MacuPlex - MacDermid Industrial Solutions

MacuPlex
Plating On Plastics
SM
MacuPlex
Plating on Plastics
What is Plating on Plastics?
“Plating on plastics” is a term used to describe the decorative
or functional application of metal onto plastic substrates using
the process of electro-deposition. The coatings provide both
technical and aesthetic benefits and can be applied to meet
many different application criteria. For example, highly visible
and corrosion resistant exterior automotive components are often
plated plastics, providing a lower weight option compared to traditional metal
components. Plating on plastics is ideal for sanitary fittings that require durable and
wear resistant coatings to resist the humid bathroom environment. Electronic devices often
benefit from EMI-RFI shielding of sensitive electronic components for which plating on plastics
is an ideal solution.
Why Plate Plastics?
Wherever plastics are used to decorate items, electroplating can be used to enhance cosmetic appeal and add other
valuable functional improvements. Plating on plastics has the unique ability to offer the durability and Lustre of metals
like nickel and chrome to low weight, durable plastic substrates.
Plating on plastics provides product differentiation for consumer goods like cars, consumer electronics devices, white
goods and fashion/cosmetic items. Typically, the automotive industry uses plating on plastics extensively for decorative
trim because it offers weight saving and enhanced corrosion performance compared to solid metal equivalents.
Since the first steps were taken to plate on plastics commercially in the early sixties, the technology has developed into
a global application business. MacDermid, at the forefront of the original development, have played a leading part in
both technology improvements and expanding market applications. Today, plating on plastics is used in a wide variety
of applications, to meet both functional and decorative needs.
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Who uses Plated Plastics?
At a conservative estimate, plating on plastics appears on at least 50% of today’s cars. Likewise some 20-30% of
consumer electronics utlize plating on plastics in one form or another. White goods, plumbing/sanitary ware, fashion
items and many more applications make up the remainder of the market, with literally millions of items being
processed every day. The most obvious and visible applications include automotive grilles, door handles and chrome
trim along with badges and logos. Expansion of the market continues through the development of techniques for
plating new exotic plastics and copolymers. This has been a fundamental part of MacDermid’s research and
development strategy for two decades. Whereas twenty years ago, only two plastics were commonly plated, ABS and
Polypropylene, today we can plate over 50 plastics and copolymers, each offering different engineering and visual
properties to the designer and manufacturers.
What drives demand?
Environmental, Health & Safety: MacDermid’s product innovation strategy is to offer applicators new technology to
meet ever more stringent environmental drivers. Recent introductions such as TriMacIII, trivalent chrome plating
process, MacuPlex E 110, low chrome etchant and the MacuPlex M550 ammonia-free, ELV compliant, low nickel
electroless system are evidence of this.
Commodity and Energy Costs: Strong demand for metals such as palladium, nickel and copper particularly in
growing economies, has led to increased pressure on prices. MacDermid have introduced new systems such as
Mactivate 360 low palladium activator and CuMac Pulse acid copper system, both of which are proven to reduce metal
consumption. Many customers also benefit from the low nickel concentrations of our bright nickel and electroless
metallization systems.
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MacuPlex
Applications
Automotive
Automotive use for plated plastics is at the forefront of worldwide demand. Applications vary from simple internal
decorative trim to highly visible front grilles for the worlds most prestigious cars. Whatever the requirement, MacuPlex
systems have been trusted for the most demanding applications for over 20 years, making it the most widely used
system available today.
Not only does MacuPlex deliver consistently high performance and reliability, it offers applicators and OEM’s a choice of
systems that comply with specification and environmental needs.
Every new MacuPlex product is put through rigorous testing to ensure it meets or exceeds today’s most demanding
specifications. And as new plastic alloys are developed, MacDermid has an active research and development program
to help provide new techniques to allow these materials to be metallized.
Sanitary & Plumbing
Plastic sanitary and plumbing fittings are ideal candidates for chromium plating, taking advantage of both the
aesthetically pleasing and tough abrasion resistance of the hard metallic deposits. The finish also offers exceptional
ductility preventing premature failure when subjected to hot and cold thermal cycling conditions. High
humidity in many bathroom applications, means the coating must work constantly to resist corrosion
and the build up of lime scale and dirt.
MacDermid have developed MacuPlex pretreatment and plating systems to
meet the special requirements of the sanitary ware market. The processes
have been designed to economically deliver coatings of high quality and low
rejects on both ABS and Polypropylene. Whilst ABS is the most popular choice
of plastic due to its availability and moulding properties, Polypropylene’s low
water absorption makes it ideal for many applications that require resistance to
permanent water exposure.
New plating developments include CuMac Pulse (high distribution acid copper) and
MacuPlex M 550 (ammonia free, low concentration electroless nickel). Both offering improved
deposit functionality and environmental compliance.
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Consumer Electronics
Consumer electronics industries prefer products that are highly visual and aesthetically pleasing. Our MacuPlex systems
include a portfolio of products that have been specifically developed to deliver both the visual and physical properties
sought by the electronics industry.
MacuPlex provides the building blocks to transform simple plastic mouldings into eye catching packaging accessories.
These accessories come in many forms including:
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Electronics
Mobile Phones, MP3, CD & DVD Players, PDA’s & Laptops
Accessories processed with MacuPlex systems have the option to be finished in a wide range of final coatings such as
white metal, dark metal or yellow metal finishes and can be either bright or matt.
Considering the eventual waste disposal of used packaging items, the MacuPlex range includes processes that avoid
incorporation of heavy metals such as Lead and Cadmium, making ultimate disposal much less problematic.
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MacuPlex
White Goods
Plastic plated components are often used for cookers, fridges, washing machines and household electrical appliances
for both decorative and functional effect. The most popular finishes are chrome and satin chrome, which can both
provide an attractive, hard wearing and easy to clean metallic finish.
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Cookers
Knobs & Trim
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Washing Machines
Facias & Doors
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Fridges
Handles & Trim
Satin chrome is available in several levels of satin effect ranging from a smooth
semi bright to a matt “stainless steel”. The latter offers a cost effective method of
matching brushed stainless steel appliances with stainless steel effect knobs
and trim.
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Fashion & Cosmetics
A cost effective method of producing fashion items is to mould them from plastic and finish with metallic electroplated
coatings. This technique provides a low cost and flexible production process for relatively short runs of components like
buttons, badges, buckles and perfume caps. The low weight of the plated plastics facilitates its use for parts that may
otherwise be too heavy for the application. The MacuPlex system recognises the importance of the metallized plastic
fashion accessories mirroring the visual lustre and tactile properties of the “true metal” equivalents.
Our MacuPlex process can transform simple plastic mouldings into attractive, eye catching accessories desired by
today’s fashion houses and consumers.
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Caps
Perfume Bottles
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Compacts
Make-up and Powder
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Dispensers
Beverage and soft drinks containers
MacuPlex systems are capable of providing a diverse range of metallic finishes, ranging from bright white chrome to
gold and even dark (antique) metal finishes. Most are available in a range of gloss levels, from mirror through satin to
matt. Combinations of these effects ensures designers have an array of finishes that can be used to enhance the value
of fashion items and meet the highest aesthetic standards.
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MacuPlex
Process Technology
Pretreatment
MacuPlex Etch Additives: The chrome etch gives the plastic
substrate a greatly increased hydrophilic surface and forms the
microscopic texture needed to provide the bonding sites for the
deposited metal. MacuPlex etch additives help control the rate of etching
as well as reducing dragout of the etch solution. To further help reduce costs MacuPlex E110 can be used at low
concentrations of chromic acid.
MacuPlex Neutralizers: Used to neutralize residual chrome from the Etch stage, preventing harmful materials being
carried over to subsequent process stages. MacuPlex ECR has been designed to promote a more efficient and
ecologically friendly method of reducing hexavalent chromium.
MacuPlex Catalysts: MacDermid lead the field in developing palladium activator technology. Mactivate 360, our latest
development, can be used at ultra low operating concentrations while being flexible enough to work successfully on a
variety of different plastic blends.
MacuPlex Accelerators: Designed to condition the surface ready for electroless plating, MacuPlex accelerators are
available in both liquid and powder versions to suit every applicators needs.
MacuPlex Metallising systems: The final stage in the pretreatment cycle is the application of the electroless deposit.
For improved working environments and reduced effluent costs our ammonia-free MacuPlex M 550 electroless nickel is
already production proven in high volume facilities.
Electroplating
Copper: Copper electroplate provides a highly ductile layer that helps prevent thermal expansion cracking of the
overlying nickel. The CuMac range of bright, levelled acid copper systems have been developed to provide this
buffering function, as well as helping level out minor surface imperfections.
The latest addition to our copper range and particularly suitable for sanitary applications is CuMac Pulse. This
revolutionary acid copper, delivers even deposit distribution through the use of a specially developed pulse electrolyte.
This helps ensure excellent thermal cycling properties by depositing a uniform copper thickness even in deep recesses,
without over plating in the high current density areas. This is particularly useful for components that are subject to high
temperature variances during their service life.
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Nickel: Nickel provides both the deposit lustre and high corrosion resistance of the metallized coating. MacDermid’s
NiMac Quad nickel system meets the industries highest performance requirements. The system includes NiMac SF
semi-bright, sulphur free nickel deposits affording exceptional deposit ductility. NiMac Hi-S 8108 high sulphur provides
a high step potential for maximum corrosion performance. NiMac Clarion range of high levelling nickels are designed
to deliver outstanding clarity and deposit ductility, ideal for plating plastic components. Finally, NiMac Hypore XL micro
porous nickel maximizes the corrosion performance of the overlaying MaCrome or TriMac chrome deposits. In order to
meet lower service conditions often specified for sanitary and consumer electronic goods, NiMac Clarion bright nickels
will ensure fully bright and levelled deposits are obtained with minimum nickel thickness.
Satin Nickel: For today’s demanding stylist, satin nickel is a popular finish. MacDermid’s unique M-Satin system, fully
approved for automotive use, was developed specifically to provide a satin finish that is repeatable and consistent
throughout typical production cycles.
Chrome: MacDermid offer two routes to plate the final chrome layer. Many platers take advantage of the flexibility and
ease of use of the MaCrome 8210 or Mach2 hexavalent chrome based systems. Alternatively, to comply with today’s
new Environmental, Health and Safety requirements, our new TriMacIII high performance trivalent chrome process can
be installed in most existing plating lines.
MacuPlex Process Sequence
Process Stage
Typical Products
Moulding
ABS, ABS/PC, PP
Etch
MacuPlex E110
Neutralise
Neutracel 9338
Catalyst
Mactivate 360
Accelerate
Macelerate 9369
Metallize
MacuPlex M550
Copper
CuMac
Nickel
NiMac
Final Finish
TriMac
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MacuPlex
Technology
The development of new and improved technologies for plating on plastics is a constant source of innovation
challenges for MacDermid.
Today’s market drivers are mainly environmental, safety and ecology needs. Developing systems with lower health and
safety risk and minimal environmental impact are key deliverables for our R&D groups.
Our latest developments include:
MacuPlex E110
Etch system with reduced environment impact
Mactivate 360
Improved activity and lower precious metal concentrations for all applications
MacuPlex M550
Ammonia, Cd & Pb free low metal electroless nickel, meets even the most
demanding market specifications
Process developments are vital to ensure MacuPlex processes continue to deliver economical coatings of high
quality and low rejects across the range of different plastics and blends.
MacuPlex E110
Low Chrome
Etch Stage
Conventional
Chrome
Etch Stage
MacDermid’s latest low chrome etch process “ MacuPlex E110” demonstrates
significantly lower chrome drag out, giving saving in both chemistry and
waste treatment costs.
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Expertise…. for every plastics application
MacDermid’s pioneering role in the development of plating on plastics has helped us become globally recognized as
an innovator and world-class solutions provider. Our MacuPlex brand is the industry’s most widely trusted system for
plated plastic pretreatments. It is used to plate an increasing variety of plastic types including ABS, Polycarbonate,
Nylon, Polypropylene and other exotic plastics alloys.
Our customers benefit from our continued development of new technology driven by market needs such as
environmental compliance, health and safety, and globalization of manufacturing.
Developing solutions for new plating on plastics applications is often the result of partnership with highly responsive
and proactive customers. New plating on plastics opportunities often begin as small scale evaluations. Process
development partnerships forged with our customers often result in successful production processes previously
unavailable. This co-operation results in a deeper understanding of the application needs.
Likewise, our technical service for plating on plastics is renowned worldwide. At the disposal of our customers are some
of the most knowledgeable and dedicated staff to be found anywhere in the surface finishing industry.
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It takes more than innovative, high performance products
and superior technical service to help our customers
compete and win in today's global marketplace. It takes
a total commitment to understanding their needs
and the ability to provide the right solutions—every time.
When success is your only goal, trust the company that says
“Yes We Can.”
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