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Electroforming of small structures

We are a research lab trying to set up an electroforming facility. The finished part should replicate features of about 10 µm (or even much smaller) and will be used as mold insert (Is nickel the only choice?). We need to purchase the solution, or if there is a "kit" available.

Weidan Liu
electroforming - Amherst, Massachusetts
2004

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The replication of small features is no problem at all. Electroforming can easily give you a 10 µm pitch (example: 5 µm lines and 5 µm spaces). L. T. Romankiw even made a copper machine component on a 4 µm spiral pitch (3 µm line, 1 µm space, 12 µm thick). Nickel, nickel-cobalt, copper, and gold are commonly electroformed. Nickel sulphamate is probably the most common electroforming solution.

Generally people would go to a job shop like Bowers Molds, Epner Technology, or NiCoForm [a finishing.com supporting advertiser] for their electroforming rather than do it in house. But you can contact suppliers like Technic for electroforming equipment (although the word "kit" seems like almost an oxymoron when used in conjunction with high precision electroforming). Most plating process suppliers can offer you a nickel sulphamate or other electroforming process if you want to use your own equipment.

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
2004