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Ten common surface treatment processes
2025-05-22
Vacuum Plating
Vacuum plating is a physical deposition phenomenon. That is, argon gas is injected under vacuum, and the argon gas hits the target material, and the target material is separated into molecules that are adsorbed by the conductive material to form a uniform and smooth imitation metal surface layer.
Applicable Materials
1. Many materials can be vacuum plated, including metals, soft and hard plastics, composite materials, ceramics and glass. Among them, aluminum is the most commonly used for electroplating surface treatment, followed by silver and copper.
2. Natural materials are not suitable for vacuum plating because the moisture in natural materials will affect the vacuum environment. Process cost: During the vacuum plating process, the workpiece needs to be sprayed, loaded, unloaded and re-sprayed, so the labor cost is quite high, but it also depends on the complexity and quantity of the workpiece.
Environmental impact
Vacuum plating has little impact on the environment, similar to the impact of spraying on the environment.
Electropolishing
Electropolishing is an electrochemical process in which atoms of a workpiece immersed in an electrolyte are converted into ions and removed from the surface due to the passage of an electric current, thereby achieving the effect of removing fine burrs and increasing the brightness of the workpiece surface.
Applicable Materials
1. Most metals can be electropolished, and it is most commonly used for surface polishing of stainless steel (especially austenitic nuclear grade stainless steel).
2. Different materials cannot be electropolished at the same time, and cannot even be placed in the same electrolytic solvent.
Process cost
The entire process of electrolytic polishing is basically completed automatically, so the labor cost is very low.
Environmental impact
Electrolytic polishing uses less harmful chemicals, the entire process requires a small amount of water and is simple to operate. It can also prolong the properties of stainless steel and slow down the corrosion of stainless steel.
Pad printing process
Pad printing technology refers to the ability to print text, graphics and images on the surface of irregular shaped objects, and is now becoming an important special printing.
Applicable materials
Almost all materials can be printed using pad printing technology, except for materials that are softer than silicone pads, such as PTFE.
Process cost
Low mold cost and low labor cost.
Environmental impact
Since this process is limited to soluble inks (which contain harmful chemicals), it has a high impact on the environment.
Galvanizing process
The galvanizing process refers to a surface treatment technology that coats a layer of zinc on the surface of steel alloy materials for aesthetic purposes and to prevent rust. The surface zinc layer is an electrochemical protective layer that can prevent metal corrosion. The main methods used are hot-dip galvanizing and electro-galvanizing.
Applicable materials
Since the galvanizing process relies on metallurgical bonding technology, it is only suitable for the surface treatment of steel and iron.
Process cost
No mold cost, short cycle/medium labor cost, because the surface quality of the workpiece depends largely on the manual surface treatment before galvanizing.
Environmental impact
Since the galvanizing process increases the service life of steel parts by 40 to 100 years and effectively prevents the workpieces from rusting and decaying, it has a positive effect on protecting the environment. In addition, after the service life of the galvanized workpiece expires, it can be returned to the galvanizing tank, and the repeated use of liquid zinc will not produce chemical or physical waste.
Electroplating process
The electroplating process uses electrolysis to adhere a layer of metal film to the surface of parts, thereby preventing metal oxidation, improving wear resistance, conductivity, reflectivity, corrosion resistance and enhancing aesthetics. The outer layer of many coins is also electroplated.
Applicable Materials
1. Most metals can be electroplated, but different metals have different levels of purity and electroplating efficiency. The most common ones are: tin, chromium, nickel, silver, gold and rhodium.
2. The most commonly used plastic for electroplating is ABS.
3. Nickel metal cannot be used for electroplating products that come into contact with the skin because nickel is irritating and toxic to the skin.
Process cost
No mold fee, but fixtures are required to fix the parts / time cost depends on the temperature and metal type / labor cost (medium-high), depends on the specific type of electroplated parts, such as the electroplating of silverware and jewelry requires extremely highly skilled workers to operate because of its high requirements for appearance and durability.
Environmental impact
A large number of toxic substances are used in the electroplating process, so professional diversion and extraction are required to ensure minimal environmental impact.
Water transfer printing
Water transfer printing is a method of printing colored patterns on transfer paper onto the surface of three-dimensional products using water pressure. As people's requirements for product packaging and surface decoration increase, the use of water transfer printing is becoming more and more extensive.
Applicable materials
All hard materials are suitable for water transfer printing, and materials suitable for spraying are also suitable for water transfer printing. The most common ones are Injection Molded parts and metal parts.
Process cost
There is no mold fee, but a fixture is required to water transfer multiple products at the same time. The time cost generally does not exceed 10 minutes per cycle.
Environmental impact
Compared with product spraying, water transfer printing makes fuller use of printing coatings, reducing the possibility of waste leakage and material waste.
Silk screen printing
Silk screen printing uses a scraper to squeeze the ink, so that it is transferred to the substrate through the mesh of the image part, forming the same image as the original. Silk screen printing equipment is simple, easy to operate, simple to print and plate making, low cost, and highly adaptable.
Common printed materials include color oil paintings, posters, business cards, binding covers, product signs, and printed and dyed textiles.
Applicable materials
Almost all materials can be Silk screen printed, including paper, plastic, metal, ceramics and glass.
Process cost
The mold cost is low, but it still depends on the number of colors, because each color must be made separately. The labor cost is high, especially when it comes to multi-color printing.
Environmental impact
Light-colored silk screen printing inks have less impact on the environment, but inks containing PVC and formaldehyde have harmful chemicals and need to be recycled and disposed of in a timely manner to prevent water pollution.
Anodizing
It is mainly the anodization of aluminum, which uses the principle of electrochemistry to form a layer of Al2O3 (aluminum oxide) film on the surface of aluminum and aluminum alloy. This oxide film has special characteristics such as protection, decoration, insulation and wear resistance.
Applicable materials
Aluminum alloy and other aluminum products.
Process cost
During the production process, the consumption of water and electricity is quite large, especially in the oxidation process. The heat consumption of the machine itself needs to be continuously cooled by circulating water, and the electricity consumption per ton is often around 1000 degrees.
Environmental impact
Anodizing is not very energy efficient, and in aluminum electrolysis production, the anode effect also produces gases that have a destructive side effect on the atmospheric ozone layer.
Brushed Metal
It is a surface treatment method that forms lines on the surface of the workpiece by grinding the product to achieve a decorative effect. According to the different lines after drawing, it can be divided into: straight drawing, random drawing, corrugation and spiral drawing.
Applicable materials
Almost all metal materials can use metal drawing process.
Process cost
The process method is simple, the equipment is simple, the material consumption is very small, the cost is relatively low, and the economic benefit is high.
Environmental impact
Pure metal products, no paint or any chemical substances on the surface, does not burn at 600 degrees high temperature, does not produce toxic gases, and meets fire protection and environmental protection requirements.
In-mold decoration
In-mold decoration is a molding method in which a film with a printed pattern is placed into a metal mold, and the molding resin is injected into the metal mold to bond with the film, so that the film with the printed pattern and the resin form a whole and solidify into a finished product.
Applicable materials Plastic surface.
Process cost
Only one set of molds is needed to reduce costs and working hours. Highly automated production simplifies the process. There is a one-time Injection Molding method that can achieve molding and decoration at the same time.
Environmental impact
This technology is green and environmentally friendly, avoiding the pollution caused by traditional painting and electroplating.
