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#279 Application of Electroforming

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February23, 2017

Electroforming has been utilized for producing precise copies of metal objects by accurately replicating surface conditions and dimensional accuracy even for complex-shaped objects that are difficult to work with or not compatible with machining. In recent years, electroforming has been developed for more applications in a wide range of fields. However, due to many disadvantages of electroforming introduced in the previous volume, it is frequently used for products that their quality and accuracy outweigh the cost performance. Electroforming is utilized in the following fields:

1) Production of replicas

Master copy of music records, compact discs, laser discs, and optical discs.
Marking board used for reproducing wood-grain, crocodile, and woven patterns on plastics, leather, or cardboards.
Press plates for printing, printing rolls, standard specimen for surface roughness, spray masks for painting, clock face, etc.

2) Production of molds

Production of plastic injection molds in complex shape/design, compression molding dies, continuous casting molds for steel, heat-resistant molds for glass, aluminum, and zinc die cast, molds for printing letters, etc.

3) Electrosizing

Repair, reclamation, or calibration of mechanical components, including molds, rolls, shafts, bearings, and gauges, to compensate the lack of dimensional accuracy or overlaying worn-out areas.

4) Electroassembly

Assembly of pitot tubes and waveguides, production of cutting tools with abrasives (diamonds/silicon carbide) attached, and production of various composite materials, etc.

5) Electrocladding

Nickel coating for steel plates, jewelry and rare metal decorations, coatings for plastic processing, photo film/print rolls, etc. Apply metal coating over wooden or plastic products to add mechanical strength and metallic appearance.

6) Production of foils, laminates, sheets, and hollow products

Production of seamless pipes, hollow containers, copper float, containers, foils, sheets, screens, wire meshes, sieves, outer blades of electric razors, etc.

7) Others

Production of parts requiring precise dimensions or surface conditions that cannot be produced by any other methods. The examples are radar waveguides, caps for fountain pens, reflecting mirrors, Venturi tubes, meandering tubes, bellows, mechanical parts including cams, horns (musical instrument), precision electronic components, jet engine parts, space development fields, etc.

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