Electroformation

Electroformation is a process used to create solid objects by electrodepositing a metal onto a removable mold. This technique leverages electroplating principles, where metal ions from an electrolyte solution are reduced and deposited onto a cathode. The mold, which acts as the cathode, is typically made of a conductive material or is coated with a conductive layer. The shape of the mold dictates the final form of the electroformed object.

The process begins by preparing the mold, ensuring it is clean and has a uniform conductive surface. The mold is then immersed in an electrolyte solution containing the metal to be deposited. An anode is also placed in the solution, and a DC current is applied between the anode and the mold. Metal ions from the electrolyte migrate to the mold (cathode) and deposit onto its surface, gradually building up a layer of metal. The thickness of the deposited metal layer can be controlled by adjusting the current density and deposition time.

Once the desired thickness is achieved, the electroformed part is removed from the electrolyte. The mold is then separated from the deposited metal, often through mechanical means or by dissolving the mold material if it is soluble in a specific chemical. The resulting object is a hollow shell or a solid piece, depending on the initial mold design and whether the mold is intended to be removed. Electroformation is used in various applications, including the creation of intricate metal components, decorative items, and specialized scientific instruments, often where complex shapes or high precision are required.