Plastic Chrome Plating

Cleaning

Removes grease, fingerprints and impurities which would otherwise badly affect the adhesion.

Surface preparation

The surface conditioner, which is prepared from special acids, transforms the

structure of the plastic surface in such a way that a strong adhesion can be obtained

between it and the chemical nickel/copper. This conditioning is an important step in

the chemical treatment of plastic for electroplating. Defects related to poor adhesion are mostly caused by surface conditioning.

Surface activation

The surface activator contains palladium, which attaches itself to the surface of

the plastic. The component is then immersed in an accelerator to remove a

protective film from the surface of the palladium.

Electroless nickel deposition

The activated component is then immersed in an electroless nickel solution, which

deposits a thin layer of metal over the entire plastic substrate. This metal

layer then becomes the conductor for subsequent electroplating.

Electrolytic copper plating

Electrolytic plating, nickel and chrome

Proper drying of resin

ABS must be pre-dried for 2–3 hrs at 80–85 °C prior to moulding

Proper fill speeds

Small components up to 90 g: 5–7 secs

Large components over 90 g: up to 25 secs

Proper melt temperature: 245–270 °C

Too-cold melt temperature causes internal stress, leading to uneven etch and thermal cycling test failure

Too-hot melt temperature may cause the material to degrade and give poor adhesion

Proper mould temperature: 65–80 °C

Too-cold mould will cause the plastic to flake. Material which hits the mould wall hardens and the hot material under it flows, creating a surface skin effect that may cause delamination

Proper cooling time: up to 30 secs

Longer cooling times increase risk of internal stresses

Highly polished mould

Poor mould surfaces can cause defects in the moulded part

Material moisture content <0.02%

Design gates/in-moulds for tension free-mould flow

Plateable ABS/PC

Possibility to rack

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

Additionally, plating on plastic can be an effective means of protecting a substrate against the forces of corrosion and make it more resistant to damage from chemicals used in the manufacturing process. In some instances, plating on plastic can increase the strength and wear resistance of the substrate.

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

Alongside appearance, plating onto plastic offers several other benefits for the item's physical characteristics:

Corrosion and chemical resistance: Plating on plastic can be an effective means of protecting a substrate against the forces of corrosion and make it more resistant to damage from chemicals used in the manufacturing process.

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

Increased structural strength: Electroplating can improve a part's overall structural strength for greater durability. This added strength is one of the top benefits of electroplating onto plastic. If strength is your goal, nickel plating can be a good choice since nickel can resist corrosion and improve the lifespan of products.

Stable and low contact resistance: In addition to corrosion resistance, plating can also reduce contact resistance, so you can increase the part's resistance to wear, chemicals and corrosion.

RFI and EMI protection: Electronic devices release electromagnetic interference (EMI) and radio frequency interference (RFI), which contribute to signal interruptions and equipment malfunctions. Plating adds a layer of protection to block these harmful EMI and RFI waves.

Plating onto plastic is a great way to add durability in a range of different environments. It offers protection for everyday wear from contact, as well as more robust defenses against chemicals and interference. Meanwhile, structural integrity is a significant advantage in many applications, and adding conductivity to plastic is a great way to increase the design flexibility of a part while maintaining the cost-effective nature of plastic construction.

There are a variety of conditions during the molding, handling, and plating of plastic components which could potentially lead to imperfections in the finished product. Understanding the causes of some of the common imperfections can aid in identifying root causes of these imperfections and effective implementing corrective actions throughout the supply chain.

Splay

Splay is a cluster of breaks, mars, or marks, visible on a plated part. Though it is only visible once plated, it is caused my molding issues; trapped moisture in the plastic can come to the surface during the plating process, causing splay.

Flash

Flash is a protrusion of plastic on a part edge. Flash on a molded component often goes unnoticed until after the component has been plated, because plating builds up on the protrusion. This plate buildup can make the edge of the part sharp, and can also interfere with fit and appearance. This imperfection is caused during molding by excess plastic or the component not breaking from the mold cleanly.

Blisters

Blisters, like the skin condition, are air pockets beneath the skin—in this context, between the plastic and the metal deposit. Like splay, blisters can be caused by moisture trapped within the molded component; however, blisters can also be caused during the plating process, between layers of metal deposit. To determine the cause of a blister, cut and peel the blister back. If it originates at the plastic, and the underside of the blister has plastic that has separated from the component, the blister resulted from trapped moisture in molding.

Scratches and Dents

Scratches and dents can be caused during molding or handling (of the raw or plated part). While the plater will generally perform an incoming audit on molded components for plating, some scratches or dents in the plastic may not be immediately obvious, or raw parts may be scratched during handling. Scratches and dents can also occur during handling post-plate; it may be possible tell by the depth of the scratch or dent and plating deposit on the area whether the imperfection is superficial or in the base material.

Dry Down

Dry down is marred plating and it occurs during the plating process when the part becomes too dry between metal deposits. This can be avoided by careful process control of the plating operation.

Warp

Warp is the dimensional distortion of a component and can occur at a few stages of the production process. Molding errors could cause warp, and warp could also be caused by exposure to extreme temperatures, racking the part incorrectly, or mishandling the part.

Skip plate

Skip plate is the absence of plating on a surface—the base material is exposed. It can be caused by contaminants on the surface of the part, which prevent the plating from being deposited on the surface of the part. Ensuring that raw parts are handled properly and kept free of surface contaminants can reduce the occurrence of skip plate.

Acrylonitrile-Butadiene-Styrene (ABS)

Acrylonitrile butadiene styrene (ABS) is a thermoplastic polymer widely regarded as the first plastic material used for electroplating. The process was specifically developed for the automotive industry in the 1960s and is still practiced today.

Yes – you can get your plastic parts treated in chrome-like (metallic) colours. Our colour finishing incorporates electroplating, so it is more durable and robust than spray finishing alone. So if you’d prefer your plastic dashboard to be finished in a colour but still have the depth and lustre of a chrome finish – you can!

Chrome Plastic Plating Process

Step 1 – Etching. We immerse the part into a tank that contains a mixture of concentrated sulfuric and chromic acids.

Step 2 – Neutralization.

Step 3 – Catalyzing and Accelerating.

Step 4 – Electro-less Plating.

Step 5 – Electro Plating.

Step 6 – Quality Inspection.

Real chrome, you most definitely can polish and wet sand to restore the finish. Fake chrome (plastic film or chrome plated) can be polished, but in the lightest of fashion.

Like metal, plastic can also be chrome plated. For this method, you'll have to send off the plastic parts you want to add chrome to for plating. The plating company will coat your part in layers of nickel and copper before it then applies the chrome.

The process of deposition of thin metal foils on ABS substrates involves many steps such as surface activation, etching, catalyzing, electroless deposition, electro plating and surface cleaning...