A Process Systems Engineering Approach to Model and Optimize Cr⁶⁺-Free and Pd-Free Plating on Plastics Technologies

Area of Science:

• Materials Science and Engineering
• Chemical Engineering
• Sustainable Manufacturing

Background:

• Conventional plating on plastics (PoP) relies on hazardous hexavalent chromium for etching and critical raw material palladium for activation.
• These traditional methods pose significant health, environmental, and economic risks, driving the need for safer alternatives.

Purpose of the Study:

• To develop and validate a novel, chromium-free and palladium-free PoP technology.
• To establish a comprehensive modeling approach for simulating and predicting the performance and material properties of the new PoP process.
• To create a Decision Support Tool (DST) for optimizing the process based on economic, environmental, safety, and Safe and Sustainable by Design (SSbD) principles.

Main Methods:

• Utilized piranha solutions (H2O2-H2SO4) for surface etching, nickel salts for activation, and sodium borohydride (NaBH4) for reduction.
• Developed a comprehensive modeling approach, including state-of-the-art and data-driven techniques, to simulate unit operation performance and material properties.
• Constructed a user-friendly Decision Support Tool (DST) integrating the developed models.

Main Results:

• Successfully demonstrated a Cr-free and Pd-free PoP technology forming metallic nucleation sites for subsequent plating.
• The modeling approach accurately predicted reaction kinetics, yields, contact angle, and adhesion across various processing stages.
• Identified combinatorial relationships between process conditions, performance, and material properties, enabling process tuning to meet specifications.

Conclusions:

• The new PoP technology offers a safer and more sustainable alternative to conventional methods.
• The developed Decision Support Tool (DST) effectively aids in optimizing the process for desired product specifications and SSbD objectives.
• The modeling approach provides valuable insights for controlling and improving PoP processes, supporting economic, environmental, and safety goals.