Electroforming

Non-conductive (glass, silicon, plastic) mandrels require the deposition of a conductive layer prior to electrodeposition.

In extreme cases, where a thickness of several millimetres is required, there is preferential build-up of material on sharp outside edges and corners.

In recent years, due to its ability to replicate a mandrel surface with practically no loss of fidelity, electroforming has taken on new importance in the fabrication of micro- and nano-scale metallic devices and in producing precision injection molds with micro- and nano-scale features for production of non-metallic micro-molded objects.

[2] Compared to other basic metal forming processes (casting, forging, stamping, deep drawing, machining, and fabricating), electroforming is very effective when requirements call for extreme tolerances, complexity, or light weight.

Multiple layers of electroformed metals can be bonded together, or to different substrate materials, to produce complex structures with "grown-on" flanges and bosses.