| Electroforming |
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Electroforming is a metal forming process that forms thin parts through the electroplating process. The part is produced by plating a metal skin onto a base form, known as a mandrel, which is removed after plating.[1] 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. |
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| In recent years, due to its ability to replicate a mandrel surface precisely atom-by-atom with practically no loss of fidelity, electroforming has taken on new importance in the fabrication of micro and nano scale metallic devices and in producing precision injection molds with micro and nano scale feature for production of nonmetallic micromolded objects. |
| Advantages and disadvantages |
| The main advantage of electroforming is that it reproduces the external shape of the mandrel within one micrometre. Generally, forming an internal cavity accurately is more difficult than forming an external shape, however the opposite holds true for electroforming because the mandrel's exterior can be accurately machined. |
| Compared to other basic metal forming processes (casting, forging, stamping, deep drawing, machining and fabricating) electroforming is very effective when requirements call for extreme tolerances, complexity or light weight. 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 wrought metal due to its refined crystal structure. Multiple layers of electroformed metal can be molecularly bonded together, or to different substrate materials to produce complex structures with "grown-on" flanges and bosses. |
| Tolerances of 1.5 to 3 nanometres have been reported.[citation needed] |
| A wide variety of shapes and sizes can be made by electroforming, the principal limitation being the need to strip the product from the mandrel. Since the fabrication of a product requires only a single pattern or mandrel, low production quantities can be made economically. |
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| GOLD |
PLATINUM |
SILVER |
COPPER |
PALLADIUM |
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