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Electroforming is a highly specialized process for fabricating a metal precision part or sieve by electrodeposition in a plating bath over a mandrel which is subsequently removed.
Electroforming should be thought of as a basic manufacturing process when considering alternatives best suited for making any particular metal precision part or filter. Other basic metal forming processes including stamping, photo etching, wire erosion and laser cutting may serve well for most applications, but can be pressed beyond their limits when requirements call for extreme tolerances, complexity or specific holeshape. Electroforming is a real problem solver in these instances.
The electroforming technology offers considerable advantages compared to etching, punching, laser-cutting and wire-erosion. The advantages of the electroforming process include:
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Extreme high precision (standard up to 5 micron holes with +/- 2 micron tolerance) |
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No burrs, no stress, naturally flat products (build up ion by ion) |
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Complex shapes possible |
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Sharp edge definition |
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Excellent reproducibility |
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Economical tooling and parts |
Electroforming is a highly cost-effective method for prototyping, small and (very) large series
The animation below describes the process.
The electroformed components are produced on a flat metal mandrel, which is cleaned and coated with light sensitive photo resist. The mandrel is then exposed to ultra violet light through the Photomaster. The resist on the unexposed area is developed away to produce a matrix. The metal mandrel is then immersed in the electroforming plating bath.
Carefully controlled electrolysis migrates metal atoms to the mandrel until the desired thickness is attained. Once the mandrel is removed from the solution and rinsed, the grown component can be separated from it.
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More information about:
Why is Electroforming superior to Chemical Etching?
Electroforming is an additive process and herein lies electroform´s superiority over etched metal and other forming technologies. 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.
Etched metal, EDM, and laser machining rely on the removal of material to form the desired features. All have limitations associated with one or more of the following: resolution; tolerancing; process repeatability; or cost. In etched metal the minimum opening diameter is limited to 1.5 times the metal thickness. EDM and laser machining have resolution limits and normally are more costly than electroforming. None of these alternatives provide the surface finish within the hole or aperture that electroforming does.
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