Electroplating is a process that involves depositing a metal or alloy onto a substrate by passing an electric current through an electrolytic solution where the workpiece serves as a cathode. The electroplating method involves two electrodes: the anode, made of the depositing metal, and the cathode, the workpiece. When you apply the electric current, metal cations dissolve from the anode into the solution and deposit onto the cathode, creating a thin metal layer on the workpiece. In some processes, the metal to be deposited exists as metallic ions dissolved directly in the bath. For those cases, manufacturers use anodes made from non-reactive metals like lead or titanium.
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In this guide on electroplating, we’ll discuss:
The purposes of electroplating are varied and include enhancing the appearance, protection against corrosion and wear, and providing special surface properties. Owing to its ability to improve both functional and decorative aspects of objects, this process is wide utilization across various industries, including aerospace, nuclear, electronics, and jewelry.
Electroless plating, by contrast, does not require an electric current. Instead, it uses a chemical reduction process to deposit metal onto the substrate. This process involves a plating solution that contains metal ions, a reducing agent, and other chemicals that initiate and regulate the plating reaction. Electroless plating is particularly valued for its ability to produce a uniform metal layer, even on complex shapes and non-conductive surfaces, which is a limitation in some electroplating processes due to uneven current density effects. Examples of materials used in electroless plating include nickel, gold, and palladium.
Basic illustration comparing the electrolytic plating process (electroplating) to the electroless plating process
The main differences between these two plating techniques stem from their respective mechanisms and applications. Electroplating allows for greater control over the thickness and properties of the metal coating by adjusting parameters such as current density, agitation and plating time. It is typically used where specific conductivity or corrosion resistance characteristics are needed. Electroless plating, however, is chosen for applications requiring uniform coverage over complex geometries and excellent corrosion and wear resistance without the need for external power.
Electroplating encompasses various methods and materials, each offering specific benefits depending on the application requirements. Here’s a summary of the most common types of electroplating and their specific uses and benefits:
Zinc plating provides excellent corrosion resistance, making it ideal for automotive and hardware applications, as well as an effective undercoat for paints. It is relatively cost-effective and offers good protection for steel parts against rust.
Zinc plating is used on fasteners to improve the lubricity and hardness of the threads
Often used for decorative purposes, gold plating adds aesthetic appeal and significant corrosion resistance. It’s also valued in electronic applications for its excellent conductivity and resistance to oxidation. There are, however, both electrolytic and electroless gold plating processes.
Printed circuit board with gold plating
Similar to gold, silver plating is used for both its conductivity and appearance. Manufacturers commonly apply silver plating to electrical components, jewelry, and cutlery, particularly valuing it for settings requiring high electrical and thermal conductivity.
Engineers often use copper as a base layer to improve the adhesion of other metals. Copper plating is essential in the electronics industry because it significantly enhances the electrical conductivity of components. Copper plating is also in use for decorative purposes.
Image shows a copper plating bath for printed circuit boards
Known for its hardness and durability, nickel plating improves wear and corrosion resistance and adds a reflective and shiny finish. Nickel has common uses in the chemical, petroleum, and food processing industries.
Often referred to as chrome plating, it provides an extremely hard surface with high wear resistance. Chromium is in use across various industries due to its functional and protective properties.
Bearings plated in Armoloy nodular thin dense chrome
Choose each type of electroplating based on the desired properties of the final product, such as appearance, resistance to metal failure modes, or enhanced electrical conductivity. The choice of plating material greatly depends on the specific application requirements and the characteristics that are most valued for the end-use of the plated component.
Numerous industries widely utilize electroplating for its enhanced corrosion resistance, electrical conductivity, wear resistance, and aesthetic appeal. Here is a detailed summary of the primary applications and industries where electroplating is essential:
Image of surgical hip replacement plated with biocompatible thin dense chrome
Electroplating of Armoloy performed on core sub for its anti-galling properties, wear and corrosion resistance.
Nuclear components, like the nuclear fuel rod element shown above, use electroplating processes to safeguard components from potential critical failures.
The process of electroplating involves several key components and steps that ensure the successful deposition of a chosen material onto a substrate. Here, we provide an example with an overview of the electrolytic silver plating process:
Equipment and Components
The process begins with the preparation of the substrate, which includes cleaning and sometimes a base layer deposition if necessary to improve the adhesion of silver. The next step is to immerse the substrate into the plating solution where it acts as the cathode. The anode, made of silver, dissolves under the application of an electric current, and silver ions deposit onto the cathode, forming a thin, even layer of silver.
Illustration of standard electroplating circuit
Controlling temperature, agitation, and anode-cathode distance is essential for achieving the desired silver layer thickness and quality. Adjustments to these parameters can help manage the rate of deposition and the properties of the silver layer, such as its brightness and adherence. This controlled process yields a durable, conductive, and attractive silver layer, valued in electronics and decorative industrial applications.
Electroplating processes can have environmental impacts from using hazardous chemicals, which leads to air and water pollution if mismanaged. Common pollutants from electroplating operations include heavy metals such as cadmium and lead, as well as cyanides, all known for their toxicity. However, responsible plating organizations can conduct electroplating safely when they manage it adequately. Reputable plating companies use strict protocols and advanced systems to reduce environmental contamination and ensure safe chemical handling.
In the United States, various EPA guidelines regulate electroplating facilities to minimize environmental impact and ensure worker safety. These regulations include the National Emission Standards for Hazardous Air Pollutants (NESHAP) for plating and polishing operations, which mandate controls on air emissions and prescribe specific management practices to reduce exposure to hazardous air pollutants.
The EPA’s Electroplating Effluent Guidelines also play a critical role, setting standards for wastewater discharges to protect water quality. These guidelines are part of the broader framework under the Clean Water Act, aiming to reduce direct and indirect pollutant discharges into water bodies.
Compliance with these regulations requires meticulous recordkeeping and reporting of emissions, waste management practices, and any incidences of non-compliance. Facilities must maintain detailed records of all operations, emissions, and waste treatment processes. They must also comply with regular reporting requirements to demonstrate adherence to environmental standards.
Despite its complexities, advancements in technology and stricter regulatory frameworks are paving the way for greener and safer electroplating practices. Adopting non-toxic plating alternatives and improved waste management systems reduces the environmental footprint of this essential industrial process. These improvements will enhance electroplating sustainability, ensuring it remains crucial in manufacturing and aligns with global environmental standards.
Armoloy provides both electrolytic and electroless surface solutions that tackle metal challenges while exceeding strict industry standards and regulations. Chat with an applications engineer today for more information on our start-to-finish surface solutions for your next project.
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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.
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.
White PaperRead on 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) end-use strength and durability.
Download the White PaperElectroplating 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).
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.
If you are looking for more details, kindly visit Industrial electroplating machine.
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.
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:
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.
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.
WebinarIn this webinar, learn how electroplating expands the material palette of SLA 3D printing to achieve high-stiffness, wear resistant end-use parts.
Watch the Webinar NowElectroplating 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.
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.
Numerous industries use electroplating to make everything from engagement rings to electrical antennas. Here are some common examples:
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).
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.
Electroplating is very common in the automotive industry. Many major automotive companies use electroplating to create chrome bumpers and other metal parts.
Electroplating can also be used to create custom parts for concept vehicles as well. For example, VW teamed up with Autodesk to create hubcaps for their “Type 20” concept vehicle. The prototype hubcaps were 3D-printed and then electroplated.
Restoration companies and vehicle customization businesses also use electroplating to apply nickel, chrome, and other finishes to various car and motorcycle parts.
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.
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.
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.
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.
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