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DFM Guide · Metal Plating

Chrome. Nickel.
Zinc. Tin.
Plate-friendly.

Metal plating adds 5-50 µm of corrosion-resistant or wear-resistant metal to substrate. Design for plating coverage, contact points, hydrogen embrittlement avoidance.

01 · Key principles

Key principles.

Hanging contact points

Mark on part

Part hangs in plating bath via wires. Contact points on part. Designate non-cosmetic locations.

Drainage

Internal cavities

Plating solution must drain. Hidden cavities trap solution causing future corrosion.

Sharp internal corners

Coverage issue

Internal corners have lower current density (electroplating). Less plating thickness. Round corners help.

Hydrogen embrittlement

For hard steels

Steel > 60 HRC absorbs hydrogen during plating. Bake at 190°C × 8-24h after plating to drive out.

Mating parts

Account for thickness

Plating adds 5-50 µm per surface. May affect bearing fits, mating clearance.

Through-hole dilution

Plate inside?

Holes < 1.5× wall thickness: poor internal plating. Specify if internal coverage critical.

FAQ

Chrome vs nickel vs zinc?

Chrome: hardest, wear surface. Nickel: corrosion + decorative. Zinc: cheapest, sacrificial steel protection.

Electroless nickel benefits?

Uniform thickness on complex geometry. Heat-treatable to 900+ HV. Corrosion + wear in one.

Decorative chrome thickness?

25-50 µm typical decorative. Hard chrome 25-50 µm functional. Specify per application.

Hydrogen embrittlement risk?

Steels above ~50 HRC. Can crack days after plating from absorbed hydrogen. Bake-out essential.

Substrate finish requirements?

Plating mirrors substrate finish. Polished base = mirror plate. Rough base = rough plate. Pre-plate finishing matters.

Environmental concerns?

Hex chrome (Cr6+) regulated. Trivalent chrome (Cr3+) increasingly used. Consider environmental compliance for new designs.

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