Metallized FinishesMetallized Finishes

PL ET 370PL ET 370Travis HunterTravis HunterJose PerezJose Perez

Josh SindlingerJosh Sindlinger

IntroductionIntroduction• Secondary ProcessesSecondary Processes• Cosmetic or Mechanical EnhancementCosmetic or Mechanical Enhancement• Excellent EFI & RFI ShieldingExcellent EFI & RFI Shielding• Three Basic ProcessesThree Basic Processes• Wide Range of Compatible MaterialsWide Range of Compatible Materials

Presentation OutlinePresentation Outline

• ApplicationsApplications

• ProcessesProcesses

• MaterialsMaterials

• EquipmentEquipment

ApplicationsApplications

• Cosmetic Enhancement – Faucet HandlesCosmetic Enhancement – Faucet Handles• Lighting – Reflector HousingsLighting – Reflector Housings• FilmsFilms

– Protect Light Sensitive FoodsProtect Light Sensitive Foods& Products& Products

• Corrosion ResistanceCorrosion Resistance

ApplicationsApplications• EMI/RFI Shielding - ElectronicsEMI/RFI Shielding - Electronics• Reflective Coatings - CDsReflective Coatings - CDs• Adding Electrical ConductivityAdding Electrical Conductivity

– Circuit BoardsCircuit Boards

ProcessesProcesses

• Vacuum MetallizingVacuum Metallizing

• PlatingPlating

• Spray/Aerosol PaintingSpray/Aerosol Painting

Vacuum MetallizingVacuum Metallizing• Vaporized Metal onto Plastic SubstrateVaporized Metal onto Plastic Substrate

• Thin CoatingsThin Coatings

• Consistent ThicknessConsistent Thickness

• Most Popular Method AvailableMost Popular Method Available

Vacuum MetallizingVacuum MetallizingPROCESS/EQUIPMENTPROCESS/EQUIPMENT

• Part is CleanedPart is Cleaned

• Surface PrepSurface Prep

• Part is PlatedPart is Plated

• Excess Metal is Spun OffExcess Metal is Spun Off

– (optional)(optional)

• Sealant (if necessary)Sealant (if necessary)

Vacuum MetallizingVacuum Metallizing ADV/DISASADVANTAGESADV/DISASADVANTAGES

• AdvantagesAdvantages– High Quality FinishHigh Quality Finish– Thin CoatingThin Coating– No Environmental ConcernsNo Environmental Concerns

• DisadvantagesDisadvantages– Poor Thermal ProtectionPoor Thermal Protection– Line of SightLine of Sight

PlatingPlating• Electrolytic (Chrome Plating)Electrolytic (Chrome Plating)

– Thick Metal Base CoatThick Metal Base Coat

– Cosmetic Top CoatCosmetic Top Coat

– Electrical Current Builds LayersElectrical Current Builds Layers

• ElectrolessElectroless– Chemical Deposition of MetalChemical Deposition of Metal

– Circuit Boards TracesCircuit Boards Traces

Electrolytic PlatingElectrolytic Plating PROCESS/EQUIPMENT PROCESS/EQUIPMENT

• PPart Ceaning/Prepart Ceaning/Prep

• Nickel PlatingNickel Plating

• Aqueous BathAqueous Bath

• Copper PlatingCopper Plating

• Nickel PlatingNickel Plating

• Chrome Plating Chrome Plating

(if necessary)(if necessary)

Electroless PlatingElectroless Plating PROCESS/EQUIPMENT PROCESS/EQUIPMENT

• Part Cleaned & EtchedPart Cleaned & Etched

• Catalyst Released onto Part SurfaceCatalyst Released onto Part Surface

• Electroless Copper PlatingElectroless Copper Plating

• Electroless Nickel PlatingElectroless Nickel Plating

• Sealant Sealant (if necessary)(if necessary)

PlatingPlatingADV/DISASADVANTAGESADV/DISASADVANTAGES

• AdvantagesAdvantages– High Quality finishHigh Quality finish– Covers Irregular SurfacesCovers Irregular Surfaces– Wear ResistantWear Resistant

• DisadvantagesDisadvantages– Caustic ChemicalsCaustic Chemicals– Very Slow ProcessVery Slow Process

Spray/Aerosol PaintingSpray/Aerosol Painting• Parts Coated with Conductive PaintParts Coated with Conductive Paint

• Little Specialty Equipment NeededLittle Specialty Equipment Needed

• Four MethodsFour Methods– Air AtomizationAir Atomization

– AirlessAirless

– Electrostatic Spray PaintingElectrostatic Spray Painting

– DippingDipping

Spray/Aerosol PaintingSpray/Aerosol Painting PROCESS/EQUIPMENT PROCESS/EQUIPMENT

• Part is Cleaned & Prepped (if necessary)Part is Cleaned & Prepped (if necessary)

• Surface is Coated with PaintSurface is Coated with Paint

• Coating Baked or Air DriedCoating Baked or Air Dried

• Well Ventilated Booth NecessaryWell Ventilated Booth Necessary

Spray/Aerosol PaintingSpray/Aerosol Painting ADV/DISASADVANTAGESADV/DISASADVANTAGES

• AdvantagesAdvantages– Good to Excellent FinishGood to Excellent Finish– Low CostLow Cost

• DisadvantagesDisadvantages– Poorer AdhesionPoorer Adhesion– Uneven ThicknessUneven Thickness– Environmental & Health ConcernsEnvironmental & Health Concerns– Waste/OversprayWaste/Overspray

Other ProcessesOther Processes

• Hot Film StampingHot Film Stamping

• Thermal Spray CoatingThermal Spray Coating

• Selective Electroless PlatingSelective Electroless Plating

• Direct MetallizationDirect Metallization

• Metallic Conformal CoatingMetallic Conformal Coating

• Physical Vapor DepositionPhysical Vapor Deposition

MaterialsMaterialsAmorphous ThermoplasticsAmorphous Thermoplastics

• Higher surface energyHigher surface energy

– ABS (Most Common)ABS (Most Common)

– HIPS, PMMA, and PC Also CommonHIPS, PMMA, and PC Also Common

MaterialsMaterialsSemi-Crystalline Thermoplastics Semi-Crystalline Thermoplastics

and Thermosetsand Thermosets• Low Surface Energy and Good Low Surface Energy and Good

Chemical ResistanceChemical Resistance– PolypropylenePolypropylene– AcetalAcetal– NylonNylon– Most Epoxies and PolyestersMost Epoxies and Polyesters

Processing/Design Processing/Design RequirementsRequirements

• Reduce Sharp CornersReduce Sharp Corners

• Low Residual StressesLow Residual Stresses

– Slow Fill TimesSlow Fill Times

– No Gating Onto Area to be MetallizedNo Gating Onto Area to be Metallized

• Avoid Weld LinesAvoid Weld Lines

• Avoid Release AgentsAvoid Release Agents

Additional RequirementsAdditional Requirements

• Surface Cleaning & PrepSurface Cleaning & Prep

• Need High Surface EnergyNeed High Surface Energy

• Sealant May Be UsedSealant May Be Used

• Processes Sensitive to Heat & MoistureProcesses Sensitive to Heat & Moisture