Nearly every die cast material requires a coating for corrosion protection. Typically, for components with cosmetic finishes, nickel is the best undercoat for finishing. It has excellent adhesion properties and acts as a barrier for the skin. For example, we would cast the component and then apply a layer of nickel plating to create a foundation for the cosmetic coating, whether satin chrome, PVD or similar.
With the continued growth of wearables and fitness trackers, concern arises when the coating is scratched off, leaving nickel in contact with the skin. This creates challenges for die casters and suppliers in the consumer electronics industry. Buyers with sensitive skin can develop a rash from metal wearables containing nickel, resulting in negative publicity for your business. With 15% of Dynacast's customers coming from consumer electronics, our Dynacast Singapore facility set out to find a solution.
Highly cosmetic nickel-free plating options
For years, to address allergic reactions caused by nickel-to-skin contact, companies manufactured components using MIM with stainless steel or machined them from aluminium or steel billet. Depending on component complexity, die casting can be a more economical choice than MIM and is almost always more cost-effective than machining from billet. This can save several dollars in part cost, which adds up very quickly in high-volume production runs. However, businesses must take the necessary steps to prevent legal liability arising from an unhappy customer.
Dynacast Singapore offers an excellent alternative. Nickel-free plating options for die castings that will not leave consumers with severe skin rashes. This coating is used as the base layer before the cosmetic finish and can be used on almost any material—although it works best on aluminium and zinc alloys. This gives design engineers greater design freedom.
The ability to design and manufacture zinc and aluminium components for the wearable-device market, while offering allergy-free products, has opened up a wealth of opportunities in the consumer electronics industry. These die casting options are less expensive than current components.
This coating is also suitable for use in the virtual reality and medical device markets. With over 18 different colour options, the possibilities for this coating are endless.
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