Electroforming:
a tremendously accurate additive process

How does electroforming work?

A cleaned mandrel is coated with a photo sensitive material to UV light ➀. The image of the part to manufacture is transferred by insolation on the mandrel through a photo-tool as a mask ➁ ➂ . During the development of the image, the non-exposed areas to be plated are removed ➃. The electrodeposition of metal atoms on the matrix is made by electrolysis to build the parts ➄. Separation from the mandrel of the electroformed product completes the manufacturing process ➅.

With electroforming unrivalled accuracy can be achieved: close-tolerance of +/- 3 µm with 3 up to 80 µm thickness. It enables to achieve openings narrower than electrodeposition's thickness. For optical applications, we can offer deep black surface treatment on one or both sides of the product.

How does electroforming work?

An additive process enables to build the part atom-by-atom which ensures unrivalled micrometric accuracy.
Compatible with extreme complex shape, very narrow dam and very small opening.
A unique technology that guarantees burrs and stress free, no break point and no heat-affected zone (HAZ).
Low tooling cost.
High flexibility in case of design modification.
Short manufacturing time.
A process available for nickel or copper materials and compatible with an optical black surface treatment.

What are the advantages of electroforming compared to alternative processes?

Electroforming and chemical etching compete with alternative cutting processes: laser cutting, stamping, wire EDM and water jet cutting. Some processes are suitable for very thin metal strips and some others for thick metal sheets. Some are best suited for mass production and some for samples or medium quantities. The cutting quality and accuracy depend on the selected process.

Filter
Thickness 30µm
Dam 100µm
Aperture 400µm

Optical fence
Thickness 110µm
Fence 100µm
Both sides black surface treatment

Electroforming is characterized by an unrivalled accuracy. No other process offers the same high performance: very complex shapes, perfect cutting quality, extreme narrow dams and very small openings.

Quantities	Electroforming	Laser cutting	Stamping	Wire EDM	Water jet cutting	Photo etching
Samples or small quantities	VERY SUITABLE	VERY SUITABLE	NOT ADEQUATE TOO EXPENSIVE	ADEQUATE BUT DEPENDS ON THE NUMBER OF OPENING	VERY SUITABLE	VERY SUITABLE
Medium quantities	VERY SUITABLE	ADEQUATE	NOT ADEQUATE TOO EXPENSIVE	ADEQUATE BUT DEPENDS ON THE NUMBER OF OPENING	ADEQUATE	VERY SUITABLE
Big quantities	ADEQUATE	NOT ADEQUATE TOO SLOW	VERY SUITABLE	NOT ADEQUATE TOO SLOW	NOT ADEQUATE TOO SLOW	ADEQUATE

Material	Electroforming	Laser cutting	Stamping	Wire EDM	Water jet cutting	Photo etching
Compatibility with thin material	YES	NO	YES	NO	NO	YES
Compatibility with thick material	NO	YES	YES	YES	YES	MEDIUM
Hardness of material	ONLY NICKEL AND COPPER	COMPATIBLE	NOT ALWAYS COMPATIBLE	NOT ALWAYS COMPATIBLE	NOT ALWAYS COMPATIBLE	COMPATIBLE

Cutting quality	Electroforming	Laser cutting	Stamping	Wire EDM	Water jet cutting	Photo etching
Burrs	NONE	WITH	WITH	WITH	WITH	NONE
Stress and breaking point	NONE	NONE	WITH	MEDIUM	MEDIUM	NONE
Heat-affected zone (HAZ)	NONE	WITH	NONE	WITH	NONE	NONE

Accuracy and flexibility	Electroforming	Laser cutting	Stamping	Wire EDM	Water jet cutting	Photo etching
Average accuracy (% of the thickness)	+/- 5%	+/- 5%	+/- 10%	+/- 10%	+/- 25%	+/- 10%
Narrow dams	VERY SUITABLE	NOT ADEQUATE TOO SLOW	NOT ADEQUATE TOO SLOW	NOT ADEQUATE TOO SLOW	SUITABLE	VERY SUITABLE
Design changes	EASY	EASY	EXPENSIVE AND TIME CONSUMING	EASY	EASY	EASY

Electroforming: a tremendously accurate additive process

How does electroforming work?

How does electroforming work?

What are the advantages of electroforming compared to alternative processes?

Electroforming:
a tremendously accurate additive process