The optimization of the electroless nickel plating process used for textile applications was investigated with the orthogonal array testing strategy. It was found that the electroless nickel plating process conducted at 40 degrees C and PH 10 for 20 min was the most effective method for improving the metal adhesion performance. The performance of nickel-plated polyester fabrics was confirmed to be dependent on the amount of nickel particles adhering to the fabric surface. The properties of the optimized nickel-plated polyester were enhanced in terms of the fabric weight, fabric thickness, and tensile strength. However, there was a moderate decrease in the tearing strength and crocking fastness. (C) 2008 Wiley Periodicals, Inc.