Typo trouble. It's POWDER coat. Yes, the mask is probably the cause of the problem. The powder particles can't get underneath it, but the liquid can, and will. You can check, if you can chemically (not mechanically) remove any epoxy from the surfaces hat should be bare. There is probably a trick that seals the edge of the mask to the metal, so the liquid can't get in, but I don't know what the trick is. It could be as simple as ordinary grease, but NOT silicone grease, because you will never be able to get it off the metal.

On 2026-01-29 19:50, Brian Gregory wrote:
 Hi folks,
Our bare-metal prototype passed FCC Class B RE with flying colors;  8-12 dB margin. Now, a fairly similar unit (hey, they're prototypes) whose enclosure is power coated is now failing by 10-20 dB.   The worst failures are at low frequencies, under 50 MHz, apparently. Is there anything more complicated we should look at apart from the powder coat mask not working well enough, such that covers and side panels aren't properly grounded with all that epoxy ?   What else could account for this difference?
 thanks,
Colorado Brian
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