Primary process: Electroforming. The full route, materials, tolerances and design tips for an electroformed foil, with an indicative cost.
ElectroformingPrimary process
SurfaceFamily
4Route steps
+/-0.01mmTypical tol.
An electroformed foil is primarily made by Electroforming. Electroforming builds a part by plating metal onto a mandrel, then removing the mandrel to leave a thin, precise shell. Below is the full route to make an electroformed foil, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How an electroformed foil is made
The usual route, raw material to finished part. The amber step is where the electroformed foil gets its basic shape.
Mandrel
Make a precision mandrel shaped to the electroformed foil's inner surface and apply a release layer.
Tooling None Tolerance ±0.125mm, to ±0.025mm Lead 1 to 10 days
Electroforming
Electrodeposit metal onto the mandrel until the electroformed foil reaches its wall thickness.
Tooling Medium (mandrel) Tolerance ±0.002 to 0.02mm Lead 2 to 4 weeks
Separation
Part the electroformed foil cleanly from the mandrel.
Finish and inspect
Trim the edges and check wall thickness, form and finish.
Need the real cost for an electroformed foil? The free route above is yours. Unlock the full dossier to quote and source it.
Builds precise thin metal parts by depositing onto a mandrel (meshes, bellows, optics); slow, for precise or thin shapes.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for an electroformed foil at your volume, in your currency, are in the dossier.
MODEL EST.
$130 to 365per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on an electroformed foil and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
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An electroformed foil is primarily made by electroforming. The route is: Mandrel; Electroforming; Separation; Finish and inspect.
What does an electroformed foil cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $130 to 365 per part at 1 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is an electroformed foil made from?
Common choices are Nickel; Copper.
What is the main process for an electroformed foil?
Electroforming. Thin, precise metal parts and moulds, like mesh, bellows and nozzles.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
