The process of electroforming
The process of electroforming is a highly specialized process for fabricating a metal part. Electroforming is a metal forming process that forms thin parts through the electroplating process. The process creates an electroform piece through electrodeposition of a base form (mandrel) in a plating bath. In this process, an electrolytic bath is used to deposit nickel or other electroplatable metal (gold, cupper) onto a conductive patterned surface, such as glass or stainless steel. Once the plated material has been built up to the desired thickness, the electroformed part is stripped off the master substrate.
This process differs from electroplating in that the plating is much thicker and can exist as a self-supporting structure when the mandrel is removed.
The electroforming process allows high-quality duplication of the master and therefore permits quality production with high repeatability and excellent process control. The process is therefore suited for high volume and low cost production.
Electroforming is very effective when requirements call for extreme tolerances, complexity or reapeatability compared to other metal forming processes like lasercutting, stamping, machining and fabricating. The precision and resolution inherent in the photographically produced conductive patterned substrate, allows finer geometries to be produced to tighter tolerances while maintaining superior edge definition with a near optical finish. Electroformed metal is extremely pure, with superior properties over basic metal due to its refined crystal structure.
This process differs from electroplating in that the plating is much thicker and can exist as a self-supporting structure when the mandrel is removed.
The electroforming process allows high-quality duplication of the master and therefore permits quality production with high repeatability and excellent process control. The process is therefore suited for high volume and low cost production.
Electroforming is very effective when requirements call for extreme tolerances, complexity or reapeatability compared to other metal forming processes like lasercutting, stamping, machining and fabricating. The precision and resolution inherent in the photographically produced conductive patterned substrate, allows finer geometries to be produced to tighter tolerances while maintaining superior edge definition with a near optical finish. Electroformed metal is extremely pure, with superior properties over basic metal due to its refined crystal structure.
The animation describes the process;
Technical specifications
Materials: Nickel
Material thickness (t) 0.010 - 0.2 mm
Tolerances general ± 0.010 - 0.015 mm, limit ± 0.002 mm
Minimum hole/slot 0.005 mm - t = 0.05 mm, > 0.05 mm = 0.3 t
Minimum bar-width 0.015 mm + 2t, thick resist system 1.5t
Pitch tolerances general ± 0.01 mm x distance, limit ± 0.005 mm x distance
Angular tolerances general ± 30² - 40² of arc, limit ± 20² of arc
Corner radii inner corner (r) = 90° angle, outer corner (r) = t
Post treatments blackened, gold, Ru, Pt, lead-tin plated
If your needs exceed the specifications listed our specialits are at hand assist you in searching for the right solution for your application.
More information about Electroforming
General contact information
Stork Veco BV
Karel van Gelreweg 22
6960 AA Eerbeek
The Netherlands
+31 (0) 313 672911
info.veco@stork.com
Stork Veco International, Inc.
15 A Street, Unit 2
Burlington, MA 01803-3404
USA
+1 781-425-6050
sales.vecousa@stork.com
