Electroforming is a photochemical production method that uses selective electrolytic plating to produce the specified part. An additive process is employed to construct metal parts on a metal substrate (a mandrel), and the resulting shape is based on a preliminary photolithography process. Electroforming technology enables the most precise production. It is ideal for miniature parts and particularly intricate mesh grids.
Metal construction using the electroforming method involves the following stages: Processing the product file obtained from the customer, then preparing the slides and a sheet of conductive metal (the metal substrate). The metal that is used as a conduit is cleaned and selectively masked by light-sensitive material (photoresist). The substrate metal sheet is immersed in an electrolyte bath and suspended in it for the required duration, until the metal parts are formed on top of the metal substrate, in the areas that are not masked.
When the electroforming process is complete, and the parts conform to the specified dimensions (in terms of height and thickness), the conductive metal and the metal parts attached to it are removed from the electrolyte bath. At the end of the process the formed metal parts are detached from the metal substrate, by chemically corroding the metal substrate. The parts are cleaned and transferred to the Quality Assurance department for visual inspection, and to check the dimensions.
Electroforming technology enables the production of top grade precision metal parts. The precision metal forming process integrates built-in quality assurance, thanks to the ability to control the duration that the conductive metal is immersed in the bath. This ensures the production of superior parts with high repeatability.
Electroforming Technical Details:
Thickness of Material: .0002″-.008″
Metal sheet Size: 22″X24″
• thick material and large area: +/- 0.004 “
• standard: +/- 0.002 “
• special: +/- .0002 “
Suron produce electroformed stencils with the licensed NiColoy® process, developed by NiCoForm, Inc.