In the electrostatic enameling process of air-gas heat exchange corrugated plates, excessive enamel deposition at the plate edges (commonly known as “fat edge”) frequently occurs, leading to edge spalling defects under compressive stress during packing and assembly. These defects significantly reduce the product qualification rate. In this study, a series of technical innovations - including enhancing the adhesion performance of the enamel, increasing the thermal expansion coefficient of the enamel, and optimizing the electrostatic powder manufacturing process - were researched and developed to systematically solve the problem of excessive edge enameling thickness. Thereby, it improves edge enameling uniformity and reduces edge spalling defects significantly in air-gas heat exchange corrugated plates enamel applications.