In the world of technology, we are obsessed with the new: AI, quantum computing, nanobots. Yet one of the most critical technologies underpinning our entire modern infrastructure is a process invented nearly 200 years ago. It’s not glamorous, but without it, the high-performance world we know would literally corrode and fall apart. As industries push the boundaries of performance, this legacy technology is more vital and innovative than ever.

Beyond the shine: the strategic impact of galvanization

Forget decorative chrome bumpers. Modern industrial galvanization is a high-stakes science of surface engineering. By applying a precisely controlled electric current, a microscopic layer of metal is deposited onto a component, fundamentally changing its properties at the molecular level. This isn’t just a coating; it’s a transformation. It’s how a common copper or aluminium busbar can be engineered to carry massive electrical currents with minimal resistance, or how a steel component can be given the corrosion resistance to endure thousands of hours of salt-spray testing.

The impact spans multiple sectors:

• Automotive: Zinc-nickel and tin plating protect underbody parts and connectors from road salt and corrosion, extending vehicle life and safety.
• Aerospace and heavy industry: Hard, wear-resistant coatings ensure reliability under extreme mechanical stress.
• Electronics and power systems: Silver, tin, and nickel plating on connectors, busbars, and PCB components ensure stable conductivity and reliable performance, even in harsh conditions.

A case study in innovation: the electric vehicle revolution

Nowhere is the quiet innovation of this field more visible than in e-mobility. Electric vehicle battery systems, busbars, and charging infrastructure rely on flawless, low-resistance connections. A micro-thin layer of silver or tin on copper conductors prevents oxidation, reduces heat generation, and ensures efficiency and safety. Without this protective shield, the reliability of the entire EV market would be compromised.

Electris Coating Systems has developed advanced galvanization lines that combine precision plating with selective powder coatings. This unique capability allows critical areas to remain highly conductive, while others are insulated with epoxy or polyester powders—an essential solution for high-voltage EV systems.

The future is coated: why this matters now

As industries accelerate toward electrification, renewable energy, and lightweight design, galvanization is becoming even more critical. It allows engineers to use cost-effective base materials such as copper or aluminium, while tailoring their surfaces with high-performance coatings only where needed. This reduces resource consumption, weight, and cost, while enhancing durability.

At Electris, innovation goes hand in hand with sustainability. Fully automated plating lines, in-house chemical laboratories, rigorous testing, and advanced wastewater treatment systems ensure both performance and environmental responsibility.

The lesson is clear: sometimes the most profound innovations don’t come from inventing something entirely new, but from perfecting and re-imagining the technologies we’ve had all along.