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Precision Electroformed Components
DRC has refined the electroforming art
to its highest level, through a patented process that
employs a conductive patterned glass substrate and
proprietary plating baths. Superior edge definition, 1
micron features, superior dimensional control, and near
"optical" finishes are achievable. Precision metal patterns
with cross-section ratios of up to 1:1 and resolutions of
above 2 million holes per square inch can be provided.
In the basic electroforming process, an
electrolytic bath is used to deposit nickel or other
electroplatable metal onto a conductive patterned surface,
such as glass or stainless steel. Once the plated material
has been built up to the desired thickness, the
electroformed part is stripped off the master substrate.
This process allows high-quality duplication of the master
and therefore permits quality production--at low unit costs
with high repeatability and excellent process control.
Why Electroforming is Superior to
Chemical Etching
Electroforming is an additive process
and herein lies electroform's superiority over etched metal
and other forming technologies. The precision and resolution
inherent in the photographically produced conductive
patterned substrate, allows finer geometries to be produced
to tighter tolerances while maintaining superior edge
definition with a near optical finish.
Etched metal, EDM, and laser machining
rely on the removal of material to form the desired
features. All have limitations associated with one or more
of the following: resolution; tolerance; process
repeatability; or cost. In etched metal the minimum opening
diameter is limited to 1.5 times the metal thickness. EDM
and laser machining have resolution limits and normally are
more costly than electroforming. None of these alternatives
provides the surface finish within the hole or aperture that
electroforming does.
A Electroformings advantages, compared
to other fabrication methods includes:
- Electroforming is essentially
insensitive to temperature or humidity
- Electroformed parts have excellent
light transmission when used in optical application
(encoders, aperture plates, slits, etc.)
- Electroformed parts have very low
mass (weight and inertia)
- Electroformed parts are electrically
conductive and essentially unbreakable
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