In situations when an accurate copy of a fragile parts is desired, a versatile and efficient solution is to deposit a thick metal layer by electroforming and then separate the part and the copy. The only requirement for this to work, is that the original part is electrically conducting.

Non-conducting materials can be made conducting by deposition of a thin metal coating (50 nanometer) using physical vapour deposition (PVD) or sputtering. This way exact copies of optical components, biological materials (wood, leader, etc.) or other parts with a micro or nano structured surface can be made.

The purpose of the electroforming is usually to make a tool insert for injection moulding of polymer products or tools for metal forming.

IndireCt Tooling

Electroforming is an indispensable process is several sequences called indirect tooling. The term indirect tooling entail:

• a substrate that is machined using milling, electrochemical discharge machining (EDM) or similar
• the substrate materials is selected for easy and accurate machining (f.ex. an aluminium alloy for fast milling with minimal wear on the milling tool)
• a thick layer of metal (typically nickel) is deposited on the substrate using electroforming
• the substrate is chemically dissolved or separated mechanically from the electroformed part

IPU have access to several different electroforming processes. These processes are optimised for hardness (longer tool life), low internal stress, corrosion resistance and the ability to fill substrates with high aspect ratios (up to 5). Indirect tooling is particularly useful for micro and nano structured substrates.

Contact: Peter T. Tang (tlf. +45 45 25 48 04)