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In this paper, the optimisation of electroless nickel plating is investigated through the Orthogonal Array Testing Strategy. It was found that the electroless nickel plating process at the deposition stage with various parameters, i.e. temperature = 40°C, time = 20 minutes and pH = 10, is the most effective method in improving the metal adhesion performance. The performance of nickel-plated polyester fabrics was found to be dependent on the amount of nickel particles adhered on the fabric surface. The properties of optimised nickel-plated polyester were enhanced in term of fabric weight, fabric thickness and tensile strength. However, there was a moderate decrease in tearing strength and crocking fastness.

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