Processing–Structure–Property Relationships in Nickel‐Electroplated Stereolithography Epoxy Polymers

ABSTRACT This study investigates the influence of nickel electroplating as a post‐processing technique on the surface and mechanical performance of stereolithography (SLA) epoxy parts. Epoxy specimens were fabricated using three layer thicknesses (25, 50, 100 μm) and four build orientations (0°, 30°, 60°, 90°), followed by controlled nickel deposition producing coating thicknesses of 100–160 μm. Flexural strength tests (ISO 178) and surface roughness (Ra) analyses were evaluated to assess structural and surface modifications. Nickel coating significantly enhanced performance: maximum flexural strength increased from approximately 45–152 MPa, while surface roughness decreased from 0.9–2.3 μm to 0.35–0.60 μm. The coating reduced orientation‐dependent variability and mitigated anisotropy‐related weaknesses inherent to SLA fabrication. Cross‐sectional and fracture observations confirmed the formation of continuous and well‐adhered metallic layers without delamination. These results demonstrate that nickel electroplating is an effective surface engineering strategy for improving the mechanical reliability and surface quality of SLA‐fabricated epoxy components, thereby expanding their potential use in precision and load‐bearing applications.