Manufacturing Process

Every BADGERCHROME anode begins with precision-engineered titanium substrates, fabricated in-house at our comprehensive titanium fabrication shop. Whether the final product is mesh, plate, tube, or a custom form, each anode is built to exacting specifications for durability and dimensional stability. This in-house control ensures consistency and quality at every stage of production.

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Once formed, the titanium surfaces are thoroughly prepared using a combination of mechanical and chemical treatments, including abrasive blasting and acid etching. This step is critical to achieving strong adhesion between the titanium and the coating.

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A carefully formulated mixed metal oxide (MMO) solution is then applied using controlled deposition techniques such as brushing, dipping, or spraying. This solution typically includes a combination of noble and semi-noble metal oxides - most commonly iridium, ruthenium, and titanium oxides—chosen for their catalytic activity and corrosion resistance. The exact coating thickness and composition are tailored to the specific electrolyte chemistry, operating voltage, and current density of each application, ensuring optimal performance and service life.

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Following each coating cycle, the anode undergoes thermal activation, a high-temperature process that bonds the coating to the substrate and transforms the metal salts into a stable, conductive oxide layer. Multiple passes may be required to achieve the desired loading density, depending on the end-use environment and current demands.

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The finished product is then inspected for coating thickness, adhesion quality, and electrical performance. Each BADGERCHROME anode is delivered fully assembled and tested - ready to install for long-lasting, maintenance-efficient service in demanding electrochemical systems.