Periodic Reporting for period 1 - FreeMe (Toxic Free metallization process for plastic surfaces)
Reporting period: 2022-06-01 to 2023-11-30
The main objective of the FreeMe project is the elimination of use of hexavalent chromium (Cr6+) and palladium (Pd) from the Plating on Plastics (PoP) process.
The use of plastics in industrial applications has gained popularity due to their advantageous properties, including lightweight, low density, flexibility, strength, and cost-effectiveness. However, to enhance their wear and corrosion resistance and improve their aesthetic appearance, a metallic coating is required on the plastic surface. Since most plastics are non-conductive materials, a series of intermediate steps are necessary to enable the deposition of the metal coating:
1.Pre-treatment step involves surface etching to promote metal adhesion. Currently, chromic (Cr6+) acid bath solutions are commonly used for this purpose, despite the associated occupational safety and environmental risks.
2. Surface activation process is carried out to disperse nucleation sites, ensuring electroless metal deposition. Presently, Sn-Pd baths are utilized for this step, even though Pd is considered a critical raw material.
3. Metallization stage involves metallization via electroless plating, where a thin metal film is initially deposited on the plastic surface, making it conductive and ready for further electrodeposition of metals.
4. Plating on Plastics (PoP) process, however, is subject to certain environmental and health concerns due to the use of hexavalent chromium (Cr6+) and palladium (Pd).
In response to this, the FreeMe project aims to eliminate the reliance on these toxic substances and improve the process's sustainability by using REACH compliant chemicals. The goal is to ensure long-term viability while avoiding the use of harmful compounds.
To achieve this, FreeMe proposes two safe and sustainable approaches for the metallization of polymeric surfaces:
A. The first approach involves using sprayable resins with suitable nickel-based precursors. These resins will be deposited on the plastic surface, creating the necessary nuclei for the subsequent step of electroless deposition and the formation of the conductive layer.
B. The second approach entails a Cr6+ & Pd free pre-treatment of the surface. Afterward, nickel active sites are incorporated by reducing nickel salts on the plastic surface. The electroless plating process will then take place, resulting in the formation of the conductive layer.
The application of these proposed technologies is intended in three different industries: a. Automotive, b. Aerospace and c. Home appliances.
By adopting these innovative approaches, the FreeMe project seeks to revolutionize Plating on Plastics (PoP) by making it more environmentally friendly and sustainable.
The use of plastics in industrial applications has gained popularity due to their advantageous properties, including lightweight, low density, flexibility, strength, and cost-effectiveness. However, to enhance their wear and corrosion resistance and improve their aesthetic appearance, a metallic coating is required on the plastic surface. Since most plastics are non-conductive materials, a series of intermediate steps are necessary to enable the deposition of the metal coating:
1.Pre-treatment step involves surface etching to promote metal adhesion. Currently, chromic (Cr6+) acid bath solutions are commonly used for this purpose, despite the associated occupational safety and environmental risks.
2. Surface activation process is carried out to disperse nucleation sites, ensuring electroless metal deposition. Presently, Sn-Pd baths are utilized for this step, even though Pd is considered a critical raw material.
3. Metallization stage involves metallization via electroless plating, where a thin metal film is initially deposited on the plastic surface, making it conductive and ready for further electrodeposition of metals.
4. Plating on Plastics (PoP) process, however, is subject to certain environmental and health concerns due to the use of hexavalent chromium (Cr6+) and palladium (Pd).
In response to this, the FreeMe project aims to eliminate the reliance on these toxic substances and improve the process's sustainability by using REACH compliant chemicals. The goal is to ensure long-term viability while avoiding the use of harmful compounds.
To achieve this, FreeMe proposes two safe and sustainable approaches for the metallization of polymeric surfaces:
A. The first approach involves using sprayable resins with suitable nickel-based precursors. These resins will be deposited on the plastic surface, creating the necessary nuclei for the subsequent step of electroless deposition and the formation of the conductive layer.
B. The second approach entails a Cr6+ & Pd free pre-treatment of the surface. Afterward, nickel active sites are incorporated by reducing nickel salts on the plastic surface. The electroless plating process will then take place, resulting in the formation of the conductive layer.
The application of these proposed technologies is intended in three different industries: a. Automotive, b. Aerospace and c. Home appliances.
By adopting these innovative approaches, the FreeMe project seeks to revolutionize Plating on Plastics (PoP) by making it more environmentally friendly and sustainable.
The main outcomes of the FreeMe project in the first 18 months can be summarized as follows:
- Definition of REACH compliance baths chemistries;
- Pre-assessment of the substances involved in the different processes, from the toxicological and sustainability point of view, based on the SSbD framework, form the EC’s JRC;
- First successful UV-curing of biobased resin in lab;
- Comprehensive description description of the results derived from the studies on the toxic-free metallization of plastic substrates (ABS, PC/ABS and PA-12) supplied by the project's end-users, with a specific focus on the etching and activation steps;
- Simulations conducted to study the adhesion on a PLA substrate of the epoxy coating developed within FreeMe;
- Measurements taken from samples and outlines a technique to monitor resin layer thickness in an in-line production settin.
- Definition of REACH compliance baths chemistries;
- Pre-assessment of the substances involved in the different processes, from the toxicological and sustainability point of view, based on the SSbD framework, form the EC’s JRC;
- First successful UV-curing of biobased resin in lab;
- Comprehensive description description of the results derived from the studies on the toxic-free metallization of plastic substrates (ABS, PC/ABS and PA-12) supplied by the project's end-users, with a specific focus on the etching and activation steps;
- Simulations conducted to study the adhesion on a PLA substrate of the epoxy coating developed within FreeMe;
- Measurements taken from samples and outlines a technique to monitor resin layer thickness in an in-line production settin.
During this first reporting period, the FreeMe project has achieved important milestones towards the implementation of FreeMe's basic goal. However, this section will be thoroughly be updated in the next reporting periods.