Electroforming - Produces thin-walled components with tight tolerances

A thin metal layer is deposited by electroplating onto a machined aluminium component (aka mandrel). The mandrel is removed mechanically or by dissolving it in an alkaline solution, leaving the thin metal plating as the finished product.

Applications for electroforming:

Electroforming is used for manufacturing complex components with uniform wall thicknesses and very tight tolerances. Applications include flexible tubes (aka bellows) used for flexible shaft couplings, and springs for electrical contact applications. It is used to make electromagnetic interference shielding and narrow metal cavities used as tooling for plastics.

Details:

Nickel and nickel alloys are often used for electroforming, but it is also possible to use copper, silver, or gold. The wall thickness depends on the time and current in the plating tank and usually ranges between 0.01 and 1 mm.

Idea:

Create corrosion-resistant flexible covers for actuators.

The sample:

You get a sample set with a flexible bellow, a very small below in a bag and a thin hollow tube. See the product picture.  

All samples come with a laminated information card, which includes contact details for the supplier.