New Development in Computer Aided Electroforming for Rapid Prototyping Applications

Abstract

Electroforming enables metallic parts manufacturing with good mechanical properties and high level of accuracy and reproducibility. A thin metallic shell is deposited on a model and later released from it. There are several applications of electroforming combined with rapid prototyping: injection moulds, EDM electrodes, moulds for rotational moulding, complex metallic parts, etc. However the two main disadvantages of electroforming are the non uniform thicknesses distribution and high time of shell manufacturing. The paper focuses on a new development in order to achieve uniform thickness and otherwise a faster shell manufacturing. A new device and software have been developed, named Elecform3D™. The device is an automatic machine controlled by computer and assembled into the electroforming equipment. Otherwise the software not only controls the device but also simulates and calculates the optimal positions of the cathode based in the electrolytic parameters of the bath. The software recommends an automatic program of movements or allows the operator to decide another alternatives programs if necessary. Elecform 3D is an important step beyond electroforming so far. RP 3D printer combined with Elecform 3D is a cheaper alternative for high quality metallic parts manufacturing in comparison with SLS-SLM technologies or high speed machining, mainly for rapid tooling and even rapid manufacturing.

Boundary Element Method Applied to Electroforming Process

“…With the aim of define these movements or positions sequence, it is necessary to approximately evaluate thickness of deposit on each position of the study in order to select from them those which deviate in thickness related to an average value as minimum. In this simplified method the calculation time is quite fast although the final accuracy is worse [11]. The results obtained with this first version were very promising, and also indicated the need for a more precise analysis of electrochemical phenomena in the process of electroforming.…”

Investigation and modeling on electroformed micro electrolysis pump using regression analysis

“…Also because current density distribution results from electric field intensity distribution, so by solving the Laplace equation for static field, current density distribution is reachable. By adjustment of anode shape and its position, the current density will change and it will affect the thickness distribution of the Electroformed part (21,23,30). For fixed shape anode, its position in the electrochemical cell can affect the thickness distribution strongly.…”