Technical Description of the Electroforming Process

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Electroforming involves an engraving process that makes use of electroplating process technology. Duplicates can be obtained from the direct moulding of patterns that are characterised by a design reproduction very faithful to the original. A 0.2 to 0.3 millimetre thick nickel coating is electroplated onto a negative mould. This coating is separated from the mould to obtain a positive that accurately reflects all mould details.

The exact manufacturing process for our electroforming plates is as follows:

(1) The manufacture of the original part from pure copper. A large part of this involves precision work by hand as the primary shape should already display all fine detail and also the surface composition that the customer requires for the production part.

(2) This original is electroplated with a 0.5 millimetre thick nickel coating. This is treated chemically before being applied so that a further nickel layer to be applied only adheres weakly and later can be easily removed.

(3) The nickel layer is removed from the original to produce the first negative mould that still needs to be cleaned up by hand.

(4) The finished negative mould is again treated with a separating layer and electroplated with a 0.5 millimetre thick nickel layer.

(5) This layer is again removed to produce the first positive part. All surfaces that are high gloss in the mould are also this on the positive part. All matt or textured surfaces are likewise matt or textured on the positive part. It is even possible to transfer fine structures such as hologram effects. As the metal surfaces do not need to be machined, the finest detail can be depicted with great exactness and precision.

(6) The first positive mould is used to manufacture (again via electroplating) two positive parts. These are soldered together in predetermined distances. This double original is used to produce a double negative mould, from which in turn two double positive moulds are made that (soldered together) produce a quad mould. It is in this way using further copying and composition that the production mould is produced that always measures 220 x 240 millimetres. Several nameplates can be produced at the same time depending on the size of the plate.

(7) The production mould and an electroplated nickel application of 0.2 - 0.3 thickness are used to manufacture boards with positive parts. The individual parts are stamped out and coated, printed or configured with colour in accordance with the customer's wishes. Last but not least, the finished nameplates (if desired) are furnished with a cut sticker.

The quality of the plates manufactured using this electroforming method cannot be attained by any other process. This is why virtually all manufacturers worldwide embellish their high quality technical products with them.