Electroplating thickness is one of the most important factors when it comes to the plating process. Many conversations we have with customers involve this question: whether we can meet the specified microns of their design and how the plating might affect performance. Therefore, we have created this small guide to help inform customers about thickness.
If you have specific coating thickness requirements, please contact us with your required micron specification or submit a technical drawing so we can advise you
What is plating thickness?
As electroplating is a process that involves applying a layer of metal onto a base substrate, plating thickness refers to the measurement or depth of the deposited coating applied to the base metal. Plating thickness is usually measured in microns, also known as micrometres.
Electroplating thickness typically ranges from very thin decorative layers below 0.1 µm through to functional coatings in the 5–25 µm range, with heavy build processes reaching 85 µm and above where required. The appropriate thickness depends heavily on the metal, process, and end‑use application.
Why is thickness critical in electroplating?
Plating thickness is crucial because it is determined by a combination of the functionality you want to enhance through plating and the environment that the part will be used in. Many applications rely on adequate coating thickness to ensure that they function as intended over their full-service life.
Getting plating thickness right is important, as it is directly linked to the durability of a part and the final quality of the finish. Get the coating too thin and you risk premature wear, corrosion, and electrical failure. Apply it too thick and you increase component weight, costs, and assembly issues.
A part of the design process
Plating thickness is an integral part of the design process, as it must be specified in line with the environmental, operational, and performance requirements of the application.
Designers and engineers typically define:
- The electroplating processes (e.g. copper, nickel, zinc, silver, or combinations).
- The minimum and target thickness in microns.
- Critical surfaces or features that require controlled build.
- Tolerances and allowances for dimensional change due to plating.
Conductivity and electrical performance
The thickness of the plating material directly influences electrical performance of the component. This is true for many power and high‑reliability electronics applications. In many cases the substrate is already conductive, but the plated layer provides a controlled, often more conductive, surface or additional cross‑section for current flow.
In some cases, a thicker layer of plating reduces electrical resistance and improves current carrying capacity, although different electroplating processes have varying conductivity levels. Therefore, the choice of plating material and the specified thickness must be matched to current density, operating temperature, and reliability requirements.
Across electronics and power distribution systems, performance demands are increasing due to AI, data centres, electrification, and growing reliance on advanced technology. Manufacturers and R&D teams, now look for plating processes that can deliver high reliability at increased currents and temperatures, with optimum durability and thermal management. As a result, we are now seeing customers demanding high-thickness finishes for plating processes such as copper plating in order to meet performance requirements.
Durability
Plating thickness also plays a central role in durability and enables processes such as heavy build plating. Heavy build electroplating refers to plating that is significantly thicker than normal plating processes. Heavy build plating also increases the durability of components in many ways. The thickness of the coating can ensure that the wear resistance of a component is improved.
Where a sacrificial coating is used (for example, zinc or nickel or copper in specific environments), greater thickness generally extends the time before the substrate starts to corrode, helping preserve the integrity and dimensional stability of the part.
In aggressive environments, such as marine or petrochemical service where key infrastructure and components (drills, fasteners, rigs, pipelines, and valves) may be continuously exposed to seawater, high‑thickness plating systems are often used as part of a wider corrosion‑protection strategy.
Copper and copper‑alloy surfaces, including heavy build copper plating on suitable components, can also help reduce marine growth because copper ions in the surrounding water are toxic to many fouling organisms, making the surface less favourable for barnacles and similar growth.
Sliding components
Sliding and moving components, typically experience higher levels of friction and mechanical wear. As a result, such components may require thicker plating to account for wear of their service time, as there will be a lot of friction in contacts and moving parts.
On the other hand, static components with no relative movement and lower mechanical loading can often use thinner coatings, if corrosion and environmental requirements are still met.
In both cases, the chosen thickness should reflect realistic wear rates, contact pressures, and maintenance or replacement intervals.
Weight
In use cases where the weight of the components is under heavy scrutiny or particularly important such as aerospace, motorsport, electronics, or certain automotive and defence components, the weight added by plating can become an important constraint.
Consequently, designers carefully balance the need for corrosion resistance, durability, and electrical conductivity against strict weight and dimensional targets.
That is why choosing the right electroplating partner is essential. A specialist metal finisher that understands tolerance control, consistent plating thickness, and precision process management becomes a critical part of the engineering chain, ensuring that functional coatings are achieved without compromising the component’s intended performance. When microns are tight and failure is not an option, electroplating expertise truly matters.
What other factors affect plating thickness?
It’s not only the above (functionality and durability) that determine electroplating thickness. In many industries and applications, coating thickness is also specified sometimes very tightly by regulations, customer requirements, and international or sector‑specific standards.
Electroplating Thickness Across Various Industries
Aerospace
In aerospace, coatings are controlled by rigorous standards that define plating systems, thickness ranges, and testing requirements for critical components. Standards such as BS EN 2786 and BS EN 3196 cover silver plating and related coatings for components that may be exposed to high temperatures and severe mechanical loading, where adequate thickness is vital to resist galling, seizing, and fretting.
Automotive & Defence
Defence sectors also have standards that specify coating thickness, such as AMS 2404, due to the nature of the applications involved. This is also the case for components in the automotive industry, particularly those requiring zinc plating.
For example, based on IPC standards (including IPC-A-610 and IPC-6012), copper electroplating thickness requirements depend on the class of the product (Class 1, 2, or 3). These requirements focus on ensuring reliability, especially for plated-through holes.
PCB Plating Thickness
For example, in printed circuit boards, standards such as IPC-6012 (Qualification and Performance Specification for Rigid Printed Boards) define plating thickness requirements.
Power distribution
In power distribution, busbar and switchgear designs must comply with applicable low‑voltage switchgear and control gear assembly standards such as IEC 61439‑1.
Engineers select busbar dimensions including thickness to meet current‑carrying and mechanical requirements and then verify compliance through testing or analysis according to IEC 61439‑1.
Other industries
Fasteners are used in a wide variety of applications, and standards such as ISO 4042 and ASTM B633 can specify plating thickness due to increased risks of corrosion and galling.
How we can support you
We value the importance of electroplating thickness and delivering high-quality finishes for our customers. Thickness control is a key service offering for us as a business.
We deliver high-quality finishes by ensuring every project meets agreed specifications every time. Our in-house measurement capabilities include:
- XRF Analysis: Both static and handheld machines.
- Microscopy & Cross-Sectioning: For deep-level structural verification.
- Specialist Testing: Through our network of technical partners.