High modulus laser direct structuring polycarbonate composites with enhanced plating performance and broad laser window and methods for the manufacture and use thereof

A method for making a molded article, comprising:

• 1. forming a blend composition comprising
• a. from about 20% by weight to about 84% by weight of a polycarbonate polymer,
• b. from about 1% by weight to about 10% by weight of a laser direct structuring additive capable of being activated by electromagnetic radiation to form an elemental metal nuclei,
• c. from about 10% by weight to about 50% by weight of a reinforcing filler, and
• d. from about 5% by weight to about 20% by weight of a laser direct structuring synergist comprising a polycarbonate-polysiloxane copolymer, a branched polycarbonate, or a combination thereof,
• 2. forming the molded article from the blend composition;
• and
• 3. subjecting the molded article to a laser direct structuring process,
• wherein
• the polymer composition has an enhanced laser plating efficiency of at least 10% relative to a substantially identical reference composition in the absence of the laser direct structuring synergist,
• the molded article has a notched Izod impact energy at 23° C. of from about 100 J/m to about 165 J/m,
• the polymer composition is capable of being plated after being activated using a laser, and
• weight percentages are relative to total weight of the polymer composition.

An article molded from a polymer composition comprising:

• a. from about 20% by weight to about 84% by weight of a polycarbonate polymer;
• b. from about 1% by weight to about 10% by weight of a laser direct structuring additive capable of being activated by electromagnetic radiation to form an elemental metal nuclei;
• c. from about 10% by weight to about 50% by weight of a reinforcing filler;
• and
• d. from about 5% by weight to about 20% by weight of a laser direct structuring synergist comprising a polycarbonate-polysiloxane copolymer, a branched polycarbonate, or a combination thereof;
• and
• wherein
• the article has an enhanced laser plating efficiency of at least 10% relative to a substantially identical article in the absence of the laser direct structuring synergist,
• the article has a notched Izod impact energy at 23° C. of from about 100 J/m to about 165 J/m,
• the article is capable of being plated after being activated using a laser, and
• weight percentages are relative to total weight of the polymer composition.