Electropoli - metal surface treatments and finishing technologies
Electropoli - metal surface treatments and finishing technologies
Electropoli - metal surface treatments and finishing technologies

R & D

A R&D center at the service of industrial performance, technological innovation, and sustainable responsibility with 31 patents/trademarks filed since 1992.

Denis Morice, senior expert in custom surface treatment and co-engineering at Electropoli

“Useful innovation, sustainable industrialization.

Our ambition is to combine industrial performance, technological innovation, and environmental responsibility. We transform your needs into robust, scientifically validated solutions, which are then transferred into production at our European sites.

Our priorities: high performance, energy efficiency, replacement of CMR substances, and REACH anticipation.

Together with our customers and partners, we are designing today the surface treatments of tomorrow.”

Denis MORICE
Group R&D Director

A structured method, from the laboratory to industrial transfer

Our approach covers initial scoping, laboratory testing, formulation, corrosion testing, feasibility validation, pilot lines, and finally, on-site transfer.

This approach guarantees reproducibility, risk control, and reliable deployment across multiple plants when necessary.

 

An integrated R&D center dedicated to industrial performance

Based in France and accredited by the Research Tax Credit (CIR), our Electro-Research center brings together engineers, doctors of chemistry, technicians, and specialized students.

With the support of our factories, they develop new baths, optimize existing processes, and support large-scale industrialization.

Our analytical resources guarantee the quality and reliability of results:

Advanced analyses: ICP, chromatography, X-ray fluorescence, scanning electron microscopy.

Multiple cyclic corrosion tests: salt spray (SS), CASS, ECC1.

Physical measurements: thickness, adhesion, internal stresses…

Pilot lines for technical validation prior to industrial deployment.

 

Our key areas of expertise

We focus our efforts on the major challenges facing the industry:

· Developing solutions that comply with new regulations (REACH, PFAS, RoHS).

· Design of low-emission processes optimized for energy and water consumption.

· Substitution of hexavalent chromium and CMR substances.

· Treatments adapted to materials of the future: light alloys, batteries, magnets, electric mobility devices.

We create now the future of surface treatments

Our project portfolio covers industrial and academic partnerships, with 31 patents already filed since 1992.

2019-2027

Nickel free surface treatment


Zn high % Fe deposition vs ZnNi coating with the same performances.
Target: Anticipate possible future regulation compliance vs Nickel.
Partnership : IRT Zephyr, Airbus, Nexter, Aerospace

2020-2028

Ecological surface treatment for bushes anti-vibration market


Zn + Polymer deposition vs ZnNi coating.
Target: Cost savings & Adhesion and anticorrosion enhancement vs traditional ZnNi coating
Electropoli R&D, UTINAM Besançon

2024-2028

Environmentally friendly processes


Target: Zero reject approach CO2 neutral. Electropoli R&D

2022-2027

Surface treatment for new magnets


(with less rare earth elements)
Target: Environmental & Cost savings. Anticorrosion plating on Magnets.
Partnership : CEA, Orano

2026

Surface treatment for new electrical battery pack


(Next generation)
Target: Electrical conductivity and/or insulation - Adhesion enhancement Fire retardancy.
Electropoli R&D

2024-2027

Hard Trivalent Chromium


Target: Avoiding use of hexavalent chromium Partnership : IRT Neptune

Proven expertise in the field :

  • More than 70 years of experience in surface treatments.
  • 31 patents/registered trademarks.
  • International presence: France, Poland, Czech Republic, China.
  • Complete management of your projects: from idea to series delivery.

Tailor-made services

Collaborative development


At Electropoli, we design tailor-made surface treatment solutions in close collaborations with our customers.
Our ambition is to create sustainable and innovative processes that meet the technical and environmental requirements of each application in the Mobility, Aerospace, Defense, and General Industry sectors.

From idea to industrialization


From analysis of specific needs to industrial validation, Electropoli adapts products and processes – preparation, treatments, finishing – to your parts from the design phase.
Prototyping, pre-series testing, co-engineering, and dedicated tooling ensure a complete, reliable industrialization process.

concrete examples of
developments

Electropoli industrializes a customized surface treatment solution for large electric battery components


 

Electropoli industrializes a customized surface treatment solution for coupling drill pipe sleeves


 

Electropoli develops a dedicated surface treatment area for missile launch pad components


 

Electropoli industrializes interference-fit bushes assembly for aircraft landing gear


 

concrete examples of
developments

Electropoli industrializes a customized surface treatment solution for large electric battery components


 

Electropoli industrializes a customized surface treatment solution for coupling drill pipe sleeves


 

Electropoli develops a dedicated surface treatment area for missile launch pad components


 

Electropoli industrializes interference-fit bushes assembly for aircraft landing gear


 

Denis Morice, senior expert in custom surface treatment and co-engineering at Electropoli

Do you have a project?
An idea to develop?
A specific need to be validated?

LET’S TALK TOGETHER.
+33 (0)6 87 80 43 26

By collaborating with Electropoli, which is CIR approved, your R&D projects can benefit from a 30% tax credit.

Electropoli industrializes a customized surface treatment solution for large electric battery components

Customer need

Ensure the industrial processing of large electric battery components, combining high production volumesdemanding quality standards, and environmental compliance, through a dedicated surface treatment line.

Electropoli setup​

Electropoli conducted an in-depth analysis of the technical, logistical and industrial requirements, leading to the design of a tailor-made surface treatment line adapted to large electric battery components.​

The solution consists of two interconnected, fully automated processing lines combining zinc-nickel and cataphoretic (E-coat) coatings, operating in tandem to ensure consistent and controlled surface treatment at industrial scale.​

Robotized handling module is also taking care of part transfer to lasering cell, supporting touchless approach, from raw part packaging to finished goods packaging.

Following client approval, the dedicated line was assembled and industrialized at our Nowa Sól site in Poland, enabling stable high-volume production under demanding quality and environmental requirements.

Achievement

  • Stable high-volume output, supported by adedicated and fully automated surface treatmentline designed for large components.
  • Consistent quality performance at industrial scale,ensuring repeatability across high production volumes.
  • Reduced environmental footprint, achieved through heat recovery systems, recycling loopsand reduced water consumption.
  • Compliance with future regulatory requirements, through the use of chemical components aligned with upcoming standards.
  • Full traceability and process monitoring, enabled by onboard sensors supporting quality control and smart preventive maintenance.
KUKA industrial robot arm automating the handling process on the surface treatment line

Behind this achievement are dedicated engineers, technicians, automation specialists, andoperators.

Our goal: to combine industrial excellence, technical innovation, and respect for the environment.

This module is now a showcase of what we can offer our customers facing complex and specific challenges.

KUKA industrial robot arm automating the handling process on the surface treatment line
KUKA industrial robot arm automating the handling process on the surface treatment line

Electropoli industrialises a customised surface  treatment solution for coupling drill pipe sleeves

Customer need

Develop a surface treatment solution for coupling tubular sleeves with internal female threads. The components must with stand at least five tightening and loosening cycles without losing their mechanical coupling and anticorrosion properties.The treatment must be applied to the inside of the threaded tubular parts(approximately 400 mm long, various diameters), while preserving the integrity of the surface and dimensional accuracy.

Electropoli setup

Electropoli conducted a one-year R&D program to develop a ternary alloy coating aligned with the customer’s functional requirements.

After customer validation, a dedicated and scalable surface treatment line was designed and fully industrialized. The line was engineered to process around ten different references and three base materials, requiring adapted pre-treatment sequences.

Specific control solutions were implemented to treat and inspect internal female threads, including 90° probe-based inspection systems.

Achievement

  • Successful commissioning and operation of the dedicated surface treatment line, fully compliant with the customer specifications.
  • Five years after start-up, technical and industrial upgrades enabled the integration of a second coating process (binary alloy treatment) on the same line, ensuring long-term adaptability and customer satisfaction.

Electropoli develops a dedicated surface treatment ​area for missile launch pad components

Customer need

To protect the missile base against corrosion during long-term storage over several years, while maintaining electrical conductivity by keeping large areas of the component uncoated.
Achieve a significant increase in annual production volumes for sensitive missile
launch pad components.

Components are deployed in naval and land-based defense environments, requiring high reliability and surface integrity.

Electropoli setup

Electropoli created a fully dedicated working area to manage the increased production volumes of sensitive parts.

The area integrates specific equipments adapted to heavy components (up to 80 kg), including blasting units, masking stations, specific tooling and dedicated lifting systems.

Operators were specifically trained to perform these multi-step manual operations in compliance with defense standards and strict surface protection requirements.

Achievement

  • Implementation of a dedicated production area designed tomeet the customer’s quantitative and technical requirements.
  • Establishment of a long-term and trusted partnership with theOEM, supported by more than ten years of experience in thistype of surface treatment for defense applications.

Other parts we can treat

Do you know that this treatment requires 12 steps ?

Degreasing Rinsing Drying

Degreasing
Rinsing
Drying

Masking

Masking

Sandblasting

Sandblasting

Degreasing Rinsing

Degreasing
Rinsing

Phosphating Trication

Phosphating
Trication

Rinsing

Rinsing

Cataphoretic Coating

Cataphoretic
Coating

Rinsing

Rinsing

Baking

Baking

Cooling

Cooling

Inspection

Inspection

Demasking Finishing

Demasking
Finishing

Electropoli industrializes interference-fit bushes
assembly for aircraft landing gear

Customer need

Secure a critical fit to prevents movement
(fretting), assure functional performance and corrosion while maintaining  long-term reliability.

Parts range from 10 cm to 1 m and up to 30 kg, with zinc-nickel coated bushes in bronze or stainless steel.

Certifications

This process has been qualified through multiple certifications covering Corban fitting, marking and sealant application operations, confirming our ability to control the operation.

Electropoli setup

Electropoli implemented a multi-step, high-precision interference-fit assembly, enabling the insertion of rings intometallic components without altering existing surface treatments. While the bushing is placed in liquid nitrogen toshrink its diameter, the housing is heated in order to extend the dimension and ease the installation.

The fitting is performed manually to ensure maximum control and surface protection, using:
• dedicated positioning tools to facilitate and secure the operation,
• aluminium or copper drifts to ensure the proper alignment,
• lubricants selected according to applicable configurations and requirements.

Achievement

  • A dedicated team specialized for this process.
  • A robust, repeatable interference-fit assemblyprocess industrialized for sensitive aeronauticparts.
  • Surface treatments preserved throughout the operation,maintaining corrosion resistance and functionalperformance.
  • A validated method developed with on-site support fromSafran SLS engineers, ensuring alignment with expectedrequirements.

The reliability of a mechanical assembly often dependson details that remain invisible. 

Interference-fit ring assembly is one of them.

Aircraft ring

Electropoli industrializes a customized surface treatment solution for large electric battery components

Customer need

Ensure the industrial processing of large electric battery components, combining high production volumesdemanding quality standards, and environmental compliance, through a dedicated surface treatment line.

Electropoli setup​

Electropoli conducted an in-depth analysis of the technical, logistical and industrial requirements, leading to the design of a tailor-made surface treatment line adapted to large electric battery components.​

The solution consists of two interconnected, fully automated processing lines combining zinc-nickel and cataphoretic (E-coat) coatings, operating in tandem to ensure consistent and controlled surface treatment at industrial scale.​

Robotized handling module is also taking care of part transfer to lasering cell, supporting touchless approach, from raw part packaging to finished goods packaging.

Following client approval, the dedicated line was assembled and industrialized at our Nowa Sól site in Poland, enabling stable high-volume production under demanding quality and environmental requirements.

Achievement

  • Stable high-volume output, supported by adedicated and fully automated surface treatmentline designed for large components.
  • Consistent quality performance at industrial scale,ensuring repeatability across high production volumes.
  • Reduced environmental footprint, achieved through heat recovery systems, recycling loopsand reduced water consumption.
  • Compliance with future regulatory requirements, through the use of chemical components aligned with upcoming standards.
  • Full traceability and process monitoring, enabled by onboard sensors supporting quality control and smart preventive maintenance.
KUKA industrial robot arm automating the handling process on the surface treatment line

Behind this achievement are dedicated engineers, technicians, automation specialists, andoperators.

Our goal: to combine industrial excellence, technical innovation, and respect for the environment.

This module is now a showcase of what we can offer our customers facing complex and specific challenges.

KUKA industrial robot arm automating the handling process on the surface treatment line
KUKA industrial robot arm automating the handling process on the surface treatment line

Electropoli industrialises a customised surface  treatment solution for coupling drill pipe sleeves

Customer need

Develop a surface treatment solution for coupling tubular sleeves with internal female threads. The components must with stand at least five tightening and loosening cycles without losing their mechanical coupling and anticorrosion properties.The treatment must be applied to the inside of the threaded tubular parts(approximately 400 mm long, various diameters), while preserving the integrity of the surface and dimensional accuracy.

Electropoli setup

Electropoli conducted a one-year R&D program to develop a ternary alloy coating aligned with the customer’s functional requirements.

After customer validation, a dedicated and scalable surface treatment line was designed and fully industrialized. The line was engineered to process around ten different references and three base materials, requiring adapted pre-treatment sequences.

Specific control solutions were implemented to treat and inspect internal female threads, including 90° probe-based inspection systems.

Achievement

  • Successful commissioning and operation of the dedicated surface treatment line, fully compliant with the customer specifications.
  • Five years after start-up, technical and industrial upgrades enabled the integration of a second coating process (binary alloy treatment) on the same line, ensuring long-term adaptability and customer satisfaction.

Electropoli develops a dedicated surface treatment ​area for missile launch pad components

Customer need

To protect the missile base against corrosion during long-term storage over several years, while maintaining electrical conductivity by keeping large areas of the component uncoated.
Achieve a significant increase in annual production volumes for sensitive missile
launch pad components.

Components are deployed in naval and land-based defense environments, requiring high reliability and surface integrity.

Electropoli setup

Electropoli created a fully dedicated working area to manage the increased production volumes of sensitive parts.

The area integrates specific equipments adapted to heavy components (up to 80 kg), including blasting units, masking stations, specific tooling and dedicated lifting systems.

Operators were specifically trained to perform these multi-step manual operations in compliance with defense standards and strict surface protection requirements.

Achievement

  • Implementation of a dedicated production area designed tomeet the customer’s quantitative and technical requirements.
  • Establishment of a long-term and trusted partnership with theOEM, supported by more than ten years of experience in thistype of surface treatment for defense applications.

Other parts we can treat

Do you know that this treatment requires 12 steps ?

Degreasing Rinsing Drying

Degreasing
Rinsing
Drying

Masking

Masking

Sandblasting

Sandblasting

Degreasing Rinsing

Degreasing
Rinsing

Phosphating Trication

Phosphating
Trication

Rinsing

Rinsing

Cataphoretic Coating

Cataphoretic
Coating

Rinsing

Rinsing

Baking

Baking

Cooling

Cooling

Inspection

Inspection

Demasking Finishing

Demasking
Finishing

Electropoli industrializes interference-fit bushes
assembly for aircraft landing gear

Customer need

Secure a critical fit to prevents movement
(fretting), assure functional performance and corrosion while maintaining  long-term reliability.

Parts range from 10 cm to 1 m and up to 30 kg, with zinc-nickel coated bushes in bronze or stainless steel.

Certifications

This process has been qualified through multiple certifications covering Corban fitting, marking and sealant application operations, confirming our ability to control the operation.

Electropoli setup

Electropoli implemented a multi-step, high-precision interference-fit assembly, enabling the insertion of rings intometallic components without altering existing surface treatments. While the bushing is placed in liquid nitrogen toshrink its diameter, the housing is heated in order to extend the dimension and ease the installation.

The fitting is performed manually to ensure maximum control and surface protection, using:
• dedicated positioning tools to facilitate and secure the operation,
• aluminium or copper drifts to ensure the proper alignment,
• lubricants selected according to applicable configurations and requirements.

Achievement

  • A dedicated team specialized for this process.
  • A robust, repeatable interference-fit assemblyprocess industrialized for sensitive aeronauticparts.
  • Surface treatments preserved throughout the operation,maintaining corrosion resistance and functionalperformance.
  • A validated method developed with on-site support fromSafran SLS engineers, ensuring alignment with expectedrequirements.

The reliability of a mechanical assembly often dependson details that remain invisible. 

Interference-fit ring assembly is one of them.

Aircraft ring