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Electroforming
Electroforming is an industrial process allowing the manufacture or reproduction of impressions, also called electroforms produced by the electrolytic deposition of a metal on a mandrel.
The benefits of electroforming
- Precision: Allows very fine and precise details to be reproduced at the atomic scale.
- Complexity: Possibility of producing very complex geometric shapes and openings finer than the thickness of the material itself.
- Homogeneity: Homogeneous metallic structure and regular hardness
- Durability: No signs of breakage or sharp edges
The principle of electroforming
Electroforming is a manufacturing process that creates metal parts by depositing metal on a mandrel (or model) using electrolysis. Here are the main steps and characteristics of this process:
- Preparation of the mandrel: A template or mandrel, usually made of conductive material covered with a non-conductive coating, is prepared. This mandrel is a replica of the final shape of the object to be produced.
- Electrolytic bath: The mandrel is immersed in a bath containing a suitable electrolytic solution, which contains metal ions of the metal to be deposited. This bath is equipped with an anode made of the metal to be deposited.
- Electrodeposition: An electric current is applied between the anode (source metal) and the mandrel (cathode). The metal ions migrate to the conductive surface of the mandrel and are deposited there as solid metal, forming a metallic layer that faithfully reproduces the shape of the mandrel.
- Mandrel Removal: Once the desired metal thickness is achieved, the mandrel is removed. Depending on the mandrel material, it may be dissolved, melted, or mechanically removed. The final product is a hollow or partially hollow metal part, retaining the dimensions and surface finish of the mandrel with definition at the atomic scale.
Few metals are electroformed (nickel, copper, silver, gold, etc.). Nickel is by far the most used because of its good mechanical strength and its resistance to corrosion and wear.
Potential applications
Electroforming is used in various industries to manufacture complex and precise components. Some example applications include:
- Mold Making: Used for plastic injection molding or compression molding.
- Aeronautics: Sprockets, blade leading edges, structural parts
- Electronic components: Production of printed circuits and other electronic parts, leadframes.
- Optics: Manufacturing of complex lenses and mirrors for optical devices.
- Energy: Stencils for solar cells
- Medical: Nebulizers, endoscope parts