Fraunhofer Institute for Manufacturing Engineering and Automation IPA
Electroplating Technology
Sustainable. Digital. Application-Oriented: Smart Electroplating
Electroplating is a key enabling technology. Whether in the automotive industry, mechanical engineering, or medical technology, functional surfaces are essential for product quality, durability, and resource efficiency.
We research and develop innovative processes for future-ready electroplating technology: digitally connected, sustainably optimized, and ready for industrial application.
Research in Electroplating Technology
Our interdisciplinary team of experts in chemistry, electrochemistry, materials science, process engineering, and mechanical engineering develops solutions along the entire process chain – from the initial concept to industrial implementation.
- Development of new coating materials and deposition processes
- Optimization and digitization of existing process chains
- Failure analysis and root cause investigation
- Efficient and sustainable material and process development
- Customized equipment and system technologies for industrial applications
We translate research into practice – Application-oriented, scalable, and delivering tangible value for the industry.
Introduction to Digital Electroplating Technology
The fully equipped electroplating line at Fraunhofer IPA represents an innovative approach to digitizing electroplating processes and offers new perspectives for the industry on efficiency, quality, and sustainability.
The facility serves as both a demonstrator and an experimental platform for testing and further developing digital innovations under realistic conditions. The goal is to rapidly translate digitization strategies for electroplating systems into industrial practice, from sensor technologies to digital twins. Through intelligent process and electrolyte management, not only can system availability be increased, but process stability and coating quality can be improved. Manufacturing becomes more flexible, resource-efficient, and customizable – creating a clear competitive advantage for electroplating companies.
Chromium (III) Research for Future-Proof Hard Chrome Coatings
At Fraunhofer IPA, we develop innovative chromium (III) electrolytes as an environmentally friendly alternative to chromium (VI) – fully compliant with the REACH regulations. Our goal is to deposit high-quality hard chrome layers that offer impressive hardness, wear protection, and corrosion resistance. By using a modulated current and optimizing deposition parameters, the research project has already significantly improved the coatings' crack behavior.
Our pilot facility (400 liters) enables application-oriented scaling and evaluation of industry-ready solutions for electroplating.
Our Contribution to Green Electroplating
- Chromium (III) electrolyte research for REACH-compliant processes
- Process development for crack-minimized, high-performance coatings
- Industry-oriented testing from beaker to pilot plants
Sustainable Electrochemistry for Thin Coatings and Resource Efficiency
Our research focuses on electrochemical processes that make a decisive contribution to sustainable electroplating. By depositing ultra-thin metallic layers, we enable material-efficient coatings with high functionality, an important step toward resource conservation.
Another focus is the recovery of critical materials, particularly in battery recycling. Our innovative processes allow valuable metals and rare-earth elements to be recovered electrochemically – efficiently, sustainably, and economically.
Our Research Provides Solutions for
- Resource-efficient electroplating
- Recovery of critical materials such as lithium or selenium
- Sustainable processes in battery recycling
- Future-proof technologies for energy and mobility
Learning from Defects: Driving Research Forward
The analysis of coating defects and surface anomalies gives us valuable insights for further process development – practical, data-based, and aiming at maximum performance in industrial applications. We have extensive laboratory and measurement technology at our disposal, which we use to investigate electroplating defects and incorporate into our research work.
Thus, we are shaping the electroplating technology of tomorrow – sustainable, efficient, and future-oriented.