Modern manufacturing and surface finishing
The entire manufacturing process of any part can benefit from considering the final surface finish at an early stage of production. For better communication with potential partners, it is important to look at current trends in surface finishing.
The fall trade show season in the U.S., such as the International Manufacturing Technology Show (IMTS), provides numerous opportunities to explore where the fields of manufacturing intersect. Manufacturing professionals in all areas of the process chain are increasingly recognizing the importance of considering the finishing of parts in earlier stages of the production process. The traditional approach of simply machining parts and then sending them to an electroplater is outdated and should be a thing of the past. To achieve the highest quality, it is essential to work closely with all partners in the process chain, including surface treatment experts.
What are the current trends in the US surface finishing sector? Industry professionals are predominantly focused on these five key areas:
1. A.I., machine learning and IoT solutions
Similar to other areas of manufacturing, finishers and coaters are looking for ways to optimize their processes. Today, they are increasingly turning to robotics, artificial intelligence and machine learning to overcome challenges such as labor shortages, quality control and repeatability.
In the past, converters have been slow to adopt IoT (Internet of Things) and automation solutions, but various factors, such as labor shortages and the demand for environmentally friendly and sustainable processes, are accelerating the need to leverage new efficiencies.
Now that 3D printing is becoming increasingly popular in large-scale production, suitable finishes are in demand - and not just in the USA (Photo: stock.adobe.com/guteksk7)
2. 3D printing
Additive manufacturing is growing exponentially. As this technology evolves from research and development and low-volume production into high-volume production, more and more manufacturers are looking for different finishing methods to not only protect or aesthetically design parts, but also to increase their functionality.
Is there a boom in electroless nickel as the electrification of mobility progresses? (Photo: stock.adobe.com/VICHIZH Photo: stock.adobe.com/guteksk7)
3 Electroless nickel and electric vehicles
More and more electric vehicles (EVs) are hitting the roads in the USA. More and more automakers are investing in new capacity to expand their electric and hybrid vehicle offerings. Coatings are needed for a range of components - from electric motor components to batteries.
One example is electroless nickel plating. It has been used in the automotive industry for decades. Applications include piston crowns, carburetors and fuel injection components, plain bearings and transmission components. Today, electric vehicles offer exciting new opportunities for additional growth of electroless nickel in the automotive market, as this surface is used for several important components in electric vehicles.
4. environmental aspects
Environmental protection and the substitution of processes that are hazardous to health also play a role in the US (Photo: stock.adobe.com/ ckybe)Contrary to what some may think, environmental concerns are a priority in the refining industry. As one of the most heavily regulated sectors in US manufacturing, compliance is essential to the sustainability of the industry. For years, metal finishers have been negotiating with environmental organizations over air quality and wastewater treatment issues. The industry has proactively sought alternatives to potentially harmful hexavalent chromium plating and explored safer options such as trivalent chromium-based processes. Legislation in this area will continue to influence the available finishing technologies and their application methods.
Powder coating has always been a low volatile organic compound (VOC) process for coating parts, and the powder overspray is a recyclable material. Although powder coating is already environmentally friendly, new ways are being explored to further increase its sustainability.
5. coating of plastics
Plating on plastics (POP) is not new. Electroplating on plastics usually involves applying a thin layer of metal to a plastic substrate using an electrochemical process after the plastic has first been prepared for the metal to adhere to. Advances in the coating of plastics and the introduction of new materials for the manufacture of lightweight parts have opened up possibilities that go beyond traditional POP applications, which are often decorative in nature. Today, POP is being explored for use in various industries such as aerospace, automotive and electronics. The ability to electroplate high-performance plastics, lightweight composites and additively manufactured parts opens up new avenues for innovation, making the plating of plastics an option that improves not only the aesthetics but also the functionality of parts.
Metallized plastic is already widely used for switches on modern dashboards, for example. Scott Francis sees even more potential applications here (Photo: BIA)
Finishing today and tomorrow
The finishing industry is an integral part of the wider manufacturing landscape. Consumer needs and buying trends shape not only our products, but also the methods we use. For electroplaters to ensure the highest part quality, they should involve their surface finishing partners early in the production process and utilize their expertise to achieve the best possible surface finish that aligns with industry standards and consumer expectations.
