Greener electrochemical plating of ABS polymer with unprecedented adhesion via hierarchical micro–nanotexturing

Electrochemical plating is the most widely used coating process for metalizing commodity polymers, such as acrylonitrile–butadiene–styrene (ABS). Conventionally, ABS polymer pretreated in concentrated sulfochromic acid solution before to develop a highly porous surface topography that ensures adhesion. Unfortunately, using chromic produces extremely hazardous chemical waste, which costs manufacturers millions of dollars fines. This study proposes threefold greener route by employing newly developed in-mold patterning polymeric parts plating. We hot-embossed micron-sized dimples on and acid-etched it short 1 min obtain hierarchical micro–nanotextured surface. The adhesion surfaces appeared be two times higher compared conventional electroplating, while etching time was reduced three times. Microscopic characterization fracture revealed strength at hierarchically structured interface exceeded polymer, causing cohesive crack far below when peeling plated metallic film. These results imply use toxic acids electroplating industry can drastically proposed hybrid preparation method without sacrificing quality.