Metallization

Detailed specifications are established to guide both mechanical metal wrap and direct metallization processes. For metal wraps, CAD modeling ensures the formed metal shell precisely fits the molded plastic core, accounting for tolerances and stress points. For electroplating or vacuum metallization, CAD helps simulate metal distribution over complex geometries, define target layer thickness, and determine decorative finishes like satin or mirror effects.

Since plastics are non-conductive, electroplating requires an initial conductive layer. This is achieved by immersing parts in baths containing stannous and palladium chloride, followed by electroless deposition of a thin nickel or copper layer that forms without electricity. This conductive layer allows the subsequent electroplating process to build up a durable metallic coating. Without it, achieving uniform electroplating on plastic would not be possible.

Following metal deposition, processes diverge to stabilize the newly applied layers. Electroplated parts are thoroughly rinsed in deionized water to remove chemical residues and then dried using heated air or centrifugal systems. Vacuum-metallized parts remain in the chamber as it slowly returns to atmospheric pressure, allowing them to cool without thermal shock. For metal wraps, care is taken during and after assembly to protect decorative surfaces from scratches or deformation.

Every metallized component undergoes rigorous quality checks to verify visual consistency, dimensional accuracy, and structural integrity. Inspections look for surface flaws such as streaks, dents, pinholes, or misalignments, while adhesion is tested using methods like cross-hatch or tape pull tests. Coating thickness is measured with specialized gauges, and environmental resistance tests are performed to ensure durability. Only after passing these evaluations are parts approved for final assembly, packaging, or integration into the finished product.