Things Engineers Should Know About Electroplating

Electroplating has become an important technology in many industries, as metal coating can improve performance and durability of parts. Electroplating can be applied to a wide variety of materials to provide numerous benefits, such as better conductivity, resistance to wear and durability in extreme temperatures. Electroplating of parts can produce a better final product with improved longevity. Before diving into electroplating for your next engineering project, it is helpful to have a base knowledge of how electroplating works, the various types available and the benefits it has.

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What Is Electroplating?

Electroplating is a type of metal finishing where a metal coating is applied to the surface of a part or component using an electric current. The part or component, also called a substrate, is submerged in an electroplating bath and connected to a negatively charged electrode, also called a cathode. The plating metal is connected to the positively charged electrode, also known as an anode. When the electrical current is applied to the circuit, the ions in the coating are oxidized into the bath and deposited onto the substrate. This process is also called electrodeposition, as metal ions are deposited onto the substrate in a thin layer or coating.

Many components of the electroplating process must be carefully calculated to achieve the best results. Before submerging the substrate, it must be cleaned and processed in chemical baths that help to activate the surface of the parts. This ensures a strong bond will be created between the substrate and coating to produce good adhesion. The temperature and chemical composition of the electroplating bath must also be monitored during the process. The electrical current must be applied at the proper voltage and for the adequate duration of time.

Electroplating has applications in a wide variety of industries, including electronics, automotive, aerospace, medical, optics and oil and gas. While specific uses vary by sector, electroplating is generally used to improve the performance or appearance of a product or to protect it from wear. In the engineering field, electroplating has many benefits, including preventing corrosion, increasing conductivity and improving the durability of parts.

What Engineers Should Consider Before Electroplating

With many types and methods of electroplating available, you must determine the right process for the size and volume of parts you have. To achieve the best results with your electroplating, engineers should first consider a few important factors:

• Intended Use of Parts: Your end performance goals will determine the right type of electroplating for your parts, as different types of metal plating provide various benefits. You should also consider the environment in which your finished product will be used. If your parts are exposed to excessive wear or corrosive environments, these factors should also influence the type of coating you choose.

• Tolerances: Because electroplating involves depositing a layer of metal on the surface of a part, be sure to account for this change in dimension by providing tolerances. Consider the complete assembly to determine the appropriate plating thickness.

• Geometry: The shape and configuration of the parts will impact how evenly the metal coating can be distributed. Different areas will have higher or lower current density, which causes thicker or thinner plating. Corners and edges will have higher current density and thus have higher plating thickness than recesses and cavities. Consider this when designing your parts and planning for final plating thickness.

• Drainage Holes: Deep cavities or holes in parts can cause air to become trapped when the element is submerged into the electroplating solution. This can prevent the coating from adhering properly or create areas of thinner plating. Holes can also catch chemicals or solution during the cleaning process, which has the same adverse effect on the final result. To prevent the trapping of air or solution, drainage holes or weep holes can be added to the design of a part to allow air to escape, so electroplating solution can enter and coating can be appropriately distributed.

• Quality of Base Material: While metal coating can improve the appearance of parts or products, it is not intended to cover scratches or marks on the substrate. Mechanical finishing should be completed before electroplating. Additionally, if a part has an incomplete weld, this may lead to chemicals or air becoming trapped. Make sure parts are adequately welded or remove weld flux before electroplating your parts.

The last and most crucial component to consider is the best method of electroplating for your product. Depending on the size, quantity and durability of your parts, different means of electroplating will be more effective. Generally, there are two primary processes of electroplating

Batch plating is useful for smaller, durable parts that are not likely to be damaged by coming in contact with other parts. A common form of batch plating is barrel plating, in which parts are loaded into a cylinder filled with a solution that rotates to coat the parts. This method produces an even and consistent coating and is typically the most affordable and efficient option. Barrel electroplating is also valid for coating a variety of different sized and shaped parts at the same time. One risk of barrel plating is that very thin and smooth parts are prone to stick together during the process, preventing even coating. This can be mediated by adding ridges or dimples to small parts whenever possible.

For larger, more fragile or complex parts, rack plating is more effective. In this method, parts are placed on a rack or other fixture and lowered into the solution. Each component must be in contact with a pin or wire that contacts the electrical power source directly. Areas where the fixture comes in contact with the part will not be coated, so electroplating companies aim to design racks that allow for minimum contact while holding the piece in place. While more expensive, rack plating is often the best option for parts that could be damaged during rotation in a barrel.

A third option for applying metal plating is electroless plating. This option works best if you do not want to submerge your parts in liquid and submit them to electricity. In electroless plating, the metal coating is adhered using a chemical reaction instead of an electric current.

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When designing parts, consider how the electroplating process will alter their dimensions and characteristics. Be aware that the original shape, size and quality of your parts also influences the final results of electroplating. When products are appropriately designed and prepared for electroplating, a consistent and effective metal coating can be applied.

Benefits of Electroplating

As an engineer, you know high-quality parts are essential to building a high-quality machine. Adding metal plating to your parts can improve their durability and performance or alter their characteristics by increasing conductivity or reducing friction. Electroplating can provide numerous benefits that have made it invaluable in engineering and many other industries. Below are just a few of the benefits of adding a metal coating to your parts through electroplating:

• Resistance to Corrosion: Electroplating can protect against corrosion and other atmospheric conditions and better withstand more extreme conditions. This allows parts with metal coating to last longer, so you can replace them less often.

• Resistance to Wear and Abrasions: Metal coating adds a protective layer that improves resistance to abrasions and wear. Plated parts are less likely to be damaged when dropped, and brittle parts become more durable after electroplating. The metal coating will also dissolve or disintegrate before the base material, which allows the substrate it to retain its quality longer.

• Increased Thickness: For manufacturing processes that require extreme thickness, metal coating can be used. Palladium is a popular choice for increasing the thickness of parts. Added thickness also leads to more durability and increased lifespan.

• Increased Solderability: Adding metal plating to a substrate can make it easier to solder, which is beneficial when a metal with low solderability is desired for a specific project.

• Resistance to Temperature: Electroplating with metals such as zinc-nickel or gold can protect the substrate against extremely high temperatures that machine or engine parts can be subjected to. This prevents heat damage and increases the longevity of parts.

• Better Electrical Conductivity: Electroplating with highly conductive metals, such as silver, can increase the conductivity of connectors or wires. This is an important application in the electronics industry or for other electrical components.

• Reduced Friction: Friction in electrical connectors and other parts can cause excess heat and wear. Electroplating with metals such as nickel can reduce friction to prevent wear and tear on parts.

• Better Adhesion: Some metal coatings, such as copper, provide an undercoating that allows for better adhesion of paint or additional levels of coating. This, in turn, leads to improved surface uniformity and finish appearance of the final coating.

• Better Torque Tolerance: Electroplating can strengthen a substrate, so it becomes more tolerant to torque without breaking or becoming damaged. This can be beneficial in machine parts that experience a lot of strain.

Types of Electroplating

Depending on your desired result and the characteristics that are most important for your project, there are a wide variety of metal coatings you can apply using electroplating. Specific coatings are also more compatible with particular base materials, so be sure to choose a coating that will adhere properly to your substrate. Below are some of the main types of electroplating, their primary uses and the benefits of choosing them for your electroplating:

• Copper: Copper is a flexible and highly conductive metal that often serves as a plating layer before a final metal layer is added, as well as for metallization of non-metallic parts. Copper is frequently used for electroplating for electronic parts, as well as in the aerospace and defense industries. Copper plating is effective for improving conductivity, adding thickness, protecting against corrosion and heat treatment stop-off.

• Gold: Because gold is a precious metal, it can be more costly than electroplating with other materials &#; however, there are many great reasons to choose gold for your electroplating. Gold is highly conductive, protects against high heat, prevents corrosion and is resistant to wear. For aesthetic applications, such as jewelry, gold provides a bright and attractive finish. Gold is often the best choice for electroplating of semiconductors, circuits and connectors.

• Nickel: Due to its wear resistance and resistance to corrosion, nickel is a popular metal for electroplating. Nickel plating increases product longevity and can be applied to steel as a substitute for more expensive stainless steel. Nickel can also be used to increase product thickness and reduce friction. The telecommunications and electronics industries often utilize nickel plating.

• Palladium: While palladium is a precious metal, it is more affordable than gold for electroplating. Palladium is also harder than gold, while still providing a bright and lustrous finish. Palladium also offers excellent protection from wear and corrosion, as well as being magnetic and solderable. Plating with palladium is often used during the manufacture of catalytic converters to absorb excess oxygen. Palladium is also popular in the electronics industry, as well as medical and dental product manufacturing.

• Silver: Silver is another precious metal that is popular for electroplating and very applicable in the electronics industry. Silver is highly conductive of both electricity and heat, resistant to corrosion and is stronger than gold. Silver electroplating is used in solar panel manufacturing, as well as the electronics and telecommunications industries.

• Tin: Tin is a cost-effective alternative to more expensive plating materials, while still providing corrosion resistance and easy solderability. Tin is primarily used in the electronics industry and the manufacturing of hardware products. However, tin is soft compared to other coating metals, and it&#;s also prone to producing small sharp protrusions called &#;tin whiskers.&#;

• Zinc: Zinc is another popular coating metal when affordability is the focus. Zinc is an excellent choice for improving adhesion, and it is also compatible with a wide variety of base metals. Zinc is also commonly a component in metal alloys used for electroplating, including zinc-nickel.

These are just a few of the options for different types of electroplating. Many alloys are also available that blend multiple metals or a metal and another substance. If you are not sure what the best coating is for your particular application, your electroplating company may be able to guide you toward the best metal finishing for your product.

Tips for Choosing an Electroplating Company

When choosing an electroplating company to work with, be sure to have in mind the type of coating you want to use and your desired electroplating method. Look for a company that can provide the right services for you and properly protect your parts from damage during the process. Here are a few other important factors to consider when selecting an electroplating company:

• Size of Parts: If applying metal coating to large parts, be sure your electroplating company has a feasible electroplating method and rack system that is large enough to accommodate them. Small parts can typically be coated using a barrel plating method, however, if you have fragile parts to coat, you should seek an electroplating company that can secure them effectively and safely for rack plating.

• Volume of Parts: Batch electroplating is often a more affordable option because a large number of parts can be coated in each batch. Seek an electroplating company that has the capabilities to accommodate the number of pieces you want to coat.

• Geometry of Parts: Electroplating on parts that are unusual or complex shapes may require a custom fixture to be designed for rack plating to avoid damaging the parts while still applying metal coating effectively. Wiring may also be used to connect parts effectively. Look for a company that can adjust to your specific needs.

• Desired Metal Coating: Verify that your electroplating company can provide the type of metal coating you desire for your project. You may also want to consider potential future projects, so you will not need to change electroplating companies if they cannot provide the correct metal coating that you need down the road.

• Preparation Capabilities: Many electroplating companies focus solely on electroplating, but neglect to provide excellent preparation and pre-treatment services. Cleaning and treatments before electroplating have a significant influence on how well the coating adheres and the overall quality of the final product. Seek an electroplating company that can properly clean and prepare your parts before electroplating.

• Project Budget: Before committing to an electroplating company, discuss the options available for your project to find the right solution that works with your budget.

Work With SPC for Your Electroplating Needs

Whether you are seeking to strengthen your parts or improve their performance, Sharretts Plating Company can provide the right electroplating type and methods to suit your project. Our expert team will work with you to determine the proper metal coating for your needs and budget. If your project involves large or unusually shaped parts, we can create a custom rack or wiring system to ensure your parts are plated effectively and safely.

Contact us today to learn more about electroplating with SPC or request a quote for your electroplating project.

There are several metal surface finishing types for prototyping and production. However, not all of them fit well into the workings of all products. Many surface finishes focus on improving the aesthetics of your product. Others tend to improve the product&#;s functionality better, while some do both. In this article, we will focus on metal plating finishes.

Many people confuse metal plating for metal coating, and this guide will help you tell the difference. A plated finish offers several benefits to the material, and there are various reasons for choosing to plate. Here, you will learn the various types of plating techniques and their effects on the metal surface. The tips you get here will also help you ensure improved finish quality.

What Are Metal Plating Finishes?

Let&#;s go back to the basics! What is metal plating? The plating process is a post-production process. It involves the coating or covering of the surface of a workpiece with a thin layer of metal.

The basic understanding of plating is to have a thin layer of one metal coating a substrate. Consequently, the aim is to improve the overall quality of the product. Some of the many benefits of metal plating finishes include:

• Improving corrosion resistance
• Hardening the material surface
• Improving paint adhesion
• Boosting solderability
• Improving wearability of part
• Reducing friction
• Altering conductivity and conductibility
• Improving heat resistance
• Providing shield against radiation

The uses of plating differ in precision machining because it can change the qualities and performance of materials.

Metal Plating Finishes: The Basic Principle

Still on the basics, let&#;s discuss the basic principle of the plating process. Plating comes with many steps and needs some considerable steps from pretreatment to post-treatment.

You need to know that there is a wide range of plating techniques, which we will cover in this guide. However, for this section, we shall focus on the basic procedure for the most popular plating process. That is electroplating.

Step #1: Metal Plating Finish Pretreatment

The first step to plating is to prepare the substrate. So, you need first to pretreat it to prepare the substrate for metal plating. This is an important process aimed at removing all harmful contaminants, greases, and oils.

These materials may hinder the plating process and will prevent satisfactory and uniform disposition. Depending on your preferred plating or base materials, this step may include several sub-steps. The sub-steps may range from cleaning to rising and other pretreatments.

Once proper finishing of the base material is complete (in cases where there are welds, burrs, and other surface inconsistencies), then you can now clean the substrate. There are several techniques involved in cleaning the substrate&#;s surface. It can be by running it through basic or acidic chemicals.

The chemical cleaner you use will depend on the kind of material you work with. For example,

• Alkaline cleaners: These are products containing chemicals like carbonates, phosphates, borax, etc. They work better while doing a plated finish cleaning on steel, copper, nickel, stainless steel, lead, and titanium.
• Acidic cleaners: They include hydrochloric acid, sulfuric acid, and several others. They are recommended for cleaning metals like magnesium.
• Inhibited alkaline cleaners: These cleaners help to overcome the problem of negative caustic reactions on zinc, aluminum, brass, bronze, and tin.

Also, you should know that some base materials require only one cleaning. Others may need two or multiple runs of cleaning. After each treatment, thoroughly rinsing the substrate in distilled water will help remove all chemical cleaners.

Step #2: Determine Effectiveness of the Cleaning Process

The requirements of your parts will determine the plating process. At the same time, it determines how clean your substrates should be. For example, some cad plating techniques require only removing dirt and bulk soil.

Link to Boraychem

On the other hand, others require completely removing oil and grease. How then do you check for your substrate&#;s cleanliness?

• Water break test. Once you completely rise the final product, hold the base material and notice how water pours off its body. If the pouring off is in one large sheet, then there is no oily residue. However, oil and grease may still remain if there&#;s beading of water.
• Wipe test. Here, wipe the substrate&#;s surface using a clean cloth. If you notice dirt or residue on the cloth, you may need to clean the substrate further.
• Reflectivity. The reflectivity of some products helps to gauge their cleanliness easily.

Step #3: Set Up the Plating Station

Once you achieve the adequate cleanliness level, you can now begin the process. It states with the assembly of the station. First, you need a rectifier or other source of direct current. Remember, our focus is on electroplating. Other materials include a tank (or barrel), a cathode, an anode, and a proper plating solution.

The anode includes solid pieces of metal you want to deposit, while the cathode is your substrate. Most manufacturers use water as the plating solution. It is fairly easy to set up a plating station. First, Attach the negative lead of your rectifier to your substrate. Then, put the positive lead right in the plating solution.

Step #4: The Plating Process

As soon as the electrical current turns on, the deposition process begins. If you want a thicker plated finish on your product, then you need to expose them longer to the current. You need to consider some variables when for different metals before plating. These variables include voltage levels, temperatures, immersion times, etc.

In some cases, there may be already prepared electroplating solutions. In that case, you will have the settings for each factor printed on the container. Generally, higher voltages tend to deliver more adequate results. That way, there won&#;t be bubbles in the solution.

Step #5: The Post-Treatment Process

Once you achieve proper deposition on your metal surface, it is often necessary to conduct post-treatment cleaning. This is important to inhibit tarnishing. Several cleaners are available in the market. The electrolytic polishing after electroplating is also an effective technique. This works to improve corrosion resistance.

Step #6: Waste Disposal

There is often the creation of heavy metals after many plating processes. These metals can be hazardous due to their high toxicity levels. So, it becomes important to quickly and effectively. Pretreating the plating wastewater prior to its disposal is an effective way of doing this.

Standard Industrial Plating Finishes

The following are the standard plating finishes available at the industrial level

Zinc Plating

Zinc is one of the most inexpensive materials that provide galvanized coatings on metal substrates. Application of zinc is by way of molten bath dipping and spraying. The substate is the cathode, while metallic zinc is the anode in a soluble zinc salt electrolytic bath. Zinc plating process produces a very ductile coating. For this metal plating finish, it is easy to control the thickness and uniformity.

Chrome Plating

This plating process usually involves using chromic acid and trivalent chromium baths to produce an overlay on the metal parts. The main aim of chrome plating is to improve the aesthetics of the material. However, chromium metal plating finishes also increase the corrosion resistance and hardness of the material. Those chrome-plated parts are suitable for industrial applications. Sometimes, it also helps to restore tolerances on worn parts.

Copper Plating

When your applications call for cost-efficiency and high conductivity, copper plating is the way to go. This procedure usually serves as the leading coating pretreatment for the following plated finish. It is one of the most popular metal plating finishes for electronic components like circuit boards. It is a popular choice because of its low material cost and high plating efficiency.

Nickel Plating

Another popular plating metal is Nickel because of its usefulness in electroless plating. Nickel plating helps to coat household products like cutleries, shower fixtures, doorknobs, etc., to enhance aesthetics and wear resistance. This plating technique is best for aluminum and copper. However, it works on several other metals. It also serves and the underlying plating for chromium.

Gold Plating

Gold is popular for its high electrical conductivity and resistance to oxidation. A simple way to impart these important properties on silver and copper metals is by gold plating. Its application is extensive in improving conductivity in electronic parts like electrical connectors. 

Silver Plating

Similar to gold plating, silver plating also improves the aesthetic appeal of the material involved. Electrical conductivity also comes to play when it comes to silver plating. Many manufacturers choose silver plating for its cost-effectiveness as it is cheaper than gold. It also plates parts made from copper more adequately.

Different Metal Plating Techniques

There are many ways to impart metal plating finishes on metal parts. Here, we will examine the various types and their effects on the material.

Electroplating Metal Plating Finishes

As mentioned earlier, electroplating is one of the commonest methods of metal plating. This method uses an electrical current in a chemical solution to dissolve ions (charged metal particles).

In the process, the charged (positive) metal ions get attracted to the part in question. The part, in this case, is the side with the negative charge on the circuit. When you place the part in the chemical solution, the dissolved metal particles rise to the material&#;s surface.

The end result is a smooth, rapid, and even coating on the plated material. This effectively offers protection and a decorative look to the metal part. Electroplating also improves the physical, chemical, and mechanical properties of the part, affecting its behavior during machining.

Electroless (Autocatalytic) Metal Plating Finishes

As the name implies, electroless plating does not use any external electric current. Instead, it involves the induction of metal atom reduction through a chemical reaction. That is, the solution of metal particles converts to a metal solid when you mix it with a reducing agent.

The result of electroless plating is the solid plating metal overlaying the material. Electroless plating confers a fine plated finish on a wide variety of materials. This type of plating is also more cost-effective because there is no external electricity or plating baths required.

However, it is a slower process. It also can&#;t make thicker plates, and you may find it harder to control than electroplating. However, it proves to be an effective plating method for nickel plating. This metal touch plating offers protection advantages, alters the solderability and conductivity of the material.

Immersion Metal Plating Finishes

Immersion plating involves the dipping of metal into a solution containing metal ions of a noble metal. The ions of the noble metal are usually more stable. Therefore, a natural &#;pull&#; occurs to displace the metal ions from the initial metal to give a thin layer of the noble metal ions.

Immersion plating is quite slower than the initially discussed plating processes. It also only comes into the discussion when we mention noble metals like gold, silver, or platinum. The result of immersion plating is thin plating coverage.

Pros and Cons of Metal Plating Finishes

Plating is an effective post-processing process that offers several benefits. However, it comes with its downsides. Here, we will examine the advantages and otherwise of metal plating.

Pros

• Can plate a wide range of materials
• It has a wide range of specific and architectural finishes
• It is a cost-effective finishing technique
• Offers protection against wear and corrosion
• Provides increased hardness and strength to the material
• Increase the decorative appeal of the material

Cons

• Subject to chipping and cracking in some wearing environments
• It can be quite lengthy
• It may be marked by machining defects if not handles carefully

Applications of Metal Plating Finishes

Metal plating finishes offer several different advantages in multiple industries. Their ability to offer parts with improved strength and hardness makes them useful in the automotive and aerospace industries.

Improving conductivity and corrosion resistance makes them useful in the medical industry and making tools and optics. Some of the common applications include:

• Chrome plating for car parts, bath taps, wheel rims, etc.
• Zinc plating is useful for iron parts in automobiles and bridges.
• Electroplating tin onto iron makes good food storage parts like tin cans.
• Silver or gold plating is valuable in the jewelry industry.

RapidDirect: Your Metal Finishing Solutions Experts

As you begin to evaluate metal plating finishes for your applications, you should search for experience and expertise. The best company that offers a perfect mix of both is RapidDirect. RapidDirect has long years of experience in offering cost-effective surface finish solutions for a wide variety of industries.

We offer an extensive array of materials and finishes, including metal plating. Our team of experts works with you to create a custom metal finishing procedure. This way, you can be sure of high-quality services, reduction in operating costs, and overall satisfaction. Upload your design file today, and let&#;s get to work!

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Considerations for Metal Plating Finishes

Materials with a plated finish offer many benefits, ranging from aesthetics to improved functionality.

However, you need to understand some factors to help you reap the benefits of this process. Here are some of the factors you must consider before beginning the plating process.

Pre-plate material conditions

Before plating any material, such material must be in a plating-ready state. For example, a substrate with oil buildups, oxides, heat treatment scales, and other residues may have the plated deposit failing to adhere to its surface. Therefore, you must remove these buildups using pretreatment methods. These methods include chemical descalers, acid pickles, deoxidizers, alkaline presoaks, vapor blasting, etc.

Thickness tolerance

Excessive or insufficient coating thickness is likely to cause plating problems. The desired reality is to determine the adequate range of desired maximum and minimum thickness. Keep the following in mind to make the range specific and realistic in your metal finishing request.

• Electroplating results in even coatings. In this case, tight thickness tolerance will not be an issue.
• Electrolytic plating causes settling of finishes on some areas more than others. For instance, plating deposits tend to become thinner within ¾ inches of a recessed area or a corner. So, tight range tolerance is not advisable for flat and simple shapes.
• Specify the surface areas on a product that needs to remain within a tight plating thickness. It is important to consider corners, recesses, and other geometric factors.
• Establishing checkpoints to determine plating tolerance requirements is also important. Be sure to have such checkpoints on surfaces where it makes sense.

Surface roughness

You must also consider the texture of the product&#;s surface prior to plating. The surface roughness chart is an outstanding guide to help with this. Handing over products with smoother surfaces will more likely give a better result after plating. However, you should note that the exact results depend on the metal used in plating due to different leveling properties.

Hardness or strength specifications

Most metal plating finishes offer increased hardness and strength to the surface of products. Therefore, it is essential to note the current strength and hardness properties of the component. Then, your chosen plated finish should work towards meeting the specifications as set out in the initial design.

Thread inclusion

It will be best to consider other aspects of thickness for products that include any machining thread. Plating parts like screws, hydraulic fittings, etc., are often about four times thicker than flat surfaces. So, you must factor the buildup into your choice of plating process. This will ensure that the threaded parts can meet important specifications and fit together.

Metal Plating Finishes FAQs

Electroplating is the commonest plating process. This method involves dissolving positively charged metal particles using an electrical current in a chemical solution. It works by a theory of hydrolysis to deposit one metal over another.

The key difference between these two metal finishing methods is that you can carry out coating on both non-conductive and conductive surfaces. However, you can only carry out a plating process on conductive surfaces.

Electroplating is a versatile finishing technique that offers advantages in several industries&#;for example, zinc electroplating help to confer a plated finish on iron parts in automobiles. Also, chrome plating is suitable for car parts, bath taps, etc.

Conclusion

Plating processes should be simple and effective. After adding plated finishes to your material, you can be sure of improved aesthetics and functionality. Plating also improves the chemical and physical properties of products. Therefore, it is vital to work with an experienced plating company. Contact RapidDirect today, and let&#;s make your experience a seamless one.

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