Benchmarking

Benchmarking

Plating on Plastics

Shivakumar C T
POP Synopsis

 Date’s back to 1960’s for Automotive purpose

 Electroplating provided a platform for metallizing on non- conductive

parts

 Technology has improved lot with respective to ABS process is

concerned

 Properties and Applications:

• Good strength Electronic Industry
• Rigidity Automotive
• Toughness Sanitary ware
• Hardness
• Gloss
• Temp.= 96 0C
• Density= 1.04 gm/cm3

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POP Relationships

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POP Basics

 There are basically three different types of system for Plating

on Plastics
1. Ionic system
2. Conventional system
3. Direct metallization

 Ionic system does not meet most of the Automotive

requirements and is seldom used, nevertheless is still in
operation

 Focus is mainly on Conventional and Direct metallization as

they meet Automotive as well as sanitary requirements

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POP Basics

Comparison between Conventional and Direct metallization

Conventional Direct

Cleaning(optional)
Cleaning(optional)

Etching
Etching
Chrome Reducer

Chrome Reducer
Pre-Dip

Pd Activator Pre-Dip

Reducer
Pd Activator

Electroless Nickel
Electroless Nickel
Strike Cu

Electrolytic Deposition
Electrolytic Deposition

20/05/2023 Shivakumar C T 6
POP Basics

Conventional system

 Developed to meet Automotive demands

 Suitable for plating on ABS as well as ABS/PC

 Low Pd content

 Suitable for selective plating- 2K moulding

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POP Basics

Conventional system- Schematic description

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POP Basics

Direct Metallization system

 Elimination of Electroless Nickel

 Elimination of Strike Cu

 Simple integration in existing line

 Short process and therefore higher production yield

 Less waste to ETP due to elimination of E’less Ni.

 Suitable for plating on ABS as well as on ABS/PC

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POP Basics

Direct Metallization system- schematic description

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POP Basics
Etch

 Holes and pores provide mechanical adhesion

 Reaction produces a polar force which is required for
• To adsorb Palladium
• To provide required adhesion
 Surface Morphology study

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POP Basics

Activation

 One of the most critical process in POP

 Plastic surface is slightly positive polar as compared to the negative
polarity of colloid in activator
 This is due to the plastic material as well as roughness created by
Etch process on the surface
 ABS seems to be having a higher polarity as compared to ABS/PC
 Because of higher surface roughness because of higher butadiene
content and this polarity, ABS can usually adsorb more Pd as
compared to ABS/PC

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POP Basics

Activation- Structure of Sn-Pd colloidal cluster

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Comparison Study of G&W Activators

To start with, comparison of Activator Ultra (POP) with and without effect
Comparison
of mechanical agitationStudy oftemperature
at different G&W Activators
was conducted.

Activator Ultra 444(POP)

6

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Comparison Study of G&W Activators

Comparison study of G&W Activators with

mechanical
Comparison Study agitationActivators
of G&W 3.662 3.782

2.95
2.53

1.532 1.53
1.253
0.95
Pd(mg/ft2) with

Pd(mg/ft2) with
Sn(mg/ft2) with

Sn(mg/ft2) with
mechanical agi-

mechanical agi-

mechanical agi-

mechanical agi-
tation

tation

tation

tation
Temp(0C) 28 Temp(0C) 40
Activator Ultra POP Activator Ultra G

 Activator POP has got 5 gm/l of Pd conc. where as Ultra G has got 10 gm/l of
Pd conc.
 Same parameters were maintained
 We can conclude that activator Ultra G has got less consumption value as
compared to POP with same coverage and performance when components of
both the activators were compared
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Comparison Study of Competitor Activators

Comparison study of Atotech Activators

3.521 3.535
3.326 3.255

1.89
1.53 1.43
1.23

mechanical agita-

mechanical agita-
mechanical agita-

mechanical agita-
Pd(mg/ft2) with

Pd(mg/ft2) with

Sn(mg/ft2) with
Sn(mg/ft2) with

tion

tion
tion

tion
Temp(0C) 28 Temp(0C) 40
Adhemax IN Adhemax SF

 Pd content is different in both the activators with forming having 5 gm/l of

Pd content where as latter has got 7 gm/l of Pd content

20/05/2023 Shivakumar C T 16
Comparison Study between G&W and Competitor Activators

Comparison study of Activ- Comparison Study of

ators Activators
3.662 3.782 3.521 3.535

1.89
1.253 1.532 1.53
Pd(mg/ft2) with mechanical agi-

Sn(mg/ft2) with mechanical agi-

Pd(mg/ft2) with mechanical agi-

Sn(mg/ft2) with mechanical agi-

tation

tation
tation

tation
Kunststof Activator 100 Adhemax IN

20/05/2023 Shivakumar C T 17
Comparison Study between G&W and Competitor Activators

Comparison Study
Comparison Study of Ac-between G&WStudy
Comparison andofAActivator
Activators
tivators
3.326 3.255

2.95
2.53
1.53
0.95
Pd(mg/ft2) with mechanical

Sn(mg/ft2) with mechanical ag

-
1.43
1.23
agitation

itation

ical agitation
ical agitation
with mechan-

with mechan-
Pd(mg/ft2)

Sn(mg/ft2)
Ginplate Activator Ultra G Adhemax SF

LHS=RHS
20/05/2023 Shivakumar C T 18
Accelerator

Negative charged Activator particles

are adsorbed at the Polymer surface

Hydrolysis during rinsing:

Tin-Chlorides are converted into
hydroxides. Palladium clusters are
covered with Tin-alloys

Acceleration:
Tin-hydroxides are removed from the
surface. Pure Palladium functions as
catalyst for E’less deposition

05/20/2023
EFFECTS OF ACCELARATIONS
Comparison between
Performance of Accelerator Accelerators
was tested using GK 120 (Liquid Type).
 Activators used: Activator Ultra (POP) and Activator Ultra G.
 Test Protocol: Processing of Components – Stripping in Aqua Regia (Nitric
acid : Hydrochloric Acid = 1:3) known area & volume(0.4 sq dm, 40 ml) –
Analysis of Pd & Tin in stripped soln.

Effects of Accelerators
2.5
2
1.5
1
0.5
0
Pd(mg/ft2) with mechanical agitation

Sn(mg/ft2) with mechanical agitation

Pd(mg/ft2) with mechanical agitation

Sn(mg/ft2) with mechanical agitation

Activator POP+ Accelerator GK 120 Activator Ultra G+ Accelerator GK 120
Temp(0C) 40 Temp(0C) 45 Temp(0C) 50 Temp(0C) 55
Comparison between Accelerator’s

 Various competitor’s Accelerators were compared against G&W Accelerator’smpa

Operating temp. of Accelerator was maintained constant at 45 0C between
Accelerators

Content of Sn before Accelerator Content of Sn after Accelerator

Temp(0C) 45 0C Temp(0C) 45 0C

2.6 1.354
1.22 1.18
2.45 1.1
2.4
2.2
Sn(mg/ft2)

Sn(mg/ft2)
01 02 C
or
1
01 02 C 1
S S 34 t 34 or
or or xD er
a rS rS a t
r at r at e e l to to xD er
el
e
el
e upl cc er
a
er
a
pl
e ce
l
c c a c A el el cu Ac
f Ac f Ac M a x
Ac
c
Ac
c a a x
o o m f f M
tst tst he o o em
ns ns Ad tst tst h
Ku Ku ns ns Ad
Ku Ku

20/05/2023 Shivakumar C T 21
Electroless Nickel

Electroless Nickel process can be classified as:

 Alkaline
 Acidic
 High/Mid/Low phosphorus (P- containing deposits)
 Hot baths for WRC and cold baths for POP

05/20/2023
Electroless Nickel
There are lot of parameters that take part in E’less deposition which
influence
 Deposition speed
 Composition or physical properties of deposited layer
 Stability of solution
Parameters are:
1. Temperature
2. pH
3. Concentration and ration of Ni/ Hypophosphite
4. Concentration of stabilizer
5. Concentration of complexing agents
6. Bath load
7. Bath age/ orthophosphate content
8. Agitation

05/20/2023
Comparison of Electroless Nickel

To start with, two types of Electroless Nickel 414 ABS and Electroless
601 KB were taken into consideration
Performance in terms of Nickel deposition as well as resistivity were
checked in accordance with 2 Activators namely Activator POP and
Activator Ultra G.

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Comparison of Electroless Nickel

 Ni. Deposited--- 0.5 µm @ 28 degree C @ 5 min.

 Ni. Deposited--- 0.85 µm @ 35 degree C @ 5 min.

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Comparison of Electroless Nickel- Resistivity

• Resistivity was measured on panels using instrument “multimeter”

and results were found as mentioned in below table’s
E’less Ni. 414 ABS + E’less Ni. 414 ABS +
Temp( C) O
Time(min.) Activator POP Activator Ultra G
Resistivity
5 11.2 11.5
28
8 3.2 4.6
5 5.9 6.4
33
8 3.3 3.9

E’less Ni. 601 KB +

E’less Ni. 601 KB + Activator Ultra G
Temp(OC) Time(min.) Activator POP
Resistivity
5 9.9 11
28
8 5.5 4.4
5 5.5 6.2
33
8 4.4 3.6

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Trials at Customer site- M/s Exotech, Pune

Exotech- One of the premier Automotive accessories

manufacturer in India

Satisfies demands of major OEM’s such as Volkswagen,

John Deere, Mahindra, Skoda, TATA to name a few

Establishment of E’less Ni process- Ginplate 614 ABS

Sulphate based chemistry

Huge potential can be adsorbed

if we were successful in attempt

We did face a stiff completion

from competitor
β-site
α -site
Trials at Customer site- M/s Exotech, Pune

 Bath volume of 2700 ltrs.

 Total area produced – 600 m2

5
Nickel Concentration in g/L
4.5

4
Ni Conc. in g/L

3.5

3
Ni range 3-
2.5 3.5g/L
Plant Analysis
lab Analysis
2
1 3 5 7 9 11 13 15 17 19 21 23 25 27

Number of Days
Trials at Customer site- M/s Exotech, Pune

Hypo Concentration in g/L

40

35
Hypo Conc. in g/L

30

25

20

15 Plant Analysis
Lab Analysis
10
plant repeated Analysis
5
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Number Of Days

orthophosphite
160

140

120
Orthophosphite in g/L

100

80

60

40

20
orthophosphite
0
5/15/2019 7/4/2019 8/23/2019 10/12/2019 12/1/2019 1/20/2020 3/10/2020 4/29/2020 6/18/2020 8/7/2020

05/20/2023 Dates Shivakumar C T

Trials at Customer site- M/s Exotech, Pune

 We did carry out various test such as Thermal test as well as

Adhesion test to check whether the parts were in par with the quality
standards

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Trials at Customer site- M/s Exotech, Pune

Outcome of trials:-

Successful in our first attempt

 Gained confidence from customer as well

 In talks in trying to fetch another tank of E’less Ni.

 Simultaneously convincing them to start our Pre-treatment

Chemistry

05/20/2023 Shivakumar C T
Pilot Plant- Chembur

Pilot Lines allows investigation of a product and process on an

intermediate scale and assist in development of new technology
according to market requirements:

 Revamping of existing Pilot Plant in Chembur

 Facilitating to integration of Pilot line into business
 Identify new opportunities by exploiting technology
 Arrangement of integrated technological amenities such as
instruments to fasten the activity
 Single point of contact for all process and sole responsibility and
management of Pilot Plant- Manager

05/20/2023 Shivakumar C T
Our Next Move……

Triumph
Converting
opportunities
into business

Understanding
and meeting
their needs

Identify new
Customer’s

05/20/2023 Shivakumar C T
 NAMASTE

THANK
YOU.
05/20/2023