ELECTROPLATING ON PLASTIC BY SPC

Does your manufacturing operation involve the production of objects made of plastics such
as ABS, polypropylene, Teflon or polycarbonate? Do you need to give these materials the
ability to conduct electricity? An effective solution is to "metalize" these materials by adding
a metal coating via a process known as electroplating on plastic. Sharretts Plating Company
has the capacity to provide a cost-effective plating on plastic process that can meet your
requirements. Metal plating plastic is one of our many metal finishing specialties.

Electroplating on Plastic Components

Electroplating, the process of “electrodepositing” dissolved ions of one metal onto the
surface of another metal, has been a popular manufacturing technique for more than two
centuries. Manufacturers in a wide range of industries make use of electroplating for
purposes such as corrosion and wear protection, increasing surface hardness, promoting
electrical conductivity and even improving the appearance of a part or component.

While electroplating is typically viewed as a “metal on metal” manufacturing technique, it is

possible to electrodeposit metals onto other non-metallic objects as well. The process of
plating metal onto plastic is now a widely accepted industrial practice that offers a number
of crucial benefits for manufacturers everywhere.

Tracing the Development of Plating on Plastic

Plating on plastic first gained widespread use in the automotive industry in the 1960s and is
still frequently used in the industry today. Innovative plating on plastic applications include
providing finishes on fashion items such as shoes, as well as on consumer electronics
products including laptop cases and cell phones.
The first commercial metal plating plastic process was developed in the early 1960s,
primarily for use in the automotive industry. Automobile manufacturers were seeking ways
to make their vehicles more fuel efficient, which led to the increased use of lightweight
plastic parts and components. Electroplating served the purpose of “metallizing” these
parts to give them the gleaming appearance that appealed to most car buyers of the era. A
key advancement was the development of a reliable chemical process for the surface
preparation of acrylonitrile butadiene styrene (ABS), a thermoplastic polymer that offers
the toughness and impact resistance required for automotive manufacturing applications.
The new process provided sufficient adhesion between the ABS substrate and the metal
coating.

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Decline and Resurgence of the Plastic Plating Process

The use of plating on plastic continued to grow through the 1960s and well into the 1970s,
as industries such as plumbing and electronics began to discover the many benefits of
incorporating plastic plating into their manufacturing methods. However, changes in the
automotive industry, primarily a reduction in the demand for bright finishes on interior and
exterior parts and components, led to a decline in the use of plastic plating that lasted well
into the 1990s.

In recent years, there has been a resurgence in the demand for plating on plastic in a wide
range of industries, specifically in the North American and European markets. This can be
attributed to a renewed desire for bright trim among purchasers of vehicles and other
products. Additionally, improvements in quality and environmental compliance have made
the plastic plating process a more viable manufacturing technique than before.

We've Perfected a Revolutionary Plastic ELECTROPLATING

technique
While plastic on its own is not a naturally conductive material, electroplating on plastic is
still achievable. Unlike metal objects or parts, plastic materials cannot be immersed in a
bath and coated. Instead, a more specialized plating technique is required. At SPC, we have
drawn upon our nine decades of electroplating expertise to develop an innovative process
for electroplating on plastic that is the best in the industry.
Process of Electroplating on Plastic
Special preparation is necessary prior to plating on plastic. The material is initially etched in
a chromic acid-based solution to enhance its adhesive capabilities. Any excess chromic acid
that is produced must then be neutralized. A solution consisting of palladium and tin salts is
then applied to the material. Next, the surface of the material is coated with either nickel or
copper from an electroless plating solution. The palladium and tin salt solution serves as
catalyst when combined with the nickel or copper. The material is now ready for
electroplating using standard plating technology. Learn more about our industrial uses of
electroplating here.

Another option is to apply a conductive paint to the plastic surface prior to commencing the
electroplating process.

What Are the Benefits of Plating on Plastic?

The increasing popularity of the use of plastics and plastic composites in a wide variety of
manufacturing processes has also led to a greater demand for plating on plastic. Plating
plastic with a metal surface enhances the appearance of the material and creates the
impression of higher quality. As a result, it is often selected when a highly decorative look is
desired.

Additionally, plating on plastic can be an effective means of protecting a substrate against

the forces of corrosion and make it more resistant to damage from chemicals used in the
manufacturing process. In some instances, plating on plastic can increase the strength and
wear resistance of the substrate.

As we’ve seen in the automotive industry, an important benefit of plating on plastic is that it
can significantly enhance the appearance of the substrate. Most industrial plastics tend to
have a dull finish. While colorizing the plastic can make it more visually appealing, it still will
not produce the bright, shiny appearance that many product owners desire. While plating
with chrome has long been a popular technique in automotive applications, the potential
health hazards posed by the hexavalent chromium plating process has led many metal
finishing providers to employ safer alternatives, particularly nickel plating.

Electroplating can also give a non-conductive plastic surface the ability to conduct
electricity, a property that is invaluable to the manufacturers of electronic parts and
components used in automobiles, aircraft and a multitude of other products. A metal
coating can also reflect potentially damaging light away from the surface of a plastic
substrate and serve as a protective barrier against harmful gases and corrosion.
Additionally, metallization can help to control the dissipation of energy.
What Types of Plastic Materials Can Be Electroplated
Successfully?

While the initial success of plating on plastic was achieved with ABS — in fact, ABS still
comprises approximately 90 percent of all metal plating plastic applications — effective
techniques have been developed for plating on a wide range of plastic materials. Many of
these materials are classified as thermoplastics, which means they become moldable when
heated above a certain temperature, and then they solidify upon cooling. Examples of
plastics that are amenable to electroplating include:

Teflon: Brand name for a form of polytetrafluoroethylene (PTFE) developed by the DuPont
company primarily used in the manufacturing of non-stick cookware.

Phenolic: Laminated plastic material used to manufacture a wide range of molded plastic
products.

Polycarbonate: General name for a group of strong, durable thermoplastic polymers

commonly used in various automotive, aerospace, data storage and construction
applications.

Polysulfone: A group of thermoplastic polymers known for their strength, transparency and
high service temperatures, polysulfones are frequently used as flame retardants, filtration
media and dielectrics in capacitors.

Polyoxymethylene (Polyacetal): This engineering thermoplastic is typically used in high-

performance engineering applications for parts and components requiring low friction, high
stiffness and superior dimensional stability.
Which Types of Plastic Cannot Be Plated On Successfully
There are certain types of plastics that are not known for their ability to be plated on with
great success such as the Valox product family. There are other types of plastic that can
only be plated upon in a blended form. At SPC, we have the expertise to determine the
"plateability" of the plastics used in your manufacturing operation, as well as the best metal
required to achieve your objectives.

What Are the Best Metals to Plate Onto Plastic Substrates?

Plating on plastics can be achieved with various metals. Copper is the obvious choice when
there is a need to enhance the electrical conductivity of the substrate. Gold or silver plating
plastic can also be used to add aesthetic appeal to a plastic product. Nickel plating on
plastic is also a widely implemented metal finishing industry practice.

It is possible to plate a variety of metals onto plastic including:

Gold: Gold plating plastic parts will obviously improve their appearance. Gold also offers a
number of additional benefits. Gold provides protection against corrosion and is such a
good conductor of electricity that it is frequently used to provide a conductive coating on
electronic parts and components. Additionally, gold’s excellent heat shielding properties
make it suitable for high-temperature applications.

Nickel: Because of nickel’s bright, metallic appearance, it can serve as a suitable — and less
toxic —substitute for chrome when plating plastic automotive parts. Nickel also provides
protection against corrosion and wear. Alloying nickel with other metals such as tin and
tungsten can increase the hardness of the nickel deposit and enhance its corrosion and
wear resistance capabilities.

Copper: Copper is perhaps best known for its excellent electrical conductivity, which is why
copper plating is such as popular choice for metallizing non-conductive metal surfaces.
Copper plating can also be used as a heat stop-off for masking. A major benefit of copper
plating is its relatively low cost, especially when compared to precious metals such as gold
and silver.

Chrome: Despite the fact that hexavalent chromium is a known carcinogen and is listed as a
hazardous air pollutant by the U.S. Environmental Protection Agency, many metal finishing
shops still use chrome for automotive applications. Chrome provides a smooth surface
finish, good corrosion resistance and strong aesthetic appeal. However, the chrome plating
process is highly complex and can consist of as many as 30 steps. Platers that use chrome to
plate on plastic are also required to adhere to strict EPA regulations.
In many plastic plating applications, it is necessary to deposit an undercoat onto the plastic
substrate prior to electroplating in order to build thickness and promote coating adhesion.
A process known as electroless plating is typically used to accomplish the task. Electroless
plating differs from electroplating in that no electrical current is used to deposit the coating.
Instead, deposition occurs via an autocatalytic chemical reaction. Nickel and copper are the
two most commonly used metals for electroless plating, although techniques for gold and
tin have also been developed.

Overview of the Plastic Plating Process

The process of plating on plastic is somewhat different than traditional electroplating. There
are a number of additional steps that must occur prior to the application of the metal
coating. It’s essential to thoroughly clean the surface of the substrate to remove any dirt
and debris that could negatively affect coating adhesion. The next step is etching the plastic
substrate in a chromic acid solution to promote adhesion and then neutralizing any excess
chromic acid.

After that, it is necessary to activate the substrate surface with a palladium and tin salt
solution, which is followed by the application of the electroless nickel or copper coating. At
this point, the metal coating can be applied using standard electroplating techniques.

Because of the difficulty involved with plating on plastic, it is necessary to closely monitor
the process and perform troubleshooting steps as needed. Common issues include:

Too high of a chromic acid concentration during etching, which can lead to insufficient
adhesion.

Too high of a plating bath temperature that can cause the plastic part to warp.

Inadequate plating of part edges, which may be a sign that the temperature of the
accelerator used to remove excess stannous hydroxide is too high.

Overly shiny parts after etching, which is typically caused by an etching process that is too
short.
SPECIFIC PLASTIC PLATING APPLICATIONS
According to Global Market Insights, the automotive industry is still the predominant user
of plastic on plating technology (79.2%), followed by domestic fittings (plumbing; 9.9%) and
electrical/electronics (7.7%). Let’s take a look at some of the more common plastic plating
applications in each of these industries.

Automotive
Global Market Insights indicates that polymers now account for approximately 15-20
percent of the total weight of interior and exterior car parts. In addition to the lighter
weight, plastic parts provide additional design flexibility. The ability to mold and bend
plastic into just about any shape gives engineers a wider range of options to develop vehicle
styles that differentiate their company’s products from those of the competition.
Manufacturers of OEM and aftermarket parts are also making widespread use of plastic
plating.

As mentioned, nickel plating is now widely used to provide a bright, chrome-like finish on a
variety of plastic car parts. According to the Nickel Development Institute, the largest
application of nickel plating on plastics in the automotive industry is for decorative
purposes to enhance the appearance of interior and exterior parts such as grilles, wheels,
light bezels, emblems, gear shift knobs, door handles and bumpers. In some instances, a
chromium-nickel alloy is used instead of pure nickel.
Nickel electroplating and electroless nickel plating can also provide functional benefits for
auto manufacturers. The nickel coating can enhance the corrosion and wear resistance of
certain plastic parts while also increasing lubricity, which is the ability to reduce wear that
results from friction.

Electronics
The Nickel Development Institute states that electrical applications represent only a small
portion of the market for plating on plastics. However, the plastic plating process does play
a critical role in many electrical and electronics manufacturing procedures. In terms of
decorative applications, nickel and nickel-chromium plating is used to enhance the
appearance of the plastic trim on computers and mobile phones, as well as the various
control knobs, switched and buttons on a wide range of home electronics and electrical
appliances.

In terms of functionality, plating is used to make non-conductive plastic surfaces electrically

conductive. In addition, plating provides a productive coating on electrical parts that are
handled frequently or exposed to environmental conditions that could cause premature
wear. The development of heat-resistance plastics has created a need for the nickel plating
of connector blocks to enable direct soldering on their surfaces. Additionally, electroplating
can play a key role in the production of circuit systems that feature interconnecting paths.

Plumbing
The use of plastic plumbing fixtures as a lightweight, inexpensive alternative to brass has
created a demand for effective plating on plastic techniques. While the first plastic
plumbing fixtures were typically made of colored plastic, the demand for brighter, shinier
kitchens and bathrooms have helped pave the way for the use of metal-plated plastic
products as a more viable alternative. Plated plastic plumbing products provide additional
design possibilities and greater flexibility when compared to brass and offer hygienic
benefits. The quality of plastic plumbing fixtures has continued to improve over time, too.

While nickel-plated plumbing fixtures can provide the desired aesthetics for many
homeowners, applying a gold finish over the nickel coating can meet the needs of those
who want a more elegant, upscale look for their bathrooms and kitchens.

Recent Plastic Plating Developments

Plating on plastic is still a work in progress, and new techniques continue to evolve. One
recent development is a double layer nickel system featuring a semi-bright nickel coating
underneath a bright nickel topcoat, which provides significantly enhanced corrosion
protection. Another key innovation is a microdiscontinuous chromium system that
increases the corrosion resistance of nickel/chromium deposits. Using these two techniques
in tandem provides superior corrosion protection in extreme environments.
Tremendous strides have also been in the development of plastic resins that are used in
conjunction with electroplating. The formulation of various ABS and polycarbonate blends
has resulted in stronger plastic materials that also feature excellent ductility after plating.
The latter characteristic is especially valuable in automotive industry applications in terms
of facilitating the recovery of the plastic material after impact.

Sharretts Plating Company: The Best Choice for Your Plastic

Plating Needs

Because of the many challenges involved with plating on plastic, it is important to choose a
metal finishing company with extensive experience in this highly specialized area. SPC has
been a leading metal finishing innovator since 1925. Over the years, we have developed and
perfected a number of techniques that have helped to set the tone for the entire industry.
This includes a revolutionary plastic plating process that can be customized for industries
such as automotive, plumbing and electronics. We can also tailor the process to meet your
unique plating requirements.

Sharretts Plating Company is an innovative plastic plating company that can help your
business with all its electroplating on plastic needs. Our capabilities include a wide range of
plastic plating services. We also have the expertise to help you select the most appropriate
plastic plating service for your needs. Contact us today to learn more about what our
plating processes can do for you! We can also provide a no-obligation price quote for our
plating on plastic services.

Feel free to contact SPC if you would like to learn more about the benefits of plating on
plastic, as well as our cutting-edge plastic plating process. We can schedule an on-site
consultation to gain a better perspective of your company’s unique metal finishing
requirements. We will also be happy to provide a no-obligation price quote for any of our
premium metal finishing services.

Note: We do not provide cosmetic or decorative finishes.