How Engineered the Iconic Gold Chain Installation through Vacuum Forming and Electroplating Craftsmanship

How the Iconic Gold Chain Installation through Vacuum Forming and Electroplating Craftsmanship

For Michael Kors’ flagship window display, we were commissioned to produce the striking giant gold chain installation that defines the store’s luxurious aesthetic.
Each chain link — polished to a mirror finish — symbolizes strength and connection, forming the sculptural centerpiece of the brand’s campaign.

By combining vacuum forming, precision assembly, and high-gloss electroplating, Transformed lightweight materials into metal-like works of art. The result is a seamless, reflective installation that captures both light and luxury — a true showcase of craftsmanship and engineering precision.

👁️ Project Background

Michael Kors’ creative team envisioned an environment built around the visual metaphor of connection: oversized interlocking chains rendered entirely in gold.
The concept required achieving architectural scale without sacrificing elegance, proportion, or light reflection.

The installation had to meet several key goals:

• A sculptural form with perfect curvature and no visible seams.

• A mirror-finished metallic surface with flawless reflection.

• Lightweight construction for easy in-store assembly.

• A consistent gold tone matching the brand’s color identity.

We can be responsible for 3D engineering, mold fabrication, vacuum forming, finishing, and plating — delivering the project from concept to completion.

⚙️ From Design to Production

The process began with 3D modeling. Using Rhino and SolidWorks, Samtop’s design engineers translated the creative sketches into detailed CAD geometry. Each curve and connection point was optimized for vacuum forming feasibility and visual balance.
Prototypes were produced to verify proportion, joint angle, and reflective behavior under retail lighting.

Once approved, full-scale molds were CNC-machined from polished aluminum. These molds allowed for precise vacuum forming of 5 mm ABS sheets, achieving smooth curvature and even wall thickness across the entire surface.

After forming, each link shell was trimmed, aligned, and joined using ultrasonic welding, ensuring structural integrity and eliminating visible seams. The joints were then meticulously sanded and polished by hand, progressing from coarse to micro-grit abrasives to achieve a perfectly smooth substrate ready for finishing.

💫 Surface Treatment & Electroplating

Creating a mirror-like gold surface on a plastic base was the project’s biggest challenge.
Samtop’s finishing experts applied a multi-layer coating system:

1. Base Preparation — A conductive primer layer ensured uniform electrical adhesion for plating.

2. Vacuum Metallization (PVD) — Gold-tone metal particles were deposited in a vacuum chamber using sputtering technology, producing a brilliant metallic finish with over 95% reflectivity.

3. Protective Clear Coating — A transparent PU top layer sealed the surface against oxidation, fingerprints, and UV damage.

The resulting finish was indistinguishable from real metal — light, durable, and visually flawless. Every surface reflected the store’s lighting like liquid gold, amplifying the luxury feel of the Michael Kors environment.

🔩 Engineering the Structure

Despite their large size, the chain links had to remain lightweight for easy transport and installation.
Each hollow form concealed a stainless-steel skeleton, precisely welded to hold its shape while distributing weight evenly.

Samtop’s structural engineers calculated stress points to ensure stability when suspended or stacked. This hybrid design — metal inside, ABS outside — achieved the perfect balance between strength and elegance.

For sections that incorporated the “MK” logo within the chain link, CNC-machined inserts were electroplated simultaneously with the outer body, ensuring a perfectly matched tone and surface finish.

💡 Lighting & Visual Testing

After finishing, the gold chain elements were tested under various lighting temperatures — from 3000K warm white to 6500K daylight — to evaluate their reflective behavior.
The mirror finish performed exceptionally well, interacting dynamically with both ambient and spot lighting to create a sense of motion and depth.

The electroplated surface maintained consistent color across all components, verified through ΔE<1.0 color deviation testing.
Every piece was inspected under high-intensity light before packaging to ensure flawless presentation.

🏭 Manufacturing & Delivery

The project entered batch production following final approval.
Samtop’s workshop produced over a hundred chain modules in multiple sizes, each coded for assembly order.
Every component was polished, plated, and sealed within a dust-controlled environment, then carefully wrapped in protective foam and packed in shockproof wooden crates.

Upon delivery, the display system was assembled in-store within hours — no adjustments required.
The result: a monumental yet lightweight sculptural system, gleaming under spotlights, reflecting the Michael Kors brand’s signature sophistication.

✨ Results

The final installation achieved all creative and technical goals.
The reflective gold chain became a statement piece that immediately drew attention from passersby and elevated the entire store’s atmosphere.

• Visual impact: Dazzling mirror finish, creating a sense of luxury and energy.

• Seamless construction: No visible joints; fluid continuity across all elements.

• Color consistency: Perfectly matched gold tone across 100+ pieces.

• Durability: Resistant to wear, oxidation, and humidity for long-term display.

• Efficiency: Lightweight modular system allowed rapid global rollout.

Michael Kors’ VM team praised the craftsmanship for “turning industrial material into fashion sculpture.”

 Key Takeaways

1. Vacuum Forming Brings Monumental Scale to Life
   Large, organic shapes can be achieved with precision while keeping weight low.

2. Electroplating Adds the Luxury Finish
   PVD mirror coating transforms plastic into metal-like brilliance — durable, elegant, and sustainable.

3. Craftsmanship Meets Engineering
   From digital modeling to final polishing, every step demands attention to micro-detail to achieve a flawless result.

4. Samtop: From Factory to Flagship
   The success of this project reaffirms Samtop’s role as a global partner for custom visual merchandising manufacturing, delivering both artistry and reliability.