The fundamental physical principle of electrocoat is that materials with opposite electrical charges attract each other. An electrocoat system applies a DC charge to a metal part immersed in a bath of oppositely charged paint particles. The paint particles are drawn to the metal part and paint is deposited on the part, forming an even, continuous film over every surface, in every crevice and corner, until the electrocoat reaches the desired thickness. At that thickness, the film insulates the part, so attraction stops and the electrocoat process is complete. Depending on the polarity of the charge, electrocoat is classified as either anodic or cathodic.

The electrocoat process can be divided into the following four distinct zones:

• The pretreatment zone cleans and phosphates the metal to prepare the surface for the electrocoat.
• The electrocoat bath and ancillary equipment is where the coating is applied and the electrocoat process control equipment operates. The electrocoat bath consists of 80%-90% deionized water and 10%-20% paint solids.
• The post rinse is the next step in the electrocoat process in which the excess paint solids are returned to the tank.
• The bake oven then receives the electrocoated parts. The minimum bake schedule is 20 minutes with part temperature at 375°F for most electrocoat technologies. However, MetoKote also applies a "low temperature cure" electrocoat material. This material has a minimum cure of 20 minutes at a part temperature of 180°F so that many assemblies containing seals, bushings, bearings, or oil can use the electrocoat process.