Industrial Plating for Every Shape & Size
Every part plates differently, which is why our zinc and zinc-nickel processes are designed to handle a wide range of part types.
From long tubing and welded frames to threaded fasteners, castings, and machined components, each part is set-up for processing based on its geometry and finish requirements.
At Gatto, we evaluate each part before production to ensure a consistent, repeatable result. Whether the job involves thousands of small hardware pieces or large structural assemblies, our capacity and experience allow us to deliver dependable finishes at scale.
Explore Common Part Types
- Electronic Enclosures & Frames : We have techniques to minimize, and in some cases eliminate, bleed-out from seams and welds, resulting in a more uniform finish.
- Cabinets, Boxes & Housings : We address low-current density surfaces, and air-pocket-prone corners, to help minimize voids and uneven plating.
- Tubing : We control internal rust in straight and bent tubing through cleaning, drainage, and corrosion control throughout processing.
- Large Bolts & Fasteners : We handle large bolts, studs, and heavy fasteners using rack plating and post-plating baking to meet performance requirements.
- Specialty Steel Products (Bar Stock, Threaded Rod, Square Tube, Channels, Cable Tray, Etc.): We process high volumes of long steel products using large rack lines designed for efficient handling and predictable turnaround.
- Precision Sheet Metal : We focus on careful handling and process control to limit finish variation on large, flat, sheet metal surfaces.
- Hydraulic Blocks : We address internal corrosion for high-value blocks, where internal surfaces cannot be protected by electroplating, both before and after plating.
- Hinges : Our rack and barrel plating lines can handle hinges of almost any size.
- Stampings : We handle stampings in both bulk and rack processing.
- Machined Components : We manage plating thickness on functional surfaces to help protect critical dimensions and prevent over-plating.
- Weldments & Fabrications : We address the challenges welds, closed spaces, and complex geometries present, to deliver consistent coverage on fabricated parts.
- Wire Forms : We routinely process large volumes of wire-formed products. Our capacity allows us to provide reasonable and reliable lead times.
How Zinc Plating Behaves Across Different Part Types
Every part type presents its own challenges. Solving them starts with understanding how plating works.
The Science Behind Reliable Results
Even similar parts can plate differently. During electroplating, current naturally concentrates on sharp edges and outer surfaces, while recessed areas, threads, and interior surfaces receive less coverage. How a part is mounted (its rack position, spacing, and contact points) directly influences how zinc builds, plating thicker in high-current areas and thinner where current is limited. Careful setup is essential to achieving the most consistent coverage possible across the part.
Our team uses its knowledge and experience to determine the best orientation for each part. The goal is to provide uniform thickness, maximum coverage, and proper drainage to prevent air pockets when possible.
That combination of expertise and control is what helps us deliver reliable plating results across all part types.
Built to Solve Plating Challenges
Plating challenges often begin in the design, handling, or set-up stages. Over decades, we’ve refined each step of our process to minimize the variables that lead to rework, inconsistencies, and production delays.
- Bleed-out Prevention: Enhanced rinsing, part orientation, and extended dry times help eliminate plating solution from seams, cavities, and tube interiors.
- Improved Coverage In Low-Current Areas: Part orientation, proper fixturing, and spacing, are critical to achieving a uniform coating.
- Controlled Coating Thickness: Plating baths are regularly monitored to ensure the process consistently meets thickness, adhesion and corrosion resistance requirements.
- High-Volume Capability: We have high-capacity rack and barrel plating lines to provide consistent turnaround time on all part types
Our team performs both pre- and post- inspections to help identify potential issues and prevent them when possible.
Every lot is tested for thickness and examined to ensure the coating meets adhesion and appearance requirements
Setting Clear Expectations
Communication is essential to providing a finish that meets expectations. We work with customers early to align on finish goals, coating thickness, and handling details so the process fits both the part and its performance needs.
Prior to production, we review drawings, discuss potential risk areas, and explain how geometry or material can influence finish outcomes. That early alignment prevents surprises, reduces rework, and ensures your parts meet the appearance and performance standards your customers expect.
If you're ready for a quote or have questions about a finish, we're here to help. We'll walk through the finish, process, or specification details so you can move forward with confidence.
Located in Chicago, we reach 65% of the U.S. in a day, lowering freight costs, reducing lead times, and enabling direct shipping to your customer.
With 210,000 sq. ft., we process full truckload orders efficiently, keeping parts organized and on schedule with dedicated staging, processing, and tracking.
Flaking, bleed-out, poor adhesion, we catch plating issues early before they turn into costly problems.
From fast quotes to clear answers, we simplify the plating process so you can focus on the rest of your project.
Contact Our Plating Experts
Whether you know exactly what you need or just need to talk it through, we’re here to help with quick turnaround times and expert guidance.