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Discover our complete solutions portfolio covering Cathodic Protection and Corrosion management - PCB design and plating - Functional and decorative plating - Electrocoating - Acoustics
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Elsyca V-PIMS
A revolution in digital PIMS combining Pipeline Corrosion Integrity Management System (PIMS) and computational modeling capabilities
Elsyca IRIS
Deep analysis of AC threats and design and engineering of efficient mitigation systems
Elsyca CatPro
Graphical simulation platform for cathodic protection and DC stray current analysis of pipeline networks
Elsyca CPManager
3D CAD-based software simulation platform for the design and analysis of cathodic protection installations
Elsyca ACTA
Unique engineering service offering accurate, disambiguated, and tailored risk ranking report of pipeline networks
Plate
Elsyca PlatingManager
Leverage a digital twin of your plating line to predict plating performance and increase manufacturing capacity
Elsyca CuBE
Avoid signal integrity problems during the design phase using an upfront, accurate and easy DFM test
Elsyca PCBBalance
The world’s only PCB DFM software that applies automated and optimized copper balancing to your PCB design and panel layout.
Elsyca PCBPlate
State-of-the-art graphical simulation platform for enhancing the plating performance of your PCB panel and pattern plating processes.
Elsyca ECoatMaster
CAD independent software platform for the simulation of the automotive electrocoating process of a body-in-white (BIW).
Elsyca EPOS
Simulate the performances of electropolishing processes based on a virtual mock-up of the electropolishing cell.
Elsyca AnodizingManager
State-of-the-art graphical simulation platform for analyzing the production performance and quality of anodizing processes.
Innovate
Elsyca CorrosionMaster
CorrosionMaster identifies corrosion hot spots and predicts corrosion rates, enabling engineers to look at alternative material combinations and/or coating systems, or investigate corrosion-mitigating measures.
Elsyca LeakageMaster
Improve vehicles interior acoustic comfort by performing upfront virtual smoke tests.
Elsyca MeshingMaster
Automatically creates meshes for a variety of applications such as acoustics, CFD, thermal analysis, etc
Elsyca XPlorer
Interactive simulation results viewer for Finite Elements results

Electropolishing

Upfront assessment of electropolishing process performances

Controlling the quality of clean and smooth surfaces

The combination of our in-house CAE solutions and engineering services supports the development of effective electropolishing processes for a variety of components. Whatever the industry sector, from medical to aerospace, or the application, from sterilization to  post-production of 3D-printed parts, collaborating with Elsyca offers among other outcomes:

  • Insights into process performances including detection of operating window ensuring targeted surface quality (roughness, appearance) objectives;
  • The qualification of optimal process parameters including acid concentration, temperature, and imposed current;
  • The optimization of part load and rack configuration;
  • The design of prototype cell and tooling including technical drawing, and bill of materials delivery;
  • The characterization and sensitivity analysis of electropolishing baths;
Predict the microfinish precision of your electropolishing processes by an upfront assessment of the best-operating conditions

Did you know?

The process

Electropolishing is a process where a metal substrate (often steel, copper, brass, aluminum or titanium, but also a wide range of other metals and alloys) is immersed in an acid-containing electrolyte solution and an anodic electrical current is imposed onto it. This invokes a controlled corrosion process, effectively removing surface roughness and other surface irregularities, such as sharp edges caused by scratches, or burrs and hair-line surface cracks from preceding manufacturing steps. 

Although some electropolishing processes are based on non-aqueous electrolytes or ionic liquids, the vast majority of industrial electropolishing processes rely on an aqueous solution containing phosphoric acid, whether or not in combination with other acids like sulphuric acid or even fluoric acid.

The results

Electropolished surfaces are stress-free and smooth, significantly prolonging the lifetime of the processed device or part. Often electropolished surfaces have a mirrored appearance. the process also improves adhesion through the removal of oils and oxides, yielding a clean surface for any subsequent production step. 

Controlling the current density distribution and electrolyte refreshment (hence the effectiveness of the process) over the substrate is a major challenge for electropolishing processes. Low current density areas might lead to unacceptable roughness values, or even pitting of the substrate. High current density areas might lead to an excessive metal removal rate, thereby compromising the dimensional tolerances of the part, or might even lead to burning in more extreme cases.

The applications

Electropolishing is a surface treatment process that is applied to a huge variety of items, ranging from surgical devices (e.g. stents, needles, tubes) to sensors, valves, storage tanks, fasteners, cutting instruments, gears, shafts to even nuclear accelerators. 

Electropolishing provides an effective and efficient method for removing surface roughness and burrs or involuntary sharp edges that remain from preceding manufacturing steps.

Willing to know more about our solutions?