Electroplating lets you combine the strength, electrical conductivity, abrasion and corrosion resistance, and appearance of certain metals with different materials that boast their own benefits, such as affordable and/or lightweight metals or plastics.
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In this guide, you’ll learn why many engineers, researchers, and artists use electroplating and metal plating in every stage of manufacturing—from prototyping to mass production.
White PaperRead on to learn how engineers are adding metal to resin 3D prints, and why hybrid metal parts can open doors to a surprising range of applications, including (but not limited to) end-use strength and durability.
Download the White PaperElectroplating is the process of using electrodeposition to coat an object in a layer of metal(s). Engineers use controlled electrolysis to transfer the desired metal coating from an anode (a part containing the metal that will be used as the plating) to a cathode (the part to be plated).
The anode and cathode are placed in an electrolyte chemical bath and exposed to a continuous electrical charge. Electricity causes negatively charged ions (anions) to move to the anode and positively charged ions (cations) to transfer to the cathode, covering or plating the desired part in an even metal coating. Electroplating takes a substrate material (often a lighter and/or lower-cost material) and encapsulates the substrate in a thin shell of metal, such as nickel or copper.
Electroplating is most commonly applied to other metals, because of the basic requirement that the underlying material (the substrate) is conductive. Although less common, autocatalytic pre-coatings have been developed which produce an ultra-thin conductive interface, allowing a variety of metals - most notably copper and nickel alloys - to be plated onto plastic parts.
Electroplating and electroforming are both performed using electrodeposition. The difference is that electroforming uses a mold that is removed after a part is formed. Electroforming is used to create solid metal pieces, whereas electroplating is used to cover an existing part (which is made of a different material) in metal.
You can electroplate a single metal onto an object, or a combination of metals. Many manufacturers choose to layer metals, such as copper and nickel, to maximize strength and conductivity. Materials commonly used in electroplating include:
- Brass
- Cadmium
- Chromium
- Copper
- Gold
- Iron
- Nickel
- Silver
- Titanium
- Zinc
Substrates can be made of almost any material, from stainless steel and other metals to plastics. Artisans have electroplated organic materials, such as flowers, as well as soft fabric ribbons.
It’s important to note that non-conductive substrates such as plastic, wood, or glass must first be made conductive before they can be electroplated. This can be done by coating a non-conductive substrate in a layer of conductive paint or spray.
Thanks to scientific advances in materials and plastic manufacturing, lightweight and low cost plastic parts have replaced more expensive metal parts in a wide variety of applications serving various industries, from automobiles to plumbing pipes.
Although plastic boasts an array of advantages over metal, there are many applications where metal still reigns supreme. Try as you might, you’ll never get plastic to have the same opulent finish as copper. And while plastic might be more flexible material than the majority of metals, it’s not nearly as strong. This is where metal plating comes in.
3D printing offers unique advantages when combined with electroplating. Engineers often choose to 3D print substrates because of additive manufacturing’s design freedom. It is often cheaper to electroplate 3D printed parts than to cast, machine, or use other manufacturing methods, especially when it comes to prototyping.
Stereolithography (SLA) 3D printing is ideal for electroplating because it creates 3D printed parts with very smooth or finely textured surfaces that make the transition between the two materials—plastics and metals—seamless. It also creates watertight parts that won’t get damaged when submerged in the chemical bath required during the electroplating process.
From an engineering standpoint, the combination of 3D printing and electroplating offers unique tensile strength options for finished designs. As you can see in the chart above, the combination of these two manufacturing processes bridges the gap in tensile strength between the two material groups.
Metal plating can have a major impact on the mechanical performance of (3D printed) plastic parts. With a structural metal skin and a lightweight plastic core, parts can be produced with surprisingly high flexural strength characteristics.
In addition to improving mechanical behavior, electroplating can be used to protect plastic parts from environmental degradation. In applications where plastic parts are exposed to chemical attack or ultraviolet light, metal plating provides a permanent barrier that can extend the life of your parts from months to years.
When used as an aesthetic treatment, plating offers an easy way to create prototypes that both look and feel like metal. Depending on the plate thickness, electroplated plastic can be thin and light, or add noticeable weight to a part. Thicker electroplated coatings can even be texturized or polished to achieve a variety of metal finishes, from cast aluminum to mirrored chrome. More complex textures can be achieved by 3D printing a textured resin substrate.
Given the potential combinations of 3D printable materials, a variety of plating metals, and plate thickness ratios, it’s easy to see how electroplating gives engineers a new field of design options to consider.
WebinarIn this webinar, learn how electroplating expands the material palette of SLA 3D printing to achieve high-stiffness, wear resistant end-use parts.
Watch the Webinar NowElectroplating offers many benefits, including increased strength, lifespan, and conductivity of parts. Engineers, manufacturers, and artists capitalize on these benefits in a variety of ways.
Engineers often use electroplating to increase the strength and durability of various designs. You can increase the tensile strength of various parts by coating them in metals such as copper and nickel. Place a metallic skin on parts and you can improve their resistance to environmental factors like chemical exposure and UV light for outdoor or corrosive applications.
Artists often use electroplating to preserve natural elements prone to decay, such as leaves, and turn them into more durable works of art. In the medical community, electroplating is used to make medical implants that are corrosion-resistant and can be properly sterilized.
Electroplating is an effective way to add cosmetic metal finishes to customer products, sculptures, figurines, and art pieces. Many manufacturers also choose to electroplate a substrate to create more lightweight parts that are easier and cheaper to move and ship.
Electroplating also offers the benefit of conductivity. Because metals are inherently conductive, electroplating is a great way to increase the conductivity of a part. Antennas, electrical components, and other parts can be electroplated to increase performance.
Though electroplating boasts plenty of benefits, its limitations lie in the complexity and hazardous nature of the process itself. Workers performing electroplating can suffer from hexavalent chromium exposure if they don’t take proper precautions. It is essential for workers to have a properly ventilated workspace. The U.S. Department of Labor Occupational Safety and Health Administration has published numerous documents outlining the risks involved in electroplating.
Although it is possible to electroplate resin parts yourself, amateur users may run into difficulty. The main reason is quality and capability. Laminate adhesion strength using DIY electroplating methods is usually lower than what is achieved by a professional plating service. Structural plating, which requires long plate times, multiple baths, and compatibility between metals, is quite difficult to execute reliably. Successful applications of in-house plating are typically simple and small, such as jewelry prototyping, and thin (single layer) RF copper coatings.
Because of the expertise required and the dangers involved, many engineers and designers choose to hire a third-party electroplating manufacturer specializing in this process. Luckily, several companies, such as RePliForm and Sharretts Plating, specialize in custom electroplating projects. Download our white paper for a list of electroplating services by region and job size.
The video above shows how to electroplate with easy-to-acquire tools, such as a cell charger and spare copper pipe. We recommend you wear a mask, gloves, and eye protection while electroplating and only work in a well-ventilated space.
Numerous industries use electroplating to make everything from engagement rings to electrical antennas. Here are some common examples:
Many airplane components are electroplated to add a “sacrificial coating,” which increases the lifespan of parts by slowing down corrosion. Because aircraft components are subject to extreme temperature changes and environmental factors, an additional metal layer is added to a metal substrate so that the functionality of a part isn’t compromised by normal wear and tear.
Many steel bolts and fasteners designed for the aerospace industry are electroplated in chromium (or, more recently, zinc-nickel, due to changing restrictions).
Type the word “electroplated” into Etsy, and you’ll be presented with a vast array of electroplated home decor and one-of-a-kind keepsakes. Artisans often turn biodegradable items, including flowers, branches, and even bugs, into durable and long-lasting pieces of art with this process. You can employ electroplating to show off and preserve fine details in items that would otherwise quickly decompose.
Electroplating is often used to create art, such as this copper-plated beetle and honeycomb. (image source)
Digital designers sometimes use electroplating to produce sculptures. Designers can 3D print a substrate using a desktop 3D printer and then electroplate the design in copper, silver, gold, or any metal of choice to achieve their desired finish. Combining 3D printing with electroplating in this manner produces pieces that are easier (and cheaper) to manufacture, while still having the same look and finish as a sculpture that is solid cast metal.
Electroplating is very common in the automotive industry. Many major automotive companies use electroplating to create chrome bumpers and other metal parts.
Electroplating can also be used to create custom parts for concept vehicles as well. For example, VW teamed up with Autodesk to create hubcaps for their “Type 20” concept vehicle. The prototype hubcaps were 3D-printed and then electroplated.
Restoration companies and vehicle customization businesses also use electroplating to apply nickel, chrome, and other finishes to various car and motorcycle parts.
Electroplating is perhaps most commonly associated with the jewelry industry and precious metals. Jewelry designers and manufacturers rely on this process to enhance the color, durability, and aesthetic appeal of rings, bracelets, pendants, and a wide range of other items.
When you see jewelry that is described as being “gold plated” or “silver plated,” there’s a high chance the piece you’re looking at was electroplated. Combinations of various metals are used to achieve uniquely hued finishes. For example, gold is often combined with copper and silver to create rose gold.
Producing custom or low-volume metal parts for prototyping can be very costly and time-consuming with traditional manufacturing processes. As a result, engineers often combine electroplating with 3D printing for a low-cost and time-saving solution.
For example, Andreas Osterwalder of the Swiss Federal Institute of Technology in Lausanne (EPFL) has been able to speed up the prototyping process and reduce costs of advanced experimental setups by 3D printing new designs himself on his Formlabs resin 3D printer and working with Galvotec to have those parts electroplated.
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Antennas need to have electrical conductivity to propagate radio waves. While plastic 3D printed parts don’t conduct electricity, they offer almost infinite design freedom and materials with good mechanical and thermal properties. These benefits can be combined with electroplating to achieve the desired conductivity, resulting in a great solution for custom antennas for research and development in the automotive, defense, medicine, and education.
Electroplated composites are a means to a wide variety of ends. Because of its versatility, electroplating opens up countless possibilities across different industries. Want to learn more about electroplating 3D printed parts?
Download our white paper to learn how engineers are adding metal to resin 3D prints, and why hybrid metal parts can open doors to a surprising range of applications, including (but not limited to) enduse strength and durability. By the end of the white paper, you will learn new ways to apply electroplating, as well as design considerations and practical tips on using metal electroplating to amplify the performance of your SLA parts.
In manufacturing field, metal plating is a necessity. This plating increases a product’s resistance to corrosion, its electrical conductivity and hardness and helps manufacturers make better decisions about design and development of their products.
Today we will see what metal plating is, its process, advantages and uses.
Metal plating is a manufacturing method in which layer of metal is applied on the outside of a workpiece. From automotive to electronics, metal plating finds widespread uses in different fields and it improves the performance and reliability of the products.
The field of metal plating contains different methods and all of them have particular uses and processes.
1. Electroplating
In electroplating, an electric current drives deposition of metal ions onto a substrate and it’s the most widely used method. This results in an adherent and uniform coating that increases both visual appeal and protection against resistance. Fields from automotive to electronics mostly use this versatile process.
2. Electroless Plating
Electroless plating is an autocatalytic process that doesn’t need electricity for deposition of the metal. This method gives uniform coatings on complicated shapes such as non conductive surfaces. It also achieves tolerance up to ±0. inches, hardness levels of Rc 62 and better resistance to corrosion. These characteristics make electroless plating appropriate for accuracy demanding uses in electronics and aerospace.
3. Physical Vapor Deposition (PVD)
In a vacuum environment, PVD generates ultra-thin and high-performance coatings. This atomic level process permits accurate control over the properties of coating and produces layers measuring 1 to 5 microns with extraordinary hardness (up to Rc 67) and corrosion resistance. PVD is mainly used in aerospace, medical and automotive sectors owing to its ability to produce extremely durable coatings.
Zinc Plating
Because of its sacrificial protection mechanism, zinc plating is distinctive in terms of corrosion resistance. On the basis of coating thickness (5 to 110µm), this method can tolerate up to 96 hours of salt spray test. The construction and automotive fields mostly use zinc plating thanks to its durability and affordability.
Nickel Plating
Nickel plating gives better durability and corrosion resistance. Its performance varies based on phosphorus content (3-12%) and heat treatment and it can get a minimum hardness of 850 Vickers. This method’s ability to make uniform coatings on intricate geometries with extraordinary wear resistance makes it a top choice for automotive, electronics and aerospace fields.
Chrome Plating
A thin chromium layer deposited through chrome plating gives extraordinary corrosion protection, hardness (66-70 HRC) and wear resistance. This method increases component performance and durability in automotive, mining and hydraulics sectors with its thicknesses of 0.020 to 0.127 mm.
Gold and Silver Plating
Improved conductivity and corrosion resistance define silver and gold plating. The biocompatibility of gold (99.9% pure) makes it best option for medical machinery while silver’s antibacterial properties suit water filtration systems. Both metals give extraordinary wear resistance and some gold alloys can reach 23 to 24 HRC hardness.
Cadmium Plating
For marine environments, cadmium plating is used to control corrosion. It’s gives low friction, sacrificial protection and extraordinary electrical conductivity. Despite its toxicity, military and aerospace fields continue to use cadmium plating, owing to its distinctive combination of properties.
Tin Plating
Tin plating combines corrosion resistance with high electrical conductivity. Generally applied in thicknesses of 5 to 30µm, this method gives better solderability and protection. Fields, for example electronics, food processing and automotive, value tin plating for its cost friendly performance in contrast with precious metal alternatives.
The metal plating process uses different steps to acquire high quality finishes. Every phase is given in detail:
Preparation
Surface preparation makes the foundation of successful metal plating. First, parts are separated and then stripped to remove existing coatings. Next step is polishing that produces a mirror like and smooth surface. The final step is complete cleaning for removing contaminants to confirm maximum adhesion.
This whole process, which usually includes electro cleaning with particular solutions results in an ideal substrate for plating.
Plating Techniques
After preparation, the substrate enters the actual plating phase. Different methods are present and all of them are suitable for particular uses.
Electroplating uses electric current to deposit ions of a metal on the substrate. On the other side, electroless plating depends on chemical reactions without electricity. For more specialized needs, physical vapor deposition (PVD) gives accuracy of atomic level while plasma spray coating gives better wear resistance.
Post Plating Treatments
The plating process concludes with very important post treatments that increase component performance.
Heat treatments, for example annealing, promotes adhesion and increases internal stresses. To improve corrosion resistance, passivation makes a protective layer of oxygen. Chromate conversion coatings are best for zinc and aluminum substrates. These operation specific treatments extend the functionality and lifespan of plated parts.
Better Aesthetic Appeal
Metal plating produces shining finishes which increase visual appeal. Fields from jewelry to automotive can customize shapes and colors to increase their product’s aesthetics.
Improved Corrosion Resistance
A protective barrier is produced during metal plating which protects base metals from corrosive environments. As a result, lifespan of a component increases.
Electrical Conductivity
Silver or gold plating greatly improves electrical conductivity. This help electronics because of better signal transfer and lower resistance.
Increased Strength and Hardness
Nickel or chrome coatings applied through metal plating increase overall strength and surface hardness. Consequently, durability and wear resistance improve for components in demanding operations. Examples are high performance automotive engine parts and aerospace turbine blades.
Cost Effectiveness
Long term savings result from metal plating because of reduced maintenance needs and extended product life.
Wear Resistance
Nickel or hard chrome coatings applied through metal plating greatly improve wear resistance. High friction uses such as industrial bearings and engine cylinders benefit greatly from this.
Owing to its multifunctionality, metal plating is used in different industries.
Automotive Industry
In automotive manufacturing, electroplating has a very important role. It increases the corrosion resistance of engine parts and improves aesthetics of decorative trims. It also boosts the conductivity of electrical connectors. These improvements take part in longevity and performance of vehicles.
Electronics
The electronics market depends on metal plating to maximize component performance. PCBs, semiconductors and connectors benefit from increased corrosion resistance and conductivity. For tiny electronic components, coatings of copper, silver and gold are especially effective.
Aerospace
Aerospace operations need extraordinary material properties which metal plating gives. Important parts such as landing gear, airframe structures and engine parts gain increased corrosion resistance, durability and thermal stability from plating processes.
Medical Devices
In the medical field, metal plating increases the functionality of different machines. Surgical tools, diagnostic machines and implants benefit from improved biocompatibility, antimicrobial attributes and corrosion resistance. Silver and gold coatings are particularly valuable in medical operations for patient safety and device reliability.
Decorative Uses
Metal plating also serves aesthetic purposes in addition to functional uses. It transforms the appearance of jewelry, architecture and furniture elements. While gold, chrome and silver coatings make shining finishes, custom patinas give distinctive artistic expressions. This multifunctionality makes metal plating a favorite between artists and designers.
Challenges and Considerations
Metal plating industry faces many environmental issues because of waste management and hazardous chemicals. It is difficult to get equal coating adhesion and thickness particularly on complicated shapes.
Generally, companies solve these issues by using less toxic materials and closed loop systems. They also use modern waste treatment methods. Better surface preparation is also very important for a quality coating.
Conclusion
Metal plating increases product performance, longevity and aesthetics across different industrial fields. This multipurpose process gives many advantages from improved electrical conductivity to increased corrosion resistance.
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FAQ’s
Gold, tin, silver, chrome, copper, nickel and zinc are mostly used plating metals. Each gives particular properties according to different needs like nickel gives greater resistance to wear and gold plating saves products from rust.
Metal plating increases the durability through different ways. It gives a protective barrier against corrosion, improves wear resistance and increases surface hardness.
Metal plating harms environment in some ways. These are potential release of heavy metals and toxic chemicals, generation of hazardous waste and risks of water and air pollution. Additionally, the process mainly requires high energy consumption. To deal with these concerns, companies are implementing proper waste management systems, emission control measures and adopting cleaner technologies.
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