Electroplating Explained - How It Works, Types, Benefits & ...

Electroplating is a common surface finishing process in the manufacturing industry to coat a material (substrate) with another metal. In recent years, the process has undergone many advances, making it much more accurate and capable of working with a wider range of materials.

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In this article, we will explore the modern electroplating process to understand what it is, how it works, its benefits and limitations.

What Is Electroplating?

Electroplating is a manufacturing process in which a thin layer of metal atoms is deposited to another material through electrolysis. The metal added is known as the deposition metal, and the underlying material or workpiece is known as the substrate material.

By adding a layer of the desired metal, we can improve several physical, mechanical and chemical properties of the substrate, such as its strength, heat conductivity, electrical conductivity, abrasion and corrosion resistance.

Improving these properties can allow us to combine different metals to achieve properties that perfectly suit different applications.

How Does the Electroplating Process Work?

The electroplating process works on the principle of the electrolytic cell.

In this process, two metal rods are placed in an electrolyte. The rods act as electrodes when connected to the opposite terminals of a battery or power supply to create a potential difference. The electric current causes the electrolyte bath to disintegrate into dissolved metal ions, and the positively charged metal ions deposit on the negative electrode (cathode).

These positively charged ions are part of the electrolyte. As they get deposited on the cathode, their concentration in the electrolyte reduces. By choosing a suitable element for the anode, we can replenish the concentration of the positive ions.

For instance, if we need to coat brass with copper, the brass becomes the substrate. Connecting it to the negative terminal makes it the cathode. We use an electrolyte, such as a copper sulfate solution, that gives positive copper ions upon disintegrating. On the other end, we use a copper anode to replenish the electrolyte&#;s positive ions.

We can control the plate thickness, rate of metal deposition, surface finish, colour and many other factors by manipulating the process parameters. For example, using pure copper plates will give a better appearance than regular copper rods available in the market.

Using this process, the material can be coated with one or more metals.

Types of Electroplating Methods

Over the years, the electroplating process setup has evolved to suit different applications. By choosing a method in line with the application, the efficiency of the operation can be increased significantly.

To choose the right one, we must first understand the different types. Overall, electroplating methods can be divided into four major types. These are:

1. Mass plating

2. Rack plating

3. Continuous plating

4. In-line plating

Mass Plating

Barrel plating

As the name suggests, mass plating is used for mass-production applications. The method can handle a large volume of products that require thin coatings of metal.

A common type of mass plating method is known as barrel plating. In this method, the material to be coated (substrate) is dipped in a barrel containing the metal salt (electrolyte) and the anode of the coating metal.

The barrel plating setup is highly economical for small parts that need a uniform coating. As the barrel rotates, all the parts are cleaned, descaled and uniformly coated to a greater extent compared to rack plating.

This method is not recommended for parts that require a detailed finish without scratches and entanglement.

Mass plating is generally used for small but robust parts such as nuts, bolts and screws.

Rack plating

Rack plating

When the parts are larger than those suitable for mass plating, the rack plating method is used. In rack plating, the parts are mounted on racks and immersed in the chemical electroplating bath.

The rack plating process reduces the damage to delicate or fragile parts and coats the interior contours and deep crevices of parts, unlike mass plating.

This process is, however, more expensive than mass plating. But it makes up for it by providing a plated layer of much higher quality than a mass-plated product.

Rack plating is typically best for large, fragile and complex parts that require a plating of gold, silver, tin, copper or nickel.

Continuous plating

The continuous plating process is performed on exceptionally long parts, such as metal tubes, wires and strips.

In the case of thin strips, this process is also known as the reel-to-reel plating process. In this process, a long product is passed through the chemical bath at a specified rate. The end product&#;s quality is controlled by manipulating the process parameters and the time spent in the bath.

The reel of the product to be coated is uncoiled at the initial station, and once it passes the electrolyte/anode and gets coated, it is recoiled for easier storage and transport. Then further operations can be performed to stamp it into the required shapes.

In-line plating

The in-line plating method uses an assembly line for the metal plating operation. The metal passes through the various stations and automated machinery facilitates the chemical reaction.

Line plating is generally used for coating copper, zinc, chromium and cadmium. A variety of substrates can be coated with these metals through line plating. This method is relatively cheaper than other methods because a lower amount of chemicals is needed per piece.

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Suitable Materials

Electroplating is a versatile process owing to the fact that it requires only one property in the substrate: electrical conductivity.

Since this property is exclusively available with metals (barring a few exceptions), we could initially use electroplating only for metals. But with the advent of conductive sprays and coatings, it is now possible to coat non-conducting materials such as plastic and wood too.

As a result, today, there are many more materials that can be electroplated. The substrate material can greatly vary depending on the application.

Silver or gold plating is often used to improve the appearance. To improve properties such as bacterial resistance and conductivity, copper plating is a favourite. Copper electroplating also offers increased malleability, lubricity and corrosion resistance.

Similarly, when we need to improve corrosion and wear resistance simultaneously, we go for nickel plating. Nickel also improves the appearance of the product.

Some other metals that are normally used for coating in electroplating are chromium, cadmium, zinc, iron and titanium.

But the substrate and the coating must be chosen carefully. Not all materials combine with each other. For example, steel cannot be plated with silver right away. It must first be plated with copper or nickel before silver plating.

Benefits

The first modern electroplating plant was set up in Hamburg in the late 19th century. The intention was to improve the appearance. But as science understood the mechanism and benefits of electroplating, its applications for non-decorative purposes became common.

Today, we understand the true breadth of electroplating benefits. Let&#;s list them down for a better overall understanding.

Improved physical properties (colour, lustre, conductivity, low weight)

Electroplating improves physical properties such as colour, lustre and conductivity.

Colour and lustre provide cosmetic upgrades that are necessary for many day-to-day products as well as art applications.

Everyday appliances and kitchen products such as utensils, pans, cutlery, taps, kettles and other gadgets become much more attractive when coated with shinier metals such as copper, gold or silver. It also improves their functionality, as electroplated products are often easier to clean.

The appearance of artistic installations such as sculptures and figurines can also be improved by using electroplating. As a result, electroplating also finds use in art restoration and preservation projects besides new art creation.

Functionality can also receive a boost in technical applications involving electrical components such as antennas and integrated circuits. Although metals are already conductive, coating them with a better conductor improves the overall conductivity of the part while keeping costs low.

Costs are also reduced by the fact that non-metals can be used for electrical applications after electroplating. Besides having lower costs, non-metals also weigh less, which reduces the cost and difficulty related to the transport and storage of products.

Improved mechanical properties (tensile strength, bending strength, abrasion resistance, surface finish)

Electroplating also improves mechanical properties such as tensile strength, wear resistance and durability, depending on the application.

The small increase in tensile strength is enough to bridge the gap between the SLA resins of 3D printing (plastics) and metal alloys. The distinct strength characteristics allow the use of electroplated materials in applications where previously metals would have had to be used.

The metal skin on a plastic product, besides making the product lighter, also imparts excellent flexural strength characteristics.

We can also improve the surface finish using electroplating. This makes the products easier to handle and reduces friction.

All these improvements increase the short-term performance while also lengthening the lifespan of the products.

Improved Chemical Properties (Corrosion, Chemical, UV and Radiation Resistance)

The chemical properties of a material can also be enhanced by using electroplating. Properties such as corrosion resistance, resistance to chemicals and UV light are crucial in certain applications such as medical implants.

Typically, medical implants depend on precious metal coatings of gold, silver, platinum and copper for their corrosion protection, electrical conductivity, heat dissipation, non-toxic and antibacterial nature.

Chemical and corrosion-resistant products are also required for harsh service environments where the product is exposed to chemicals, moisture and seawater.

Limitations

Electroplating has certain disadvantages that prevent its use in some cases. Let&#;s evaluate these to get a complete picture.

Complex process

The process is far from simple and can be difficult to carry out reliably. A process would have to be set with predetermined parameters to obtain parts of a consistent quality. Mistakes in preparation and pretreatment can lead to defects, poor quality and capability of finished parts.

Electroplating cannot be used for all material combinations, as they may not combine well with the plating solution.

Long plating time

The plating time can be excessively long in some cases. The metal deposition rate can be increased by either increasing the power supply or the concentration of the electrolyte or both. But this will cause uneven deposition, which can be a dealbreaker in some cases.

The benefits are limited to the surface

By its nature, electroplating is only limited to the surface. Once the surface layer is scratched off, the product can lose some or all of the benefits provided by the process.

Hazardous nature

The process releases gases due to the reduction at the cathode. If these gases are of a hazardous nature, they pose considerable risks for personnel in the vicinity.

Hexavalent chromium exposure from chrome plating is an apt example of how hazardous the electroplating process can be.

Wrapping It Up

Electroplating is nothing short of an engineering wonder. In the past, we could only use it on metals, but that is no longer the case. Today, we can electroplate plastics, ceramics and even organic materials such as leaves and flowers.

However, it still remains a very difficult process to execute consistently. This is why engineers and designers should turn to electroplating service providers for their expertise. Fractory&#;s sales engineers have plenty of experience in planning and executing custom projects, so don&#;t hesitate to get in touch.

FAQ

How do I identify the positive and negative terminals of the power supply in the electroplating solution?

It is very important to maintain the right polarity during electroplating. If for some reason you are not able to identify the anode (positive electrode) from the cathode (negative electrode), remember that the bubbles are generated on the cathode during the reaction.

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This tells us that the electrode with the bubble formation is connected to the negative terminal of the power supply.

What is the difference between electroplating and electropolishing?

Electropolishing is basically the reverse operation of plating. Instead of adding material, electrochemical polishing removes it. In the electropolishing process, the workpiece is the anode, contrary to electroplating, where the workpiece is the cathode. Thus, electropolishing is also known as the reverse plating process.

What is electroless plating?

Electroless plating works on the principle of an electrochemical cell. A chemical reaction causes the deposition of one material on another without the need for an electric current. The coating metal is usually a metal or a metal alloy and the substrate could be either a metal or non-metal such as plastic, ceramic, glass, etc.

What is electroforming?

The electroforming process refers to the use of electric current across a chemical bath to form solid models with intricate cavities. The process is similar to electroplating except that instead of a surface, we are building a solid article with a complex cavity.

It uses a template known as the mandrel. The mandrel is dipped in the electrolyte and the electrolytic reaction forms a layer of the deposition metal on the mandrel in the negative shape of the mandrel.

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. 

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

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.

If you are looking for more details, kindly visit Hard Chrome Plating Equipment.