Case Studies

Designer Outdoor Furniture

ETNA DESIGN creates outdoor furniture with an unusual fibre-based structure. Arranged strands give the pieces their distinctive geometry, while LINE-X coats the complete furniture piece, encapsulating exposed fibres and becoming part of the finished design.

The open, shaped construction presents a different coating task from a conventional flat panel. Exposed or sharp fibres need to be covered across the form, including the places where strands meet and change direction. The LINE-X hybrid polyurea coating provides an elastomeric covering over that fibre-based structure. The finish also has a visual purpose. Its texture and substantial covering help define the character of the completed furniture. Structure, shape and coating work together: the underlying arrangement creates the form, and the coating becomes a visible part of the product's identity.

ZRZ initially carried out the coating application for ETNA. This gave the relationship a practical starting point, centred on coating the actual furniture pieces and working with their unusual geometry.

As ETNA's production grew, our involvement developed into material supply and technical support for the move to in-house coating. ETNA now applies the coating within its own operation.

This project shows how a protective coating can contribute to both product function and product design. Encapsulating the fibre structure was a practical requirement; the distinctive finished appearance became an equally important part of the application.

Defence Storage Systems

SHARKCAGE manufactures storage and shelving systems for defence use. On zinc-plated sheet-metal shelves, drawers and related components, LINE-X provides an abrasion-resistant, resilient contact surface that helps protect both the storage system and the items placed inside it.

The material previously used on these contact areas was wearing away too quickly. The application called for a protective surface able to withstand repeated contact while helping reduce scratching of stored items. A LINE-X hybrid formulation was selected for this role. Alongside surface protection, the resilient coating contributes a sound-damping benefit at the contact surface. These are practical requirements for a storage component, where the coating is part of the interface between the metal structure and its contents.

Some components need coating only in selected areas. Applying the material therefore involves controlling where the spray reaches the part, as well as producing the required protective finish. Special masking fixtures were developed for this repeated work. The fixtures create a controlled shadowing effect, shielding areas that should remain uncoated. This approach makes repetitive masking and application more efficient while keeping the coating focused on the intended contact surfaces.

ZRZ first carried out trial coating, then supplied application equipment and trained SHARKCAGE's operators. The relationship, which began around 2021, continues through coating-material and consumable supply together with technical support.

The result is an in-house coating process built around the customer's actual storage components. The protective surface and the selective masking approach work together: one addresses the demands placed on the product, while the other helps integrate its coating into repeat manufacturing.

Heavy-Duty Off-Road Vehicles

TORSUS builds specialty buses and vehicles for demanding off-road environments. LINE-X is used on lower vehicle perimeter areas and, in some applications, much larger body areas to help protect surfaces exposed to gravel, stones and terrain debris.

The coating has a practical role on bodywork operating close to rough terrain. Gravel and other debris can strike exposed exterior components, making mechanical protection an important part of the surface requirement. The applications include steel bodywork and plastic components, coated using a LINE-X hybrid system. The extent of the coating varies with the application: selected lower areas may be protected, while other projects use the coating across larger or full body areas.

Its appearance is also part of the finished vehicle. The coated exterior contributes to the rugged visual character of the TORSUS products, linking a protective surface treatment with the way the vehicle looks.

ZRZ's involvement centres on enabling TORSUS to apply the coating in-house. We supplied equipment and materials, trained operators and provided technical support for the application process. The relationship began around 2022 and has continued as the customer's coating capability developed. TORSUS subsequently purchased additional equipment and established another production and application setup.

In-house application gives the manufacturer its own coating capability for these vehicle components, reducing reliance on outsourced coating. The project combines an exterior-protection requirement with the practical work of establishing and supporting coating within vehicle production.

Off-Road Camper Trailers

Lifestyle Camper manufactures camper trailers, including products intended for travel beyond normal paved roads. LINE-X is used on camper bodies and relevant exterior areas to provide a rugged protective finish for gravel, stone and debris exposure.

A camper used in rough terrain exposes its exterior to different conditions from a product that stays on smooth paved surfaces. The coating was chosen to help protect the body in this environment, where gravel, rocks and other debris are part of the intended use. The applications involve plywood and aluminium substrates with a LINE-X hybrid system. Alongside its protective role, the finish contributes to the camper's characteristic rugged appearance. The coating is therefore part of both the practical exterior specification and the visual character of the completed product.

ZRZ supplied application equipment and materials and provided technical support to establish in-house coating. Our work with Lifestyle Camper began around 2017 and continues through the supply and support relationship.

The customer later purchased additional equipment and established another production and application setup. This extended its own coating capability as the production operation developed.

For this project, the outcome is a protective exterior finish applied within the manufacturer's operation. Lifestyle Camper can incorporate coating into its own production, reducing reliance on outsourced application for the relevant camper bodies and exterior components.

Waterproof Protective Coating

Wooden hot tubs and plunge pools combine a water-containing interior with timber construction. In this application, LINE-X XS-350 pure polyurea was used to form a continuous protective lining across wood and plywood surfaces, including the joints between timber elements.

One purpose of the internal coating was to address leakage risk at plank joints. The lining also created a practical, cleanable internal surface over the timber construction. On some products, coating was applied to the underside to reduce moisture exposure from below. Internal water containment and protection from external moisture were distinct uses of the coating within this application family. The design of the structure and the preparation and application of the lining remain part of the complete water-containing system.

The coating approach supported experimentation with non-traditional hot-tub and plunge-pool shapes. The work also extended to related timber and plywood structures, including some sauna-related applications and combinations of products. This made the coating relevant during product development as well as surface finishing. A protective lining that followed the chosen construction helped the manufacturer explore forms beyond a conventional round wooden tub.

ZRZ supplied equipment, coating materials and technical support, enabling the customer to bring application in-house. The work described here relates to an approximate project period of 2016–2024.

Durable Textured Protective Finish

Speaker enclosures are one of the manufactured-product applications in which we have worked with LINE-X. This gallery brings together our own photographs from multiple manufacturers, showing the application across different enclosure projects.

The role explored here is the exterior surface: a durable, resilient, textured protective finish. Enclosure faces, edges and corners are relevant areas when considering protection during repeated handling.

The coating also contributes to the visible finish of the enclosure. The photographs provide a way to explore that texture and its use on different forms without treating every enclosure as the same product or construction.

These examples represent experience across several manufacturers. They are presented together to show the enclosure application, with the focus on physical surface protection, finish and visible application details.