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Electroforming is similar to electrorefining and electroplating. In this process, a metal surface is applied to the conductive surface. Non-conductive materials like plastic, glass and silicon require a conductive layer for electrode composition.There are some advantages and disadvantages of electroforming and we will learn the process of electroforming and its need in this article.
What is Electroforming
Electroforming is mainly used in other metals products as a good source for stamping, etching and machining. This process provides a good product known as mandrel. This process is mainly used in the electronic and aircraft industries.. It plays a great role in the electronics industry, especially.
Materials of Electroforming
A. Mandrels are used for metallic materials like stainless steel.
B. Mandrel is made from plastic material.
C. Materials which can be electroformed with a wide variety of modifications. For example copper,chromium and nickel.
D. Gold and silver are used for electroforming.
An electrolytic bath is used in the deposited metal on a conductive patterned surface. The electroformed part can be stripped off the mandrel. It is of stainless steel and alloy. When it deposits material , the electroform is separated from it. So, the mandrel would be covered with conductive coating for further electroforming process.
High current is passed through water. The water which is used will not have any organic contaminants. Due to this, the positive charge attracts negative charge. It’s the best option for removing the mandrel.
Electroforming overgrowth covers all the parts of conductive materials which are allowed to grow. This method is used for making nozzles and filters. Overgrowth is not allowed because of straight lined walls. This type of model creates a two-dimensional structure. The height of the photoresist may determine the height of the electroform.
In simple terms, we can write the steps for the process of electroforming:
1. Cleaning: The metal substrate is first cleaned.
2. Coating: The cleaned metal ‘blank’ is coated with a photoresist.
3. Exposing: The metal sheet is exposed to UV light.
4. Developing: When the image is transferred to UV light, the substrate is developed, rinsed and dried.
5. Deposition: An electrolyte bath is used to deposit metal.
6. Harvesting: The electroformed part is harvested from the mandrel.
Applications
It’s used to manufacture parts using electrolytic deposition.
Car interior parts, CD, optical lenses and electric shaver foils are produced using electroforming.
It’s used to create molds for interior parts.
This process also produces a mirror.
Mainly, it’s used in medical and electronic industries.
Used for the production of currency notes and stamps.
It can be used in specific machine parts.
This process is also used in jewellery-making.
It’s also used for determining metal purity.
Advantages
High aspect ratio.
No loss of material.
A wide variety of shapes and sizes can be made.
Multiple layers can be bonded together.
Relatively low-cost.
The metal layers used for electroforming are pure.
It can reproduce the external shape of the mandrel within 1 micrometer.
It’s used for fabricating, stamping and casting.
High surface finish can be obtained.
Laminated metals (stainless steel) can be produced.
Amount of purity
Disadvantages
Low production quantities.
The outside surface is less precise than the inside part.
If the object is thick, then it will lose more definition.
Special attention and operating parameters are required.
More time-consuming.
Limited to certain materials.
Guidelines for Electroforming Design
Product mass is above 80 kg
Thickness for the product is high.
High tolerance limit is average.
Creates all types of hollow bodies and circular shapes.
Brittleness property may be produced.
The material is not good for welding.
Points to Remember
- The article to be electroplated is always placed at the cathode.
- The metal to be plated on the article is always made the anode.
- The electrolyte must contain the ions of the metal used for plating.
- A low current must be used for a longer time.
- A direct current (DC), not alternating current (AC), should be used.
Conclusion
In this article, we learned about electroforming and its role in metals. Electroforming is mainly used in electronics and aircraft industries. Electroforming creates molds of interior parts. Nickel has a good property and it’s dominant among all other metals. It’s also used for manufacturing the parts in electrolytic deposition.
