Electroplating 101: How Metal Plating Works

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.

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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.

Electroplating: The Process & Uses in Liquid Analysis ...

Electroplating is a process that occurs when the surface layer of one type of metal is added to another kind of metal. Also known as electrodeposition, this process is used to ensure that the metal base isn&#;t subjected to rust and corrosion. The thin layer of metal that&#;s positioned on top of another metal can alter the base metal&#;s physical properties, improve wear resistance, and increase material thickness. Electroplating is also commonly used to make a product more visually appealing.

There is a range of metals that can be used during the electroplating process, which include everything from copper and zinc to silver and gold. Even though modern advancements to electroplating have made this technique more popular than ever, the process was invented back in the 18th century. At the time, electroplating only existed as a basic experiment. It wasn&#;t until  that Luigi Brugnatelli formalized the process, after which it was quickly adopted throughout most European countries. Since that time, advancements have continued to be made that allow electroplating to offer many distinct benefits.

The electroplating process always involves two different types of metals. In order for this process to occur, one of the two metals will need to be positively charged while the other is negatively charged. When an electrical current begins to flow from one metal to another, the negatively charged metal will take some molecules from the positively charged one.

For this process to work as intended, the layer of metal that you want to add to the surface of another metal must accommodate an electrical charge. This requirement means that it can be difficult to plate materials like wood and plastic that are unable to conduct electrical charges. You can bypass this issue altogether by thoroughly cleaning the material and applying a very thin layer of metal to the base material. Once you&#;ve found a material that can hold an electrical charge, the electroplating process can begin in earnest. This article offers you a detailed guide on the process and many uses of electroplating.

Electroplating Uses

Because of how versatile electroplating is, it has several different uses, which means that it can be applied in many industries. The four main uses of the electroplating process include:

• Lend various surface properties &#; Once applied, the substrate can benefit substantially from the characteristics and properties of the metal that it is plated with. The plating metal you select can increase the electrical conductivity of the substrate or reduce material friction. Each plating material provides its own distinct benefits.

• Improve an item&#;s appearance &#; The electroplating technique is commonly performed to enhance the appearance of the substrate in question. Silver and gold are two popular plating metals that can improve the substrate&#;s appearance.

• Protect the substrate &#; If you want to protect the substrate surface from damage or corrosion, the plating metal can serve as protection for the substrate below. When the finished item is exposed to harmful conditions, the plating metal will be damaged first, which ensures that the substrate has more protection than it otherwise would have.

• Improve material thickness &#; It&#;s possible to add several layers of plating metals, which can help you improve substrate thickness.

Industries That Use Electroplating

Because of the many uses that electroplating has, there is a range of different industries that benefit from the electroplating process. The five primary industries that use electroplating are:

• Medical industry &#; It&#;s common for the medical industry to use electroplating to enhance component biocompatibility. Metals like titanium, gold, and silver are used in the medical industry for their wear resistance, corrosion resistance, and biocompatibility. In fact, this process is integral for the creation of joint replacements and implants.

• Automotive industry &#; The main purpose of using plating in the automotive industry is to keep corrosion at bay when the substrate is exposed to harsh environmental conditions. While zinc-nickel plating assists with rust prevention, nickel plating is commonly paired with plastic parts and catalytic converters as opposed to chrome.

• Aerospace industry &#; Titanium is commonly used in aircraft manufacturing because of its fantastic strength-to-weight ratio. Two other plating metals that are popular in the aerospace industry include copper for heat resistance and nickel to protect against wear and corrosion.

• Oil and gas industry &#; Because of the composition and volatility of petrochemicals, corrosion protection is essential. To ensure that piping is properly protected, nickel plating is applied via the electroplating process. Performing the electroplating process in this situation ensures that the parts can last longer.

• Electronics industry &#; Electroplating is also commonly used in the electronics industry for several applications. For one, gold plating is applied to connectors and semiconductors to ensure that the item is conductive. Gold is highly resistant to corrosion, which makes it perfect for the electronics industry. It&#;s possible for copper plating to provide the same benefits. Another type of metal that can be useful as a protective coating for electronic components and equipment is palladium alloy.

While these five industries use electroplating the most, this process is also used for several applications throughout the military and firearms industries. Along with the functional capabilities that electroplating provides, it&#;s also a flexible and affordable process.

Electroplating Process Explained

The electroplating process works by directly dissolving a metal with an electric current. The dissolved metal is then placed on the substrate metal. There are four primary components that must work together if you want the electroplating process to be effective. These components include:

• Cathode &#; The cathode is the substrate material that must be plated with another metal. This is a negatively charged material.

• Anode &#; This is the metal that forms the plating and is positively charged.

• Power source &#; An electric current is sent to a circuit with a power source of some kind. The power source will apply the current directly to the anode, which allows electricity to be introduced to the item.

• Solution &#; The reaction that takes place during the electroplating process occurs within an electrolytic solution. The solution consists of at least one metal salt that helps with the flow of electricity. It&#;s common for one of these salts to be copper sulfate.

When the cathode and anode have been properly placed in the solution, a power supply will send an electric current to the anode. The current ensures that the metals oxidize, which dissolves metal atoms into positive ions. The ions will then move over to the negatively charged metal to create a thin metallic layer. The three factors that play a part in the plating quality include:

• Electric current &#; The success of this process is determined by the application time and voltage level of the electric current.

• Bath conditions &#; The chemical composition and temperature of the solution dictates what the results of the electroplating process will be.

• Part placement &#; The effectiveness of the plating can be determined by how close the anode is in comparison to the cathode.

If you want a real-life example of how the electroplating process works, consider what happens when gold is plated onto metal jewelry. While the jewelry exists as the cathode, the gold plating acts as the anode. These metals are then positioned in a solution, after which an electric current is sent to the gold.

The gold will dissolve within the solution, which creates dissolved gold atoms. These atoms will be attracted to the negatively charged metal, which is the jewelry. If performed correctly, the gold atoms will stick to the metallic surface to create a gold coating.

Different Plating Techniques

There are three primary plating techniques that can be used with the electroplating process, which include:

• Rack electroplating &#; This technique is ideal for plating sizable groups of parts. When using this method, the parts will be placed directly on a wire rack, which ensures that every part comes into contact with the power source. While this process is similar to barrel plating, it&#;s better for delicate parts that wouldn&#;t be able to withstand the barrel-plating process.

• Electroless plating &#; This plating technique is the only one that doesn&#;t require the parts to come into contact with an electric current. To bypass this requirement, the plating material of your choice is dissolved with a chemical reaction. This particular technique is best used on parts that don&#;t accommodate electric currents.

• Barrel plating &#; This plating technique is ideal when large amounts of smaller parts need to be plated. These parts will be positioned inside a barrel that&#;s filled with the electrolyte solution of your choice. From here, the barrel is rotated, which helps to agitate the parts and apply an even coating.

Metals Used Throughout the Electroplating Process

As touched upon previously, there are many different metals that can be used in the electroplating process. The metal that you choose depends on the substrate composition and your preferred price. The main metals used in the electroplating process include:

• Nickel &#; This metal provides fantastic wear resistance. The different nickel alloys can also provide the substrate with better conductivity and elemental resistance. As for electroless nickel plating, it can help provide low friction, corrosion resistance, and magnetism.

• Silver &#; This metal is malleable, ductile, and highly wear-resistant. It&#;s a more affordable alternative to silver.

• Gold &#; This metal provides high wear and corrosion resistance as well as fantastic conductivity.

• Palladium &#; This metal offers a sleek finish, hardness, and corrosion resistance. When you combine palladium with nickel, the plating quality is superb.

• Zinc &#; This specific metal has great corrosion resistance and can be enhanced when alloyed with other metals.

• Copper &#; Along with improving material adhesion, copper is ideal when used for its heat-resistant and conductive properties.

• Tin &#; This metal is environmentally friendly, inexpensive, and resistant to corrosion.

Benefits of Electroplating

The electroplating process comes with many benefits the primary of which include:

• Heat resistance &#; When metals with high heat resistance are used in the electroplating process, the substrate materials can withstand heat damage. By keeping heat damage at a minimum, plated parts should last longer.

• Added protection &#; As an added layer of protection, plated metals can protect the substrate from harsh environmental conditions.

• Better hardness &#; Plated materials will invariably be stronger and more durable, which keeps stress damage at a minimum.

• Electrical conductivity &#; Plating metals like copper and silver can enhance the conductivity of substrate materials. This cost-effective solution is very popular in the electronics industry.

• Improved appearance &#; Plating metals like silver and gold improve the appearance of base metals that may inherently have worse appearances.

Keep in mind that these benefits are dependent on the metal you use in the electroplating process. For instance, nickel plating keeps wear and tear at bay, which bolsters part longevity. Because of its flexibility and the many applications, it can be used for, electroplating is a highly important process across numerous industries. If you want to strengthen a substrate or improve its appearance, electroplating offers a cost-effective solution.

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