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Precision Photo Electroforming



Precision Photo Electroforming

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Precision parts can be manufactured with fine patterns, stepped multi-level features, high tolerances, and superior edge finishes by our photo electroforming process. Complete design assistance is available to customers for converting the pattern sketches to 2D CAD files. Our electroformed parts are extensively used in avionic systems, medical devices, electronics, and scientific controls.

Image transfer is done on multi-level electrodeposited metal products to create overgrown profiles. In the past, we have electroformed multi-level filter materials with unique hex support grids and holes as small as 40 µm for our customers. Precision filters, mesh, plus sieves are produced with zero particle entrapment, easy to clean features, and apertures down to 3 µm in size. We have electroformed a wide range of micro-embossing tools as well as multilevel dies for electronic and scientific control applications. Processing material panels in nickel, gold, copper, or any polymer, in sizes as large as 18” x 24”, is not a problem for us. Depending upon the mandrel material, we can provide photo electroformed parts with rough surfaces or optical finishes.

Specifications

Primary Services

Adhesive Bonding
Diffusion Bonding
Laser Micro Machining
Photo Electroforming
Photo Etching

Value-added Services

Embossing
Heat Treating
Kiss Cutting
Marking
Special Packaging
Plating
Welding
Assembly
Bonding

Material List

Copper
Epoxy
Gold
Nickel(Both hard and soft)
Polymer

Material Thickness

Can be as thin as 3-4 microns

Thickness Uniformity/Level

< 1% of material thickness possible

Hardness(VPN)

190 - 450

Roughness

Dependent Upon Mandrel Material
Optical Finish Possible

Maximum Panel Size

Material panels as large as 18” x 24”

Minimum Dimensional Tolerance

Generally +/-10 microns or better

Positioning Accuracy

Normally +/- 1-2 microns

Through Holes Size

As small as 2-3 microns

Aperture Sizes

< 1 to 3 µm

Feature Sizes

< 1 to 3 µm

Pitch

< 2 to 6 µm

Aspect Ratios/level

10:1 to 2:1

Typical Profiles

Overgrown and Multi-Level
Stepped Multi-Level

Software Used

AutoCAD
Autodesk Inventor
COSMOS
Ansoft Maxwell 2D

Acceptable File Formats

DWG
DXF
IGES
JPEG
PDF

Certifications

AS 9100 Certified
Clean Room Accredited to FED-STD-209 Class 10,000 Standards
FDA Registered
PRI / NADCAP Certified

Applications

Avionics
Embossing Micro Parts
Filtration/Microfiltration
Laboratory and Test
Masking
Micro-channels
Micro-circuitry
Micro-embossing Tools
Micro-reactors and Lab-on-chip
Micro-replication of Silicon Masters
Precision filters, mesh, and sieves

Industries Served

Automotive
Avionic/Space
Electronic
Fiber
Mechanical/Manufacturing
Medical
Printers
Scientific Controls

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