Characteristics and limitations of electroplating

Electroplating is the process of applying a thin layer of other metals or alloys to the surface of certain metals using electrolytic principles. It is a process that uses electrolysis to attach a metal film to the surface of a metal or other material to prevent oxidation (such as rust), improve wear resistance, electrical conductivity, reflectivity, corrosion resistance (copper sulfate, etc.) and enhance aesthetics.

Plating has many benefits, including improved strength, longevity and electrical conductivity of parts. Engineers, manufacturers and artists utilize these benefits in a variety of ways.

　　Engineers often use plating to add strength and durability to various designs. You can increase the tensile strength of a 3D printed part by 400% or more, for example by coating it with metals such as copper and nickel. By placing metal skins on polymer parts, you can increase their resistance to chemical exposure and environmental factors such as UV light.

Artists often use electroplating to protect perishable natural elements, such as leaves, and turn them into more durable works of art. In the medical world, electroplating is used to create medical implants that are resistant to corrosion and can be properly sterilized.

Plating is an effective way to add decorative metal finishes to customer products, sculptures, figurines and artwork. Many manufacturers also choose electroplated substrates to create lighter parts that are easier and cheaper to move and transport.

Electroplating also has the advantage of being electrically conductive. Because metals are inherently conductive, plating is a good way to improve the conductivity of parts. Antennas, electronic components and other parts can be plated to improve performance.

Limitations of electroplating

Despite the many benefits of electroplating, its limitations lie in the complexity and hazards of the process itself. Workers who perform electroplating can be exposed to hexavalent chromium if proper precautions are not taken. Workers must have a well-ventilated work space. The U.S. Department of Labor’s Occupational Safety and Health Administration has issued numerous documents outlining the risks involved in electroplating.

　　Because of the expertise required and the hazards involved, many engineers and designers choose to hire a third-party plating manufacturer who specializes in this process. While plating can be performed in-house, outsourcing is often the easiest solution.

The many applications of plating

Many industries use plating to make everything from engagement rings to electronic antennas. The following are some common examples:

Aerospace

　Many aircraft components are plated to add a “sacrificial coating” that extends the life of the component by slowing corrosion. Because aircraft components are subject to extreme temperature changes and environmental factors, additional layers of metal are added to the metal substrate so that the function of the component is not compromised by normal wear and tear.

Many steel bolts and fasteners designed for the aerospace industry are electroplated with chromium (or, more recently, zinc-nickel due to changing constraints).

Art & Home Decor

　Type the word “plating” into Etsy and you’ll see a wide range of plated home decor and one-of-a-kind memorabilia. Artisans often use this process to turn biodegradable items, including flowers, twigs, and even bugs, into durable and long-lasting works of art. You can use plating to show off and preserve fine details in items that would otherwise disintegrate quickly.

Digital designers sometimes use plating to create sculptures. Designers can use a desktop 3D printer to 3D print a substrate and then electroplate the design in copper, silver, gold, or any metal of choice to achieve the effect they want. Combining 3D printing with plating in this way can produce parts that are easier (and cheaper) to make while still having the same look and finish as solid cast metal sculptures.

Automotive

　　Electroplating is very common in the automotive industry. Many major automotive companies use electroplating to make chrome bumpers and other metal parts.

　　Plating can also be used to create custom parts for concept cars. For example, VW worked with Autodesk to create hubcaps for its “Type 20” concept car. The prototype hubcaps were 3D printed and then plated.

Restoration companies and vehicle customization businesses also use electroplating to apply nickel, chrome and other finishes to a variety of automotive and motorcycle parts.

　　Jewelry

Electroplating is probably most often associated with the jewelry industry and precious metals. Jewelry designers and manufacturers rely on this process to enhance the color, durability and beauty of rings, bracelets, pendants and a variety of other items.

When you see jewelry described as “gold-plated” or “silver-plated,” you are likely looking at jewelry that is plated. Various combinations of metals are used to achieve unique tonal finishes. For example, gold is often combined with copper and silver to make rose gold.

Medical and Dental

Plating is used to add a resilient exterior to various medical and dental components. Gold plating is often used to create dental inlays and to facilitate various dental procedures. Implant components such as replacement fittings, screws and plates are often plated to make the components more resistant to corrosion and compatible with pre-insertion sterilization. Medical and surgical tools, including forceps and radiographic components, are also commonly plated.

Strength

　　Many electrical and solar components are plated to improve electrical conductivity. Solar cell contacts and various types of antennas are often manufactured using electroplating. Wires can be plated with silver, nickel and many other types of metals. Gold plating is often used (in combination with other metals) to improve durability. Gold is also often used to extend the life of parts because it is electrically conductive, very malleable, and does not interact with oxygen.

Prototyping

　　Using traditional manufacturing processes to produce custom or low-volume metal parts for prototyping can be very expensive and time-consuming. As a result, engineers often combine plating with 3D printing to achieve a low-cost and time-saving solution.