A shock-resistant actuator assembly for use in a data storage system is disclosed. The actuator assembly includes an actuator body, fabricated from a first type of metal, having a central aperture for pivoting on an actuator shaft. The actuator body includes at least one composite actuator arm extending outwardly from the actuator body. The composite actuator arm includes a primary arm member, also fabricated from the first type of metal, and a plating of a second type of metal having a thickness of at least 20 microns disposed on an upper and lower surface of the primary arm member. In one embodiment, the primary arm member is fabricated from aluminum and subjected to an electroless nickel plating process to deposit a sufficient thickness of nickel thereon to appreciably increase the stiffness of the primary arm member. In another embodiment, an actuator comb assembly includes a plurality of integral composite actuator arms for supporting a plurality of head suspension assemblies. The relatively thick plating of metal deposited on the primary arm member substantially enhances the stiffness and shock resistance of the composite actuator arm.