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Electroforming Guidelines

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Electroforming Tech Brief

Low-cost, High-quality Electroforming With Utmost Repeatability and Precision

Complex multilevel electroformed structures are a specialty at Metrigraphics. This additive process is completed by electrochemically depositing metal into a precisely formed photo-resist mold. Electroforming is ideal for fabricating micron-scale metallic components as well as for making injection molds used for forming nonmetallic microstructures with nano-scale features. Benefits include low-cost, high-quality production plus high repeatability.

With our precision electroforming expertise we can create three-dimensional, single or complex, multi-layer microstructures. Geometric options are unlimited because the X, Y, Z structural plane of each layer is formed by the photoresist image. These structures may be freestanding or connected to comb-like supports to facilitate handling or fixture mounting.

Sample applications:
  • Micro injector nozzles
  • Microstructures
  • Micro Slits
  • Micro screen/mesh
  • Embossing tools
  • Orifice Plates
  • Microfluidics
  • Biological lab-on-chip base structures
  • Liquid-crystal-display processing
Commonly used materials:
  • Nickel cobalt
  • Nickel
  • Pure gold
  • Hard gold
  • Copper

Micro Screen and Micro Mesh

At Metrigraphics, we use our precision-electroforming capabilities to create micro screen with square or round apertures, with bar widths as small as 0.010 mm. We can array the apertures in a wide range of formats - hexagonal, rectangular or whatever your application requires. Medical applications include inhalant atomizers, while micro mesh is also used in such electronic applications as RF shielding and imaging screens.

Embossing Tools

We apply the micron-level precision afforded by our electroforming process to manufacture extremely precise embossing-tool master plates. Highly durable embossing molds with highly complex patterns may be electroformed using nickel cobalt, which has extremely fine grain, very low stress, and a hardness in the Vickers 500 range. We also use precision electroforming to create casting master molds for PDMS or similar materials.

To learn more about our electroforming expertise download our tech brief or read our blog.