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Electroplating systems for aerospace: OMIG's answers on quality, traceability, and certifications
In the aerospace industry, every component contributes to the safety and performance of the entire system. For this reason, surface treatments are classified as special processes, whose control is just as critical as component design or machining.
Within this framework, an electroplating system is far more than the equipment used to perform the treatment. It becomes an integral part of the company's quality management system. Process accuracy, repeatability, data traceability, and compliance with international standards are now essential for every supplier operating within the aerospace supply chain.
Since 1959, OMIG has been designing and manufacturing custom electroplating systems, to meet the production requirements of a wide range of industrial sectors. With more than 500 systems installed throughout its history, the company has acquired the expertise needed to address even the most demanding applications, where process reliability, automation, and control are decisive factors.
In this interview, OMIG's engineers explain the key features an electroplating system must incorporate to meet the stringent specifications of the aerospace industry.
Why is system accuracy so critical in the aerospace industry?
The aerospace industry operates under extremely tight tolerances and rigorous technical specifications. Surface treatment quality depends on the ability of the electroplating system to maintain every process variable within specification throughout each production cycle.
The parameters that require highly accurate control include:
- current density and applied voltage;
- bath temperature;
- electrolyte chemical composition and concentration;
- immersion time;
- rack and cathode bar movement;
- filtration, agitation, and solution recirculation systems.
Even minor variations can affect the uniformity of the metallic deposit, particularly when processing components with the complex geometries typically found in aerospace applications. For this reason, accuracy is not simply a characteristic of the finished coating but an inherent feature of the entire system design.
How does the electroplating line contribute to production repeatability?
Suppliers within the aerospace supply chain have to demonstrate that the same quality level can be consistently maintained over time, regardless of the production batch.
In our view, repeatability is one of the most critical aspects. Automated process management, continuous monitoring of operating parameters, and reduced manual intervention help minimize variability and improve production stability while facilitating process validation activities.
How have control systems evolved in this field?
The evolution of electroplating systems has led to the integration of supervisory control and data acquisition (SCADA) technology capable of monitoring every process stage in real time.
Each production cycle can be recorded by associating the processed components with information such as process parameters, operating recipes, processing times, alarms, and complete operational history. This documentation is an essential resource during audits, process qualification activities, and customer inspections.
The availability of comprehensive production data also makes it possible to analyze process deviations, implement corrective actions, and support continuous improvement programs.
Are there specific certifications for the aerospace industry?
Electroplating processes for aerospace applications fall within the category of special processes, meaning their results cannot be verified solely through final inspection of the finished component. This means that the entire process must be qualified, continuously monitored, and maintained under strict control.
The primary industry standards include:
- NADCAP, the international accreditation program for special processes, widely required by the world's leading aerospace manufacturers;
- AS/EN 9100, the quality management system standard specifically developed for the aerospace industry;
- AMS (Aerospace Material Specifications) issued by SAE International, which define the technical requirements for materials and surface treatments.
These standards are complemented by the proprietary technical specifications established by major OEMs, including Airbus, Boeing, and other aircraft manufacturers, which often impose even more stringent requirements regarding process control, documentation, traceability, and equipment validation.
Designing an electroplating system with these requirements in mind from the earliest stages simplifies the qualification process and minimizes the need for subsequent modifications.
Is the electroplating system itself evaluated during supplier qualification?
The answer is yes. In the aerospace industry, prime contractors evaluate not only the finished component but also the reliability of the entire manufacturing process. The system configuration, level of automation, data management capabilities, and audit readiness are all key factors in supplier qualification.
An electroplating system designed according to these criteria provides greater operational stability, facilitates regulatory compliance, and helps reduce the risk of nonconformities, generating benefits throughout the entire supply chain.
For the aerospace industry, designing an electroplating system means creating the conditions that enable the process to be controlled, documented, and consistently repeated over time. These are the factors that determine a company's ability to meet aerospace qualification requirements and reliably support one of the most highly regulated supply chains in modern manufacturing.
Drawing on its extensive experience in the design and manufacture of custom electroplating systems, OMIG develops solutions that incorporate these requirements from the earliest stages of every project, helping customers implement reliable processes that fully comply with aerospace industry standards.
