Engineered for versatility and precision, our electroforming molds excel in aluminum part production while supporting diverse materials—delivering ±0.005mm accuracy to meet the strict demands of high-precision manufacturing. Whether you’re producing aluminum components or working with other substrates, these molds combine material compatibility, micron-level precision, and reliable performance, making them ideal for industries ranging from aerospace to electronics.
Our electroforming molds are calibrated to achieve industry-leading accuracy, ensuring flawless replication of complex aluminum parts and beyond:
- Micron-Level Control: With dimensional tolerance as tight as ±0.005mm, these molds excel at reproducing intricate details—from thin aluminum walls (0.1–2mm) and micro-textures to asymmetrical structures (e.g., aerospace brackets or electronic connectors).
- Consistent Feature Replication: Electroforming technology captures fine geometries (e.g., 0.05mm micro-ribs or threaded inserts) with 99.9% fidelity, critical for aluminum parts requiring tight assembly or functional precision.
- Surface Finish Excellence: Achieve Ra ≤0.01μm surface smoothness on molded aluminum parts, eliminating post-processing needs and enhancing part performance (e.g., reducing friction in moving components).
Designed to adapt to diverse manufacturing needs, our electroforming molds support multiple materials beyond aluminum:
- Aluminum Expertise: Optimized for aluminum alloys (6061, 7075, etc.), ideal for lightweight, high-strength parts in automotive, drones, and industrial machinery.
- Multi-Material Support: Compatible with other substrates including copper, nickel alloys, and even plastic-aluminum composites—enabling seamless production of hybrid components (e.g., aluminum-electronic part assemblies).
- Material-Specific Tuning: Molds are tailored to handle material-specific properties, such as aluminum’s thermal conductivity, ensuring uniform cooling and preventing warping during production.
Built to withstand repeated use, these molds deliver reliability across production cycles:
- Robust Construction: Made from high-purity electroformed nickel or nickel-cobalt alloys, the molds resist wear and corrosion—supporting ≥100,000 production cycles for aluminum parts without accuracy degradation.
- Thermal Stability: Withstand temperatures up to 200°C, making them suitable for high-temperature aluminum forming processes or post-molding treatments (e.g., anodizing or coating).
- Low Maintenance: Smooth, non-stick surfaces reduce material adhesion, minimizing downtime for cleaning and extending mold lifespan.
Our material-compatible, high-precision electroforming molds serve key industries:
- Aerospace & Defense: Production of lightweight aluminum structural parts, sensor housings, and precision brackets requiring ±0.005mm tolerance.
- Electronics: Molding aluminum heat sinks, connector shells, and chassis components with micro-features for thermal management and connectivity.
- Automotive: Manufacturing aluminum trim, valve components, and ADAS (Advanced Driver-Assistance Systems) parts needing tight dimensional control.
- Industrial Machinery: Producing aluminum gears, guides, and tooling components where material compatibility and precision drive performance.
We adapt our electroforming molds to your unique production requirements:
- Material-Specific Optimization: Adjust mold design for your target material (e.g., tuning for aluminum’s flow properties or copper’s conductivity) to maximize part quality.
- Size Flexibility: Support aluminum parts ranging from small (φ5mm micro-components) to medium-sized (500×300mm panels), with custom cavity configurations for multi-part production.
- DFM Expertise: Our engineers analyze your part design to optimize mold geometry for material compatibility and precision—reducing trial-and-error and accelerating production.
- Quality Assured: All molds undergo 100% 3D inspection (via CMM with ±0.001mm accuracy) to verify ±0.005mm tolerance compliance.
- Material Traceability: Full documentation for mold materials and electroforming processes, ensuring compliance with industry standards (ISO 9001, AS9100 for aerospace).
- Technical Support: Dedicated teams provide guidance on material pairing, production parameters, and maintenance to maximize mold performance and lifespan.
Whether you’re producing high-precision aluminum components or working with diverse materials, our electroforming molds deliver the accuracy, compatibility, and reliability your production demands—backed by ±0.005mm precision to ensure every part meets your strictest standards.
