Electroplating 101: How Metal Plating Works

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.

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What Is Electroplating?

Electroplating 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).

Diagram of copper electroplating using an electrolyte bath of copper sulfate, sulfuric acid, and chloride ions. (image source)

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 vs. Electroforming

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.

Electroplating Material Options

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.

Electroplating (3D Printed) Plastic Parts

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.

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The Benefits of Electroplating

Electroplating 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.

The Limitations of Electroplating

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.

The Many Applications of Electroplating

Numerous industries use electroplating to make everything from engagement rings to electrical antennas. Here are some common examples:

Aerospace

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).

Art and Home Decor

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.

Automotive

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.

Jewelry

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.

Medical and Dental

Electroplating is used to add resilient exteriors to all sorts of medical and dental elements. Gold plating is often employed to create tooth inlays and aid in various dental procedures. Implanted parts such as replacement joints, screws, and plates are frequently electroplated to make parts more corrosion-resistant and compatible with pre-insertion sterilization. Medical and surgical tools, including forceps and radiological parts, are also commonly electroplated.

Power

Numerous electrical and solar components are electroplated to increase conductivity. Solar cell contacts and various types of antennas are routinely manufactured using electroplating. Wires can be electroplated in silver, nickel, and many other types of metal. Gold plating is often used (in conjunction with other metals) to increase durability. Gold is also frequently used to increase the lifespan of parts because it is conductive, very ductile, and doesn't interact with oxygen.

Prototyping

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.

Andreas Osterwalder used 3D printing and electroplating to manufacture this beam splitter.

RF and Microwave Products

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.

Electroplating plastic parts creates conductive parts that enable high performance RF applications.

Best Practices for Electroplating 3D Printed Parts

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.

Finishing the machined or manufactured components using the appropriate method ensures their longer durability. It is also critical for the functionality of some high-performance applications. Electroplating is one of the popular finishing methods that can customize the mechanical properties and appearance with the use of suitable plating metals. 

You can use gold, silver, copper, zinc, platinum, and other metals and alloys based on your requirements. It means you have enough options to achieve the desired aesthetic, corrosion resistance, enhanced hardness, and conductivity. 

This article will elaborate on the process, types, benefits, applications, and other various aspects to guide you through the electroplating finishes and how they can bring change to your products.

What is Electroplating?

Electroplating is an old surface treatment process in metal fabrication and manufacturing, invented back in by Brugnatelli. Initially, it was popular to plate gold on other metals. However, it is continuously evolving and becoming more and more applicable across all industries for both aesthetic and protection purposes. 

It involves adding a layer of superior metal or alloys on the substrate metal through electrochemical deposition. The workpiece(cathode) and plating source metal (anode) are immersed in the electrolyte solution and connected through a power supply. As current flows through the circuit, the metal ions from the anode move towards a negatively charged workpiece and form a layer all over the surface.

The hard plating of chrome, nickel alloy, and zinc can significantly enhance wear resistance, corrosion resistance, and durability of manufactured components. On the other hand, decorative plating like gold and silver is popular in jewelry and ornament finishing.

When to Use Electroplating?

You may have thought that electroplated coating is only for aesthetic appeal and protection from external conditions, but there are other uses too. It can customize the surface properties by adding a layer of suitable metal through electrolysis. Here are the five conditions or scenarios when you can use the electroplating finish. 

Dimensional Precision (Build thickness)

If any parts or products are shorter in dimensions than expected values, the layers of plating material can correct that through a successive building. It allows for control of the plating thickness through process variables, such as voltage, time, and electrolyte concentration.

Aesthetic Requirements

You can use electroplating finishes to customize the surface appearance. Simply, the deposition of aesthetically pleasing metal and alloys on the substrate surface gives the permanent appearance of that metal or alloy. This way you can achieve the desired luster, brightness, and texture. For example, chrome plating on aluminum and steel parts makes their surface shiny and reflective.

Need for Corrosion Protection

If your manufactured parts are made from corrosion-prone materials, you can coat them with hard and resistive metal. The plated layer sacrifices itself in harsh operational and environmental conditions like chemical and moisture exposure to protect the underlying material.

Electrical Conductivity

You can easily achieve high conductivity on the connectors and terminal surfaces made with ordinary metals by plating high-conduction metals or alloys. Often, metals like gold, silver, and copper are electroplated onto components where high conductivity is required. 

Heat Resistance

For high-temperature applications, plating the components with metals nickel and chrome helps maintain the integrity of the underlying material at elevated temperatures. For example, plating the chrome-nickel coats on the automotive exhaust parts.

How Does Electroplating Work?

Electroplating works by dissolving and depositing a metal onto another surface through an electric current. There are four primary components of this process.

Anode: The electroplating metal or alloy that is going to be a plate on the substrate surface and connected with a positive (+) terminal. 

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Cathode: The workpiece, connected with a negative (-) terminal. 

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Plating Solution: The electrolyte that will carry the metal anions toward the cathode. It contains the metal ions that are to be deposited. E.g. CuSO' for copper plating.

Power Source: A DC supply to drive the metal ions from the anode to the cathode.

Electroplating Working Principle

The working principle of the electroplating process is based on the electrolysis mechanism. It says that passing current on an aqueous solution causes a non-spontaneous chemical reaction, where ions in the solution move toward electrodes. As a result, oxidation occurs at the anode.

Here, how does electroplating work;

1. Ionization of Electrolyte 

An electrolytic solution decomposes into metal anions cations when passing the electricity. For example, copper sulfate (CuSO') dissociates into Cu²' (copper ions) and SO'²' (sulfate ions).

CuSO' (aq.) 'Cu²'+SO'²' 

2. Oxidation at Anode or Plating material 

The anode continuously oxidizes (M'Mn'+ne²') itself as its ions continuously move and build layers on the workpiece surface, continuously supplying the plating ions. For example, let's consider the above example again copper as an anode;

Cu'Cu²'+2e²' 

3. Deposition of Anions on the Workpiece Surface 

As the power continuously flows, the metal ions from the anode will travel to the cathode and will build the layer there uniformly. The thickness mainly depends on the concentration of irons and the time of electrolysis.

Again, the same example 

Cu2+(aq.) +2e''Cu (s): Deposition on the cathode, i.e. aluminum, stainless steel, etc. 

Meanwhile, the free salt ions (SO'²' in this case) go to the anode and form the metal sulfate, facilitating the continuous oxidation. 

Precautions in The Electroplating Process

• Handle the electroplating batch with great care, as it contains sulfuric acid and is highly corrosive. If the solution or electrolyte comes into contact with your eyes, rinse them thoroughly with water and seek medical attention immediately.
• Always wear safety gear such as goggles and gloves to avoid direct contact between electrolytes and skin. Additional important equipment includes an apron and a fume hood. Ensure the fume hood is in use to prevent electrolyte fumes from reaching your face.
• Avoid any contact between electrolytes and household chemicals, as such contact can trigger reactions that may render the electrolyte useless or release hazardous gases into the atmosphere.
• Store electrolytes at an ideal temperature between 40 to 95 degrees Fahrenheit. Additionally, always keep them in the original container with the lid tightly sealed.
• Follow all electrical safety precautions, including using rubber mats, grounding, fusing, and insulated gloves.
• Please refrain from wearing rings or other jewelry during the process, as they are often metallic and could cause electrocution.
• Keep plating solutions out of the reach of animals and young children.
• Use a plastic funnel when transferring the electrolyte from the electroplating kit.

Types of Electroplating Techniques

There are different types of electroplating methods to employ when coating a substrate. These include:

• Barrel Plating
• Rack Plating
• Brush Plating
• Pulse Plating

Let us discuss these methods in more detail.

Barrel Plating

The barrel electroplating type uses a 'barrel', usually made with strong and chemically resistive material like polypropylene as an electrolysis container. The substrate parts are immersed inside the barrel with an electrolytic solution and anode. Then, the rotation of the barrel ensures the uniform coating of each part. However, it can cause minor imperfections and scratches.

You can use barrel plating to coat large volumes of small-sized parts at low cost. It is especially suitable for hard material parts like tool steel bolts, screws, liners, etc. 

Rack Plating 

In the rack plating, several parts are attached to a large rack structure inside the electrolytic bath. It can accommodate multiple parts at a single time holding with hooks, bands, or screws. Consequently, the work parts suffer minimal tumbling effect and can coat intricate features precisely.

The rack plating is suitable for both large-size parts and mass electroplating. However, the upfront installation cost and high labor cost are the drawbacks. You can plate copper, gold, nickel, etc. with this method.

Brush Plating

Although it is not exactly like painting the surface with brushes, a soft cloth (or cotton) wrapped electrode performs the electroplating.  First, the cotton is soaked in a plating solution containing the metal ions then operators manually apply the coating onto the specific areas.

Unlike the conventional setup, it is portable and offers high customization. You can achieve localized coating both for selective coating and repair purposes.  However, it is not suitable for parts with large and complex surfaces.

Pulse Plating

This type of electroplating finish uses electrical pulses to coat the substrate, the current switches quickly between two different levels and becomes zero in between, which generates the pulse. Meanwhile, controlling the pulse width and amplitude deposits the finer grains and achieves high uniformity.

The pulse plating is suitable for parts requiring a finish with minimal porosity, micro cracking, and roughness. However, the setup and operation are relatively more complex than other types of electroplating, 

Metal Materials Suitable for Electroplating

You can electroplate with either one metal or a combination of metals. There are many metals that engineers use for this process. However, below are the most common metals used.

Zinc Plating

Zinc is a low-cost plating metal that protects from moisture and gives a silver-like shiny appearance. It develops a sacrificial layer on the materials that are prone to rust formation, such as steel, iron, copper, aluminum, etc. As the electroplated product reacts with moisture over time, the zinc layer degrades itself first to shield the underlying material. You can use zinc plating for screws, springs, switch plates, brake pipes, and other small-size hardware.

Gold Plating 

First, gold plating gives a luxurious appearance to various decorative items, light fixtures, and jewelry components. Although foil coating is also popular for these uses, electroplated is much more strongly bonded and durable. 

Consequently, gold is a superior electrical conductor, and the coating lasts longer than other electroplating materials. It makes good plating perfect for high-performance electrical components like connectors, circuit cables, contact points in PCB boards, microelectronics, etc. 

Palladium Plating

It is the best alternative to gold and costs relatively low. Additionally, the palladium offers wear resistance and corrosion resistance while providing a shiny and bright silvery-white appearance. Palladium plating is used for copper, brass, and other metals to prevent their degradation.

Furthermore, it is often applied on a metal surface before the gold to achieve the balance of electrical conductivity and surface hardness. Other application examples include electronic connectors, medical and dental components, etc.

Silver Plating

Silver is another plating metal with high conductivity and load-bearing resistance. It also costs less than gold and provides more oxidation resistance. The silver-plated surface further reduces the coefficient of friction. Consequently, silver-plated parts are also flexible with the soldering. However, they are not as resistant to corrosion as gold or palladium.

The silver plating is best for both the finish and conductivity of the electronic connectors. It is also used in solar panels, semiconductors, connectors, bearings, etc.

Nickel Plating

The nickel plating on substrates like steel, copper, and aluminum results smooth and durable finish. Sometimes, nickel also serves as the base plate for subsequent coats like silver or gold. Moreover, it provides corrosion resistance, longevity, and magnetism, whereas it is also heat-treatable for further surface hardness. 

You can electroplate Nickel to achieve both a bright and dull surface. Meanwhile, it has numerous color options if you want to customize the appearance. 

Copper Plating 

Copper is the most common material in electroplating, which is applied to diverse types of materials for high conductivity, lubricity, biocompatibility, and relatively low cost. The smooth and consistent copper alloy plating not only provides a shiny and bright surface but also provides excellent electrical and thermal conductivity. 

Chrome Plating 

Chrome is a highly corrosion-resistant metal with excellent mechanical strength, wear and abrasion resistance, hardness, and durability. Plating the chromium gives the substrate additional strength and hardness along with the shiny luster appeal. It can be applied to aluminum, steel, and other relatively soft metals and alloys. 

Its applications range from decorative furniture to industrial components, such as automotive & aerospace parts. 

Type of CoatingBased MaterialCoatingExamplesWhy UsedZinc PlatingSteel, iron, aluminumSacrificial corrosion protection with silver-like appealScrews, springs, switch platesTo protect the part against rust and corrosion by sacrificing itself before the base metal.Gold PlatingCopper, brass, other metalsLuxurious finish, high electrical conductivityElectrical connectors, jewelry, PCBsTo significantly enhance the conductivity and as a high-value decorative coatingPalladium PlatingCopper, brassA bright wear-resistant coatingElectronic connectors, medical componentsA cost-effective alternative to gold with good corrosion resistance.Silver PlatingCopper, brass, steelHigh conductivity and reduced frictionSolar panels, semiconductors, connectorsFor excellent electrical conductivity and eye-catching appearanceNickel PlatingSteel, aluminum, copperDurable finish with customizable appearanceIndustrial components, decorative finishesTo provide high corrosion resistant and color customizationCopper PlatingVarious metalsHighly conductive and smooth surfacePCBs, electronic parts, decorative itemsFor improved conductivity and adhesionChrome PlatingSteel, aluminumShiny, corrosion-resistant, and hard surfaceAutomotive parts, aerospace componentsTo add aesthetic appeal with high durability, wear, and corrosion resistance.

Advantages of Electroplating

BenefitsDescriptionCorrosion ResistanceIndustrial components and outdoor products require protection from corrosion to maintain their performance. Plating metals like chrome, nickel, and gold can make the manufactured parts suitable for corrosive conditions. Improved AestheticsBased on the plating metal, the substrate surface gets a brand-new look and eliminates minor flaws and irregularities. For example, gold gives a luster finish and chrome makes the surface shiny and brighter. Wear ResistanceCoat of high strength and tough metals like nickel and chrome improves the surface hardness and wear resistance. Enhanced Electrical ConductivityHigh-conductive metals like copper and gold can be used to improve the conductivity of connectors and other similar components. Reduction of FrictionNickel and chrome finish the work surface with low roughness values, which reduces friction and avoids premature wear. Improved AdhesionUnlike painting or powder coat, the plating layer chemically bonds with the underlying surface and also the subsequent coating. So, no risk of peeling off. 

Disadvantages of Electroplating

DrawbacksDescriptionLimited to Conductive MaterialsOnly electric conductive metals and alloys are compatible with electroplating as the process involves the flow of electricity for deposition.Environmental ImpactThe heat and process residues are harmful to human health and the environment.Expensive to SetupThe setup is expensive, including the equipment, tank, electrolyte, anode setup, and other components. 

Industrial Applications of Electroplating

The electroplating method has applications in a wide range of industries. Let's examine a few of them.

Aerospace

The protective sacrificial layer helps to improve the reliability and life of aircraft components. Manufacturers coat various titanium parts with nickel to withstand thermal changes and environmental stresses.  Additionally, precise dimensions and fits are also critical in aircraft manufacturing. The plating finish on their components resists wear and maintains the correct dimensions required for performance and safety. 

Application Examples: Engine parts and turbine blades with nickel or platinum coating, hydraulic systems, fasteners, structural items, valve bodies, sensor components, etc.

Automotive 

The reliability of automotive components is critical for vehicle performance and durability. Therefore, automotive parts require hard and environmentally unaffected coating, the chrome, zinc-nickel, or palladium-plated surfaces can address these requirements. Additionally, the automotive manufacturer also uses electroplating treatment to customize the aesthetic appeal.

Application Examples: Bumper, piston, cylinder liners, shock absorbers, radiator grill, fuel injectors, battery terminal and contacts, interior trims, etc.

Electronics

First, the coating of superior electrical conductive metals on electrical connectors, contacts, cables, and joining changes the complete electrical properties of the workpiece surface. It improves the performance and efficiency of electrical circuits.  Secondly, plating is also useful for the aesthetic design of enclosures and their protection from UV, corrosion, abrasion, and minor impacts. Moreover, gold, copper, nickel, and palladium electroplating are the most popular in the electronics industry. 

Application Examples: Connector pins, PCBs, semiconductors, capacitors, switch plates, battery contacts, sensors, and microelectronics parts.

Jewelry

Gold and gold alloys are most popular in jewelry plating to enhance the aesthetic appeal of ornamental items. It also provides a longer lifetime to them. Additionally, the combination of two or more types of metals gives unique appearances. You can apply other precious metals too, such as silver and rhodium.

Application Examples: Bracelets, rings, necklaces, watches, earrings, and custom items.

Electroplating Costs: What Influences the Price?

The prices can vary on different factors like which metal are you going to deposit, what is the thickness of the desired coating, whether the parts are too complex or not, and what is your production volume. All of these factors combined decide the electroplating cost.

Here is a brief elaboration of key influencing factors;

1. Material Selection

The overall coating cost is significantly affected by your material choices. It means which metal, alloy, or specific combination you want to electroplate. Especially, gold, platinum, and palladium are expensive than other metals. On the other hand, copper, nickel, and zinc are way cheaper.

Next, the exact material cost refers to the price of the total plating layer weight; a thicker layer means more material cost. 

Material Cost= Weight X Cost/kg = (Surface area x thickness x density) x $/kg 

2. Complexity and Precision 

Electroplating of intricate details or hidden areas requires specialized equipment and careful handling of the process. Often, recesses, blind holes, or internal cavities require masking techniques or multiple plating cycles for uniformity. It means slower production and more strict quality control procedures, which further increases the cost.

3. Production Volume 

High volumes typically reduce the cost per unit due to economies of scale, as setup, tooling, and overhead costs are spread across more units. Conversely, low-volume production leads to relatively higher costs per unit. 

At RapidDirect, you can get an accurate quote on how much your specific electroplating project costs.

Selecting the Right Electroplating Service Provider: What to Look For

The capability and experience of your electroplating service provider decide the end quality of the surface finish. Therefore, it is essential to consider several factors to select a reliable company that can fulfill all your requirements and coating specifications.

Here are the tips you can consider;

Does the manufacturer have the necessary equipment and facilities to achieve your electroplating specifications, including the size of parts, precision, thickness capability, etc.? Choose the manufacturer that has all the necessary electroplaters and tools to execute your finishing requirements. The processing capabilities also decide the lead time, cost, and accuracy. 

Quality Control

Like every type of surface finish, quality control is a critical aspect of electrolytic plating to ensure that each parts are electroplated with exact specifications (Ra value, color, texture, etc.). So, ask your service providers which standards they follow and what equipment they have to conduct the tests. Some companies also provide third-party quality control facilities for sensitive items like medical and aerospace components. 

Expertise and Experience

Look for a company that has a track record of working on metal electroplating similar to your project. For example, choose a company with experience in handling surface finishing projects for automotive companies if you are looking for electroplated bumpers. The experience ensures that they have related professional expertise to meet your expectations. 

Customer Support 

Responsiveness, timely communications, technical proficiency, and other customer-related aspects matter in the seamless completion of the project on time. Meanwhile, any misunderstanding of design can lead to complete failure. Therefore, ensure the customer support team has the technical expertise to offer informed advice, resolve issues, clear updates, and follow-ups.

Electroplating vs Electroless Plating

We discussed creating a protective layer of one metal on to surface of another metal by using electricity. However, it is also possible to add layers of various metals and alloys to manufactured components without using electricity, called electroless plating. Instead, chemical reactions and heat bind the coating material onto immersed substrates. Electroless nickel and chrome plating are most common across the industries.

The electroless method is also compatible with non-conductive materials like thermosets and composites. Since there is no electrochemical process, setup is simpler and cost-effective. Many industrial components need thicker and harder layers for high-stress operations. It can achieve such hard metal coatings with superior wear resistance, and thickness up to 200 µm. 

However, the deposition rate is slower in electroless coating and the thickness control is less precise than electrochemical deposition. Unlike electrolytic plating, it is challenging to automate the process.

Electroplating vs Electroforming

First, the similarity between these two processes is that both involve electrodeposition. Electroplating builds a protective coating of metal on already manufactured items, whereas electroforming creates completely new parts by depositing the materials inside a pre-shaped mold, often called a mandrel. Then, the part is removed from the mold. It makes small and complex shapes with microfeatures.

CriteriaElectroplatingElectroformingProcess DescriptionCoating of a thin metal layer to an existing surface for appearance and durability.It creates a self-supporting metal part by building up layers over a mold or substrate.ThicknessVery thin (microns), up to 0.020'Can be much thicker as it makes an entire componentSubstrate RequirementRequires a solid substrate, such as metals, plastics, or ceramics, to apply the coating.Electroforming starts with a temporary or dissolvable moldIndustrial ApplicationsIndustrial components, jewelry, electrical contact surfaces, etc.Precision components, microelectromechanical systems (MEMS), etc.Adhesion RequirementsCoating metal must adhere well to the substrateNo need for adhesion to a substrate, self-supporting.Process ComplexitySimpler process, primarily for surface treatment.More complex, suitable for small intricate and detailed shapesCostsLow cost due to simpler setup and less material usageHigher cost due to the complexity of the process and the material

Why Choose RapidDirect for Your Electroplating Needs

Every electrochemical metal plating process requires electrolysis as its base. However, what differentiates one electroplating process from another is the solution employed during the process as well as the expertise of the professional. If need metal parts with electroplating finishing, RapidDirect is your best bet.

To ensure your product stands out among competitors, RapidDirect applies a top-quality surface finish with exquisite materials that meet your requirements. Besides, we use high texturization standards to ensure a quality finish for metallic parts. Also, since we consider time an important factor in production, we shorten the production process using our self-owned factory and its established networks.

At RapidDirect, our manufacturing ability is versatile and aids in the production of high-precision and top-notch metal parts, ranging from CNC machining machines to sheet metal fabrication services. Our sheet metal fabrication aids in the production of high-precision and top-notch metal parts.

Besides, our strict quality assurance ensures you get high-quality metal parts with outstanding finishing and aesthetics. What's more, you can get a quote for your electroplating, and other manufacturing needs easily by visiting our online platform.

Conclusion

The electroplating process is one technology that has been around for a long time. It aids in the production of parts that have improved properties and are durable and aesthetically pleasing. For electroplating to be successful, it requires an anode, cathode, electrolyte, and power source.

Are you looking to electroplate an object? Doing so without proper guidance or training is a risky affair. So, you should visit RapidDirect to find out about your electroplating needs.

FAQs

Is it possible to electroplate plastics? 

Yes, it is possible to electroplate plastics. However, you cannot achieve this by immersing the plastic material in an electrolyte. This is because it requires a special plating technique.

How does a metal get deposited over others during electroplating? 

It occurs through a process called electrodeposition. The plating metal is the anode, while the other metal or substrate is the cathode. Introducing electric charge through the anode results in the oxidation of the plating metal. The electric current in the setup carries and deposits this oxidized metal into the cathode.

Does electroplating wear off over time?

The plating layer degrades itself and protects the covered substrate in corrosive environments, so it wears off over time. However, the exact life depends on the coating metal, thickness, and application environment. Coating like hard chrome can last up to 20+ years. 

What is the maximum size of an object that can be electroplated?

You can typically finish the parts with sizes up to 18 ix 18 x 24 inches. But, depending on the capability of the electrolyzer tank and other equipment, it is possible to electroplate any size.

Can the electroplating process fill in wear marks, pits, or surface scratches?

Yes! But you need to apply polishing treatment before the electroplating to eliminate the surface defects and imperfections like wear mars, pits, and tool marks. Otherwise, they can be more visible.

Is it possible to electroplate hollow objects?

Yes! It is possible to electroplate hollow objects by considering the drainage holes so the electrolyte solution can flow through them. However, it is best to consult with professionals to ensure whether your hollow parts are suitable or not.

Can items with decorative matte, textured, or photo-etched surfaces be electroplated?

Yes! These surfaces can be electroplated. But, they can be visible if not treated before the process. You can use beadblast, sandblasting, and grinding before setting them for electrolysis.

Are you interested in learning more about Hot Dip Galvanizing Machine For Metal Product? Contact us today to secure an expert consultation!