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Max Levy Online > Specialty Products > Bulletin 2100
Precision Electroformed Products
   Bulletin 2100
Download complete Electroforming Capabilities Bulletin (.pdf)  Download Acrobat Reader
ELECTROFORMING is the manufacture of products and replication tooling by the deposition of metals. Electroformed products include Clear Optical Apertures and Slits, fine Mesh Screens and Masks. These parts require extremely close tolerances that are beyond those achievable using photochemical machining.
ELECTROFORMING is an additive process. Metal is electrodeposited on a Mandrel. This Mandrel may contain three dimensional structures for the manufacture of complex, three dimensional parts or replication tooling. After the electrodeposition process is complete, the electroform is separated from the Mandrel.
ELECTROFORMS have exceptional structural strength and rigidity. The three dimensional nature of Electroforming allows small, close tolerance apertures and similar features to be incorporated with robust structures to achieve exceptional structural strength and rigidity.
ELECTROFORMING is cost effective for the manufacturing of parts and replication tooling with close tolerances and complex features. Electroforming is usually less expensive for multiple parts when compared to EDM and laser drilling.
ELECTROFORMED METAL PARTS: Examples of Metal Parts that are replicated through Electroforming as flat or complex Three Dimensional Structures include:
 
  • Metrology Standards for Surface Roughness.
  • Metrology Step Wedge Standards for Surface Height Measurement.
  • Clear Optical Path Apertures, Targets and Masks.
  • Encoder Disks and Scales.
  • Antenna Arrays and Wave Guides.
  • Focusing and Light Pipe Arrays.
  • Three Dimensional Tension Masks and Screens.
  • Mesh Products and Foils.
  • Light and X-Ray Diffusers and Masks.
  • Ink Jet, Electrographic and Liquid Diffusion Precision Hole Arrays.
  • Micro-Miniature Valves, Orifice Plates, Sprockets and Gears.
  • Precision Sensor Diaphrams, Vanes, Tuning Forks and Accelerometer Elements.
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    LENTICULAR LENS MASTER & REPLICATED NICKEL ELECTROFORM: The Concave Lenticular Lens Master, shown right, has been Contour machined with single point diamonds, nickel plated, passivated, and used to manufacture a nickel, convex lenticular "Father" electroform. This "Father" in turn, is used as a Master to electroform Concave Lenticular Hard Nickel replication dies. These dies are then used to mass-produce the Convex Lenticular Lens Array in plastic.

    The entire process of Diamond Contour Machining, Electroforming and Replication, provides the engineer with the ability to design, prototype and economically mass produce complex, large format micro structures.

    REPLICATED PLASTIC PARTS: Examples of Plastic Parts that can be manufactured from Electroformed Replication Tooling mounted in Injection Molding Machines or Vacuum Presses include:

  • Plastic Lenticular, Rear Projection, Fresnel and other lens arrays.
  • Compact Discs, (CD's) and Replicated Holograms.
  • Binary replicated Optics, Focusing Arrays, Spherical and Parabolic Mirror Blanks, Plastic Cuvettes and similar fine featured optical parts.
  • Plastic Crystal, Costume Jewelry, Artistic Reliefs, Coins, Plastic Miniatures, Toys and other complex plastic parts.
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