Electroforming Applications

Metrigraphics utilizes proprietary electroforming processes to fabricate complex 2D and 3D micro-structures. We can fabricate micron size features in nickel, nickel-cobalt, gold, and copper.

The component to the right is fabricated in nickel-cobalt, overplated with gold, and has a length of 2.7 mm (0.108") and width of 3.0 mm (0.12"). Its thickness is 250 microns (0.01"). The narrowest section has a width of 100 microns (0.004") and the same overall part thickness of 250 microns for an aspect ratio of 2.5:1. Depending upon specific feature geometry and material, higher aspect ratios are achievable. These dimensions can be held to +/- 3 microns (0.00012").
The spring component to the right is fabricated in nickel-cobalt, overplated with gold, and has a length of 6.1 mm (.244") and width of 1 mm (0.04"). The overall part thickness is 250 microns (0.01"). The spring has a width of 100 microns (0.004") and thickness of 250 microns for a 2.5:1 aspect ratio. As with the previous example, higher aspect ratios are achievable depending upon specific feature geometry. The depth of the teeth on the ends is 100 microns (0.004"). These dimensions can be held to +/- 3 microns (0.00012").
The part at the right is a gold foil with a variety of three dimensional features. The foil has a thickness of 10 microns (0.0004"). The hole diameter is 100 microns (0.004"). The posts between the holes have a height of 22.5 microns (0.0009") and a base diameter of 50 microns (0.002"). The slots are 50 microns wide, and the walls that define the slots are 50 microns wide and 22.5 microns high. Dimensional tolerance of +/- 3 microns (0.00012") can be held.
The part to the right is a contact spring fabricated in nickel-cobalt. It has an overall length of 0.173" and width of 0.1". Its thickness is 50 microns (0.002"). The width of the tip is 50 microns (0.002"). Dimensional tolerance of +/- 3 microns (0.00012") can be held.
Our electroforming technology can fabricate very precision apertures. The scanning electron microscope (SEM) image to the right shows a funnel shaped hole with a diameter of 20 microns (0.0008"). We can hold the dimensional tolerance to better than +/- 1 micron (0.00004"). By changing our processing parameters, straight wall apertures can also be fabricated.
We can fabricate more complex apertures as shown in the image to the right. This aperture has a diameter of 75 microns (0.003") and is surrounded by a circular ring that has an in inside diameter of 635 microns (0.025"), an outside diameter of 1270 microns (0.05") and a depth of 125 microns (0.005"). These tolerances can be held to +/- 2 microns (0.00008").
Below is an example of a complex 3D mechanical structure fabricated in nickel-cobalt. The overall size of this part is 0.300" X 0.450". The elements of the three springs have a cross-section of 50 microns by 50 microns (0.002" X 0.002"). The spaces between the spring elements are also 50 microns. A second electroformed layer of nickel-cobalt, 200 microns (0.008") thick, has been deposited over the non-spring areas to add structural integrity. Total thickness of the two combined layers is 250 microns (0.01").

Metrigraphics has fabricated a sample electroformed part showing ultra-high precision holes and slots. If you would like a sample part, please contact us, fill out your contact information and request the electroforming sample part.