High precision metal etching manufacturer

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0755-2708-8292 / 18938693455

Electroplating  Principle

Electroforming is a specialised processing technology that uses electrolytic deposition of metals to manufacture precision metal parts. The basic principle involves immersing a conductive mould as the cathode into an electrolyte solution (such as nickel sulphate or copper sulphate), where metal ions are reduced and gradually deposited on the mould surface under the influence of an external current, ultimately forming an independent metal product with a shape opposite to that of the mould.

Process Flow

Electroforming Principles
  • 01FILM (CAD Output)
  • 02Raw material preparation
  • 03Pre-treatment (cleaning)
  • 04Dry film Lamination (lamination)
  • 05LDI
  • 06Electroforming
  • 07Drying
  • 08Etching (ETCHING)
  • 09Peeling (shedding operation)
  • 10Check packaging, out of the warehouse

Advantages of the electroforming  process

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Achieve micron-level (1-10μm) or even nanometre-level structural replication to meet the stringent dimensional requirements of precision devices.

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Supports complex geometric structures such as three-dimensional irregular shapes, hollows, and micro-holes that are difficult to achieve with traditional processing methods.

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Electroplating layers have low internal stress, preventing part deformation or cracking and improving product reliability

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Surface roughness can reach Ra 0.05μm or less, reducing subsequent polishing processes.

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Can process various metals and alloys such as nickel, copper, gold, silver, platinum, etc., to meet different functional requirements.

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Good repeatability in mass production, suitable for manufacturing highly standardised precision part

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Combined with lithography technology, high-resolution pattern transfer (such as micro gears and MEMS components) can be achieved.

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No expensive moulds required, particularly suitable for customised, small-batch precision parts production

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Multiple layers of materials can be stacked to give parts composite properties such as conductivity, wear resistance, and corrosion resistance.

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Intercomparison of etching, stamping and other process characteristics

Process FeaturesPhotochemical etchingLaser CuttingStampingWire cuttingWaterjet CuttingElectroforming
Sample MakingLow costLow costHigh costLow costLow costModerate cost
Material typeAlmost all metalsAlmost all metalsAlmost all metalsCarbon steel and most metal alloysAlmost all metalsMainly nickel, copper, silver, gold
Metal hardnessNo restrictionsNo restrictionsHardness is too large, too small, easy to break the metal are not availableHardness needs to be chosen carefullyHardness needs to be chosen carefullyApprox 200-670 HV
ScratchingNo scratchesScratches on the edges of the cutScratches on the edges of the cutThe material will be twisted and deformed. Structural changesThe cut edge will have a few A few scratchesNo obvious scratches
BurrBurr-freeFine burrLocal burrsFine burrFine burrBurr-free
Flexibility for design changesFast, easy and efficientFast, easy and efficientVery time consuming and costlyVery time consuming and costlyFast, easy and efficientFast, easy and efficient
Process Time48 hours48 hoursA few weeks48 hours48 hours5 hours
Material thickness on Tolerance effect±10%±5%±10%±10%±15%±15%
product packaging. Is it easy to transferYesYesVery difficultYesYesYes

Application of etching process

Semiconductor, LED industry solutions

Precision electroforming provides high-precision micro-nano processing solutions for the semiconductor and LED industries, suitable for the manufacture of complex structures. In the semiconductor field, electroforming technology is used to manufacture lead frames, microelectromechanical systems (MEMS) and TSV (through-silicon via) metallisation, ensuring high conductivity and dimensional accuracy. In the LED industry, electroforming is used to produce high-reflectivity brackets, fine electrodes and micro-lens arrays, improving light efficiency and heat dissipation performance. Electroforming processes can process materials such as copper, nickel, and gold, and when combined with lithography technology, achieve micron-level pattern replication, meeting the needs of small-batch, high-customisation production. Its advantages include high resolution, low stress, and excellent mechanical properties, driving the development of semiconductor and LED devices towards smaller sizes and higher performance.

5G Industry Solutions

Precision electroforming provides high-precision, high-performance radio frequency (RF) components and antenna solutions for the 5G industry. This technology is used to manufacture key components for 5G base stations, such as high-frequency filters, waveguide cavities, and microstrip antenna arrays, ensuring low loss, high signal integrity, and excellent thermal stability. Electroforming processes can process highly conductive materials such as copper and silver, achieving micron-level complex structures to enhance the high-frequency response and power handling capabilities of components. Additionally, electroforming is suitable for mass-producing highly consistent components, such as millimetre-wave antennas and flexible circuits, meeting the miniaturisation and integration requirements of 5G devices. Its high precision and low surface roughness characteristics optimise signal transmission efficiency, supporting the high-speed, low-latency performance of 5G networks.

Medical, precision engineering industry solutions

In the medical field, precision electroforming is used to manufacture minimally invasive surgical instruments (such as endoscope components), high-precision catheters, micro-sensors, and biocompatible implants (such as neural electrodes), ensuring dimensional accuracy and biocompatibility of complex microstructures. In the precision engineering field, this technology is applied to the production of optical moulds, micro-gears, precision nozzles, and MEMS (Micro-Electro-Mechanical Systems) components, meeting requirements for nanometre-level surface finish and complex geometric shapes. Electroforming processes can process materials such as nickel, gold, and platinum, and when combined with lithography technology, they enable high-resolution pattern replication, making them suitable for small-batch, highly customised production. Their advantages include high precision, low stress, and excellent mechanical properties, driving the development of minimally invasive medical procedures and the miniaturisation of precision devices.

Electronics, 3C industry solutions

Precision electroforming technology is widely used in the electronics and 3C industries for the manufacture of high-precision micro-components, such as metal brackets for mobile phone cameras, MEMS sensor structures, micro-connectors, and micro-plating of high-density PCBs. This process can process materials such as copper, nickel, and gold, achieving complex structures at the micron level, ensuring excellent conductivity, electromagnetic shielding, and mechanical strength. In the consumer electronics sector, electroforming technology is used to produce ultra-thin metal meshes (such as speaker diaphragms), flexible circuits, and precision shielding covers, meeting the demands for lightweight, high-performance devices. Its advantages in high precision, low surface roughness, and batch consistency support the miniaturisation and functional upgrades of smartphones, wearable devices, and 5G terminals, enhancing product reliability and production efficiency.

Photovoltaic Industry Solutions

Precision electroforming technology provides the photovoltaic industry with high-precision, highly durable printing screen manufacturing solutions for the precision printing of solar cell electrodes. This process uses electroformed nickel and other metal materials to produce ultra-fine line widths (down to less than 20μm) and high opening rate screen patterns, ensuring the uniformity and conductivity of paste printing and improving cell conversion efficiency. Electroformed screens exhibit excellent wear resistance and deformation resistance, with a lifespan 3-5 times longer than traditional screens, significantly reducing production costs. Their high-precision graphic replication capability is compatible with new battery processes such as HJT and TOPCon, driving the photovoltaic industry toward higher efficiency and thinner film development.

Solutions for the Automotive Industry

Precision electroforming technology provides the automotive industry with high-precision, high-performance manufacturing solutions for micro-components, widely used in key components such as sensors, fuel injectors, micro-motor components, and EMI shielding covers. This process can process materials such as nickel and copper, achieving micron-level complex structures, ensuring excellent wear resistance, corrosion resistance, and electrical conductivity. In the new energy field, electroforming technology is used in core components such as fuel cell bipolar plates and lithium-ion battery current collectors, enhancing energy efficiency. Its advantages of high precision, low stress, and batch consistency support the development of automotive electrification and lightweight design, meeting the stringent requirements for precision components in the trends of intelligent driving and electrification.
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