What is the difference between electroplated and powder coatings, and when should each be used?

Electroplated coatings (such as silver, tin, or nickel) are applied using an electrolytic process and offer excellent electrical conductivity, corrosion resistance, and wear protection—ideal for connectors, busbars, and contact areas. Powder coatings (epoxy or polyester), applied electrostatically and cured in an oven, provide strong electrical insulation, mechanical protection, and resistance to environmental factors, making them suitable for insulation zones and high-temperature applications.

What types of components are most commonly protected with technical coatings?

Technical coatings are used on busbars, connectors, terminals, PCBs, motor parts, suspension systems, tools, and even military or aerospace components. The application depends on the functional requirement—whether it's corrosion protection, improved conductivity, thermal insulation, or mechanical resistance.

Is it possible to combine two types of coatings on a single component?

Yes. At Electris, we offer integrated coating solutions that combine electroplated and powder coatings on the same part. This approach enables the creation of components with both highly conductive areas and zones with excellent electrical insulation and environmental protection—ideal for demanding industrial applications.

Technical Coatings – their functions and industrial applications

Metal components, while durable and versatile, often require additional protection—especially in industrial environments.

In sectors such as energy, e-mobility, data centers, rail, automotive, construction, and electronics, metal parts must offer above-average resistance to wear, cracking, moisture, and mechanical damage, as well as enhanced conductivity or insulation. To meet these demands, metals are treated with specialized technical coatings. These may include electroplated layers or powder coatings. But what properties do these coatings offer, and where are they most effectively used?

What are technical coatings?

Technical coatings, also known as functional coatings, are specialized layers applied to metal surfaces to modify or enhance their physical and technological properties. Unlike decorative coatings, technical coatings are engineered for performance in demanding environments where durability, reliability, and efficiency are critical.

Examples include electroplated coatings—such as zinc, nickel, or silver layers—applied using advanced electroplating techniques at Electris. These coatings adapt the base metal for specific industrial use cases.

What are the benefits of electroplated technical coatings?

At Electris, we offer professional electroplating services—metallic layers applied via galvanic processes—allowing us to coat copper or aluminum components with technical layers in thicknesses ranging from 1 µm to 50 µm. These layers provide several critical benefits that directly impact the durability and functionality of finished components:

Enhanced corrosion resistance
Technical coatings protect metals from harmful effects of moisture, oxygen, salts, acids, and other chemical agents. This is essential in sectors such as energy, maritime, or chemical industries where components are exposed to harsh environmental or industrial conditions.
Protection against wear and abrasion
Electroplated technical coatings increase the hardness and wear resistance of metal parts, reducing friction and protecting the base material from degradation or mechanical damage.
High-temperature resistance
In high-performance applications—such as aerospace or automotive—technical coatings stabilize surfaces under extreme heat, reduce thermal expansion, and minimize material fatigue.
Improved soldering, welding, and bonding
Certain coatings improve the metal’s technological properties, making subsequent processing or assembly easier. For instance, tin or silver layers significantly enhance solderability in electronic components.
Chemical insulation
Some electroplated coatings serve as barriers that prevent oxidation, chemical reactions, or ion migration—vital for industrial automation and sensitive electronic systems.

Moreover, premium technical coatings can also restore functionality to worn or damaged parts. Electroplating enables the regeneration of surfaces in critical components like shafts, bearings, and bushings—prolonging their service life and reducing waste, which aligns with sustainable manufacturing principles.

Epoxy and polyester powder coatings – protection and functionality in industrial use

Another class of technical coatings includes epoxy and polyester powder coatings—an advanced solution for safeguarding metal surfaces. These coatings not only provide robust environmental protection but also deliver essential functional benefits such as electrical insulation, mechanical durability, and thermal stability.

Electrical insulation & thermal resistance

A key advantage of powder coatings—particularly epoxy and polyester—is their high dielectric strength, reaching up to 45 kV/mm. This makes them ideal for battery systems, power equipment, and installations where reliable electrical insulation is critical.

Additionally, powder coatings retain their stability at temperatures up to 300°C, offering outstanding performance in high-temperature industrial environments.

Flexibility & mechanical resistance

Depending on the type of powder used, epoxy and polyester coatings can be tailored for flexibility and thickness, allowing their application to complex geometries without the risk of cracking or delamination during assembly or operation.

Industrial applications of technical coatings

The ability of electroplated and powder coatings to alter and enhance the physical and technological properties of metal surfaces makes them invaluable in modern industry. Key application areas include:

Energy sector – Protecting critical infrastructure components such as busbars, connectors, and terminals from corrosion and atmospheric degradation.
Data centers, server rooms, and energy storage – Ensuring reliable electrical connections, improving conductivity, and protecting against oxidation, overheating, and signal interference.
Electronics – Enhancing solderability and preventing oxidation at contact points and on PCBs.
Rail, e-mobility, and automotive – Shielding drivetrain, suspension, braking components, and car bodies from corrosion, wear, and mechanical stress.
Construction – Safeguarding metal structural elements, HVAC systems, and piping from corrosion and mechanical damage.
Defense industry – Protecting weapons, military vehicles, and electronic systems against extreme wear and environmental exposure; electroplating improves reliability and equipment longevity.
Aerospace and space industries – Coating critical aircraft components, jet engines, and control systems to prevent wear, withstand high temperatures, and reduce material fatigue—directly impacting flight safety.
Machinery and tooling – Applying coatings to cutting tools, gears, bearings, and high-load mechanical components to improve hardness, wear resistance, and lower friction coefficients.

These technical coatings have become an essential part of modern manufacturing, offering significant performance, sustainability, and economic benefits.

Electris Coating Systems – complete galvanic and powder coating solutions

At Electris Coating Systems, we specialize in advanced technical coatings for multiple industries—particularly for power engineering applications. Our services include nickel plating, tin plating, and silver plating of non-ferrous metal components (copper and aluminum), including busbars. This dramatically enhances their corrosion resistance, electrical conductivity, and durability in challenging operating environments.

We also offer precise integration of both galvanic and powder coatings on a single component, using a multi-step process that includes:

Thorough cleaning of the entire surface
Masking of designated areas
Application of a galvanic coating (e.g., silver) for superior conductivity and corrosion protection in contact zones
Application of an epoxy or polyester powder coating, delivering dielectric insulation (up to 45 kV/mm), mechanical protection, and environmental resistance

This hybrid approach allows us to customize the functional characteristics of each component according to application requirements. Galvanic coatings are used where low electrical resistance and high conductivity are essential, while powder coatings provide strong insulation and environmental durability where needed. The result is a highly tailored solution, with consistent quality and technical parameters across every production batch.

Have questions or want to use our services? Contact Electris Coating Systems at: sales@electris.pl