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How Electroforming Works

Electroforming: the route, the tolerances it holds, materials and design tips, with an indicative cost. One of 56 processes in the free finder.

SurfaceFamily
+/-0.01mmTypical tol.
5Route steps
13Parts in finder

Electroforming builds a part by plating metal onto a mandrel, then removing the mandrel to leave a thin, precise shell.

At a glance

When to use it, and when not

Best for

Thin, precise metal parts and moulds, like mesh, bellows and nozzles.

Watch for

Slow, limited to shapes a mandrel can release, and thin sections only.

Step by step

The typical route

Raw material to finished part. Steps vary with material, volume and tolerance; this is the free route from the finder.

  1. Mandrel

    Prepare and activate the mandrel.
    Tooling Mandrel   Tolerance -   Lead -

  2. Deposit

    Electro-deposit metal onto the mandrel (slow).
    Tooling Plating cell   Tolerance -   Lead -

  3. Separate

    Release the formed shell from the mandrel.
    Tooling -   Tolerance -   Lead -

  4. Finish

    Trim and finish.
    Tooling -   Tolerance -   Lead -

  5. Inspect

    Check wall thickness and form.
    Tooling -   Tolerance -   Lead -
Precision

Tolerances it can hold

TYPICAL TOLERANCE IT CAN HOLD
+/-0.01mm typicalcoarsefine+/-1mm+/-0.1mm+/-0.01mm+/-0.005mm
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials

Materials it suits

GradeWhy it suits this
NickelPrecise, tough
CopperConductive
Design

Design tips

A few general pointers for Electroforming. The full, part-specific DFM list is in the dossier.

  • Thick sections specified. Keep walls thin (its strength).
  • Undercuts vs mandrel. Design for mandrel release.
Cost

What it costs

Builds precise thin metal parts by depositing onto a mandrel (meshes, bellows, optics); slow, for precise or thin shapes.

PER-PART COST vs VOLUME
one-offat volumeVolume per order, low to highCost per part
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for your part at your volume, in your currency, are in the dossier.
MODEL EST.
$165 to 285 per 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 this process 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
  • A quote checker that tells you if a supplier quote is fair, and the red flags to watch
  • The full DFM list and a ready-to-send RFQ draft
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Examples

Parts made by Electroforming

13 parts in the finder use Electroforming as their primary process. A sample, each with its own guide:

electroformed bellowselectroformed foilelectroformed nozzleelectroformed partelectroformingmicro meshprecision sievewaveguide
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FAQ

Frequently asked questions

How is a part made by Electroforming?
Electroforming builds a part by plating metal onto a mandrel, then removing the mandrel to leave a thin, precise shell. The typical route is: Mandrel; Deposit; Separate; Finish; Inspect. Thin, precise metal parts and moulds, like mesh, bellows and nozzles.
What does Electroforming cost per part?
It depends on size, tolerance and volume. As a rough ballpark it starts around $165 to 285 per part at low volume and falls with quantity. The dossier gives should-cost at your exact volume and currency. Model estimates, not quotes.
What tolerance can Electroforming hold?
Typically about +/-0.01 mm, tighter with extra finishing operations at higher cost.
What materials suit Electroforming?
Common choices are Nickel (Precise, tough); Copper (Conductive).
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