A clean future for plastic metallization

The metallization of polymer surfaces is indispensable in numerous industries today – from the automotive industry to consumer electronics to medical technology. The preconditioning of these surfaces is currently based on wet chemical processes that primarily use toxic chemicals. There is therefore an urgent need to develop and implement alternative, sustainable processes. The “LaStrADA” research project takes the preconditioning of polymers prior to metallization to a new level – dry, environmentally friendly, and inline-capable.

The challenge: Why new processes are urgently needed

The wet chemical preconditioning processes that have dominated to date pose several problems:

• Use of hazardous chemicals such as chromium(VI) compounds, which are toxicologically questionable and have been severely restricted or even banned by the REACH regulation
• High environmental impact due to wastewater, complex disposal, and energy-intensive processes
• Rising costs for occupational safety and waste disposal
• Lack of future security due to regulatory restrictions

The industry therefore urgently needs sustainable and future-proof alternatives that comply with the law and combine high process quality with ecological responsibility.

The solution: Combination of atmospheric pressure plasma and laser technology

The atmospheric pressure plasma process developed at Fraunhofer IFAM allows catalytically active metal nanoparticles (e.g., made of palladium, copper, silver, etc.) to be specifically generated and deposited on polymer surfaces. This process replaces expensive and environmentally critical methods based on palladium baths, which are currently state of the art.

At the same time, the upstream laser technology enables precise and controlled structuring of the polymer surfaces, which significantly improves the adhesion of the applied metal coatings.

The combination of both technologies enables completely dry, clean, and series-ready preconditioning of polymer surfaces – without compromising on quality and process stability.

The advantages of the LaStrADA solution at a glance

• Environmentally friendly & future-proof – no toxic chemicals, no problematic disposal
• Inline-capable & efficient – ideal for automated production lines and Industry 4.0 applications
• Cost-efficient – e.g., through the use of copper or silver instead of expensive palladium
• Improved adhesion & quality – thanks to precise laser structuring
• Wide range of applications – from automotive and consumer electronics to medical technology
• Industry-oriented & suitable for series production – scalable for large quantities and complex components

Practical applications – for companies that think ahead sustainably

The LaStrADA approach is suitable for a wide range of applications, including:

• Electronics: conductor tracks on 3D plastic parts
• Automotive: decorative and functional surfaces in vehicle interiors
• Consumer electronics: metallization of housings and control elements
• Medical technology: biocompatible layers on polymer components

In summary, the technical approach researched offers a scalable, material-saving, and series-production-ready solution for greener, more efficient plastic metallization.

Funding

The IGF research project “LaStrADA” (IGF project no. 344 EN/1) was funded by the German Federal Ministry for Economic Affairs and Climate Protection as part of the CORNET program for the promotion of industrial joint research (IGF) based on a resolution of the German Bundestag.