2024 in Review — PF Looks Back on the Year's Biggest Industry Topics and Trends

Products Finishing has had a busy year — and so has the surface finishing industry. 2024 was filled with a wealth of great industry events and travel opportunities. In addition to our usual U.S.-based trade shows and conferences, PF also traveled to Karlsruhe, Germany, to attend Paint Expo 2024. We had the opportunity to visit metal finishers in California as the Metal Finishers Association of California chapters met for their annual legislative day where they reviewed the latest regulatory issues affecting surface finishing operations in the state and met with legislators to educate them on the importance of the finishing industry. We toured facilities across the country and listened to the insights and concerns from the people who do this work every day.

Shifting away from hexavalent chromium

One of the biggest topics on the minds of finishers surrounds the use of hexavalent chromium. Surface finishing operations that use hexavalent chromium are facing several challenges as regulations on this toxic substance tighten. In the past, compliance with increasingly stricter hexavalent chromium standards has required investing in new equipment and facilities, like advanced air-filtration systems and wastewater treatment, which can be costly for businesses. Ongoing compliance and monitoring also adds to operational expenses.

In a PF Ask the Expert published in April 2024, Brittany McKinney of Pavco explores the environmental considerations driving these regulations: short.pfonline.com/hex2tri

Today, California-based finishing operations using hexavalent chromium are facing a phase-out of hexavalent chromium use for decorative applications by 2027 and then in 2030 for military and commercial aerospace applications. While alternative solutions to hexavalent chromium have been available for years, there has been a significant amount of work invested in trying to develop solutions that can achieve the same level of corrosion resistance, durability or finish quality as hexavalent chrome and to validate them for applications that can require extensive testing and qualification. During 2024, PF covered several stories that offer insights into this complex issue that has ramifications for the entire finishing industry.

PF attended the Metal Finishing Association of California’s (MFACA) annual legislation day event in May 2024 — an event that provides a forum for finishing operations in the state to voice their concerns to government officials. In an installment of PF’s On the Line podcast, we interviewed members of MFACA about the hexavalent chromium phase-out and other key issues for California-based finishers: short.pfonline.com/OTL44

While this fight for extending hexavalent chromium phase-out deadlines continues, many finishers are increasingly exploring alternative chemistries which are largely based on trivalent chromium chemistry. Yet, there are advantages and disadvantages of moving from hexavalent to trivalent baths. An article by Adam Blakeley of MacDermid Enthone Industrial Solutions published in the January 2024 issue of PF discusses important considerations to keep in mind for making a well-educated decision: short.pfonline.com/Crswitch

Digging further into the topic of trivalent solutions, Mark Schario of Columbia Chemical  contributed an article for the March 2024 issue of PF outlining several factors to consider when choosing between sulfate and chloride-based baths for trivalent chromium plating: short.pfonline.com/sulfchlortri

Wastewater technologies

Environmental stewardship in the surface finishing industry is always a big topic. Wastewater systems are essential for surface finishing operations, playing a crucial role in environmental protection, regulatory compliance, and operational efficiency. Surface finishing processes, such as electroplating, anodizing, and painting, generate a variety of waste materials, including heavy metals, chemicals, and other pollutants. If not properly managed, these pollutants can contaminate local water supplies, harm ecosystems, and pose health risks to surrounding communities. An effective wastewater system addresses these issues by treating and managing the wastewater generated by these processes.

Wastewater treatment systems require much thought when piecing together an effective process. Choosing the right equipment and understanding maintenance, lifespan and chemical impact is critical. In a July 2024 article, Robin Deal of Hubbard-Hall discusses considerations for successfully implementing a wastewater treatment system: short.pfonline.com/wwtshh

Coupling wastewater treatment with remote monitoring and data logging capabilities results in more consistent recovered water quality while simultaneously reducing user involvement and storing historical water quality data for review when needed. In an article from the January 2024 issue of PF, Chris Riley of Evoqua explores digital monitoring solutions for wastewater recovery: short.pfonline.com/smrtww

Of course, any discussion about wastewater today involves a discussion about PFAS chemicals, often dubbed “forever chemicals,” which have found their way into everything from our water supply to everyday products, raising concerns about their impact on health and the environment. New regulations involving these substances present new challenges for manufacturing in all areas, including surface finishing operations. In September 2024, PF’s On the Line podcast interviewed Louis LeBrun, vice president of sales with Axine Water Technologies, an industrial water and wastewater treatment company that specializes in an electrochemical oxidation technology named ElectraCLEAR that is designed to eliminate PFAS compounds. Check out the episode here: short.pfonline.com/OTL48

AI and automation

AI and automation are transforming the entire manufacturing landscape, offering new ways to enhance precision, efficiency and sustainability. As the industry faces challenges related to labor shortages, stringent regulatory requirements and the push for sustainable practices, adopting AI-driven solutions and automation technology is increasingly seen as essential for maintaining competitive advantage. In 2024 PF explored some of the ways surface finishers are implementing these solutions.

Finishing processes such as grinding, sanding, painting, polishing and buffing can be highly repetitive and physically demanding tasks. Yet, despite its repetitive nature, so much surface finishing work has traditionally been performed by hand. A PF feature from July 2024 explores how AI startup GrayMatter Robotics offers solutions for self-programming automation of different tools prevalent in manual surface finishing operations including sanding, polishing, grinding, buffing, painting, coating, deburring, trimming, sandblasting and laser ablation: short.pfonline.com/gmai

Meanwhile, implementing automation by way of robotic powder coating can help powder coaters reach their environmental, social and governance (ESG) goals. Read more from Nicolas Gervais of Carlisle Fluid Technologies in this automation clinic story from August 2024: short.pfonline.com/robopc

Finishing alternative substrates

As industries strive to innovate and meet demands for lightweight, durable and sustainable products, there is a notable trend toward using alternative substrates in manufacturing. Traditional materials like steel and aluminum are increasingly being supplemented or replaced by advanced alloys, plastics and composites in sectors such as automotive, aerospace, electronics and consumer goods. These alternative substrates offer unique advantages; however, these substrates have different surface properties, including porosity and reactivity which can make traditional metal-finishing techniques unsuitable. To ensure durability and protect against environmental exposure, manufacturers need advanced finishing solutions like low-temperature coatings, flexible primers and chemical treatments specifically designed for lightweight materials.

In a story featured in the January 2024 issue of PF, Stephanie Hendrixson, executive editor at Additive Manufacturing Media, offers a look inside RePliForm, a Baltimore-area company that specializes in the electroplating of 3D printed plastic parts with the goal of enhancing the structural properties of additively manufactured parts: short.pfonline.com/3dpp

Then in May 2024, PF explored GreenPOP, an adhesional pretreatment technology for plating on plastics and composites parts developed by Alliance Finishing and Manufacturing: short.pfonline.com/gpop

With the constant goal of lightweighting, aerospace component manufacturers are increasingly turning to advanced plastics and composite materials. Interconnect devices made from such materials often require plated metal finishes for connectivity or shielding properties. This October 2024 feature story explores surface finishing solutions available for aerospace connectors: short.pfonline.com/aercc

Meanwhile, advancements in powder coating technology make it a viable surface finish for a growing number of applications using advanced plastics or composites: short.pfonline.com/pccomp

Workforce and industry education

The surface finishing industry, like many manufacturing sectors, is facing significant workforce challenges, including an aging workforce, a shortage of skilled labor, and the need for specialized training in increasingly complex processes. However, these challenges also bring unique opportunities for innovation, skill development, and attracting a new generation of workers to the industry. By focusing on workforce development, the industry can enhance productivity, quality, and sustainability, positioning itself for a competitive future.

In this article from May 2024, PF senior editor Lori Beckman offers a roundup of educational initiatives in the industry offer training/learning opportunities for professionals who are entering the industry to seasoned employees as well as introductory programs for high school and college students: short.pfonline.com/wfed

Meanwhile, an episode of PF’s On the Line podcast sits down with Holly Gottfredson, president of American Metal Craft Inc. and Finishing Dynamics, about gender roles in manufacturing and finishing, and the importance of education in fostering a workforce for the future of the industry. Read an excerpt or stream the episode here: short.pfonline.com/OTL41

In June 2024, Products Finishing attended the SUR/FIN 2024 surface finishing industry trade show, where the National Association for Surface Finishing (NASF) announced a rebranding aimed at unifying various aspects of the organization, including its educational foundation, as well as its various chapters. We heard from Vince Noonan, president of the NASF Foundation, about some of these changes and what they mean for the finishing industry: short.pfonline.com/OTL47

Innovation in electroless nickel

Electroless nickel plating is a process that has become increasingly critical in modern manufacturing, offering exceptional wear and corrosion resistance. Unlike traditional nickel electroplating, this method requires no electric current, relying instead on a chemical reduction to coat a substrate with a uniform layer of nickel alloy. Today, the market for electroless nickel plating is rapidly expanding, fueled by advances in technology, rising demand across industries, and the need for durable, cost-effective solutions in extreme environments.

The automotive sector is a primary driver of growth in electroless nickel plating. Automotive components, such as fuel injectors, brake calipers, and engine parts, often require surfaces resistant to friction and corrosion to meet durability and performance standards. With the surge in electric vehicles (EVs) and hybrid technology, the need for nickel-plated components is rising, particularly for battery connectors and electrical contacts, which benefit from nickel's excellent conductivity and anti-corrosive properties.

This PF feature article from May 2024, contributed by Ambrose Schaffer of MacDermid Enthone Industrial Solutions, discusses the ways in which EVs present exciting new opportunities for additional growth of the use of electroless nickel plating in the automotive market for several critical components: short.pfonline.com/enev

If you’re looking to take advantage of some of the growing need for EN, this overview by Mark Adams of Columbia Chemical can help you understand the benefits of EN and appropriate applications: short.pfonline.com/benen

And for even more help adding EN to your current capabilities, this article by Travis Johnson of Cooperative Plating discusses three categories that are the ultimate deciding factor when it comes to choosing EN chemistry: the deposit properties of the technology; tools and equipment necessary to run the solution; and the cost associated with the chemistry: short.pfonline.com/chooen

Looking back to look forward

As the year draws to a close, we hope you enjoyed this retrospective of some of the industry trends and topics that PF explored in 2024. Of course, these stories are only the tip of the iceberg when it comes to some of the important topics that finishers need to stay informed about in order to stay relevant in the ever-changing manufacturing landscape. We encourage you to explore our archives for more of the latest industry trends and technologies, evergreen fundamental articles and educational offerings, and much more. Here’s wishing you a prosperous 2025!