustor – ensures complete, stable combustion for superior particle heating, improved coating quality, and exceptionally high deposition efficiency
● Independent Dual-Stage or Single-Stage Combustion Control – provides precise, independent regulation of thermal energy released at each stage, enhancing particle heating, deposition efficiency, and overall coating quality
● Flash Carbide Coatings Without Hydrogen – applies impermeable, ultra-dense carbide layers safely and efficiently, eliminating the need for hydrogen
● Excels with Standard HVOF Powder Sizes – produces dense, high-performance coatings with excellent hardness and adhesion using conventional HVOF-grade powders
● Lowest Air Consumption in Class – operates efficiently with a smaller compressor, reducing energy usage and overall operating costs
● Long-Life Combustion Chamber – rugged, serviceable design ensures durability in industrial applications and simplifies maintenance
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GDU-M5: Gas Distribution Unit for Independent MFC Control of the M5 Dual-Stage Combustion Gun
The M5 gun operates on a dual-stage HVAF combustion principle, where the secondary air-fuel mixture ignites inside the extended nozzle, creating an intensified jet for maximum particle heating and velocity.
To support this configuration, the GDU-M provides MFC-controlled, independent air and fuel supply to both combustion stages, ensuring stable operation and optimal coating performance.
● Dual-Stage Combustion Control – provides independent regulation of both primary and secondary fuel/air circuits for precise energy balance
● MFC-Driven Precision – ensures stable, repeatable gas flow for consistent coating quality and process reliability
● Optimized for the M5 HVAF Gun – delivers seamless integration, balanced combustion, and uniform performance across all modes
● Reliable Industrial Operation – engineered for continuous-duty HVAF spraying with long-term durability and minimal maintenance
→ [Specification]
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Add a Powder Feeder
Add a Gravimetric or Volumetric Powder Feeder to your M5 HVAF System
The gallery below includes Uniquecoat powder feeders recommended for use with the ULTRACOAT-M HVAF system.
If you do not plan to perform hot grit blasting, we recommend the G4™ gravimetric feeder or its economical volumetric counterpart, the V4™ — both provide stable and reliable powder delivery.
For users intending to perform hot grit blasting, we recommend adding the V1™ model, specifically designed to handle abrasive grit over extended periods without part replacement.
V1
Simple and Durable Feeder for Powders and Abrasive Grit
The V1 Powder Feeder is engineered to handle both standard thermal spray powders and abrasive media such as grit, used for surface preparation in hot-grit blasting with an HVAF gun. Its rugged construction and seal-free design ensure long service life with no wearing parts.
→ [Specification]
V4
General-Purpose Volumetric Powder Feeder
The V4 Powder Feeder is a heavy-duty volumetric unit featuring a patented blade-type feeding mechanism that ensures consistent, pulseless delivery of thermal spray powders — both metallic and ceramic. Its innovative design also prevents powder after-flow through the spray torch during shutdown, reducing waste and improving efficiency.
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G4
Precision Gravimetric Powder Feeder
Provides smooth, pulseless, and highly accurate feeding of most thermal spray powders — both metallic and ceramic — with feed rates from 10 to 500 g/min.
→ [Specification]