Original Date: 11/03/1996
Revision Date: 01/18/2007

Electroforming can produce freestanding parts by cathodically depositing metal on a mandrel. The same technique allows adherent protective coatings to be applied to a part. By default, electroforming precisely replicates the mandrel surface’s contour. However, the precise control of the opposite contour is a design and control issue. Current electroforming technology relies on multiple iterations of tooling design and fabrication; experimental tests; evaluations; and a highly-experienced expert.

Oak Ridge Centers for Manufacturing Technology (ORCMT) has developed the Electroforming Advisor System. The system offers a more robust method for handling various geometries and situations; improves processing time; performs multiple iterations computationally; and automatically optimizes the cell geometry and electroforming parameters. The system replaces physical, trial-and-error methods; eliminates several discrete modeling and analysis steps; and reduces the waste generation of spent electroforming electrolytes.

ORCMT’s Electroforming Advisor System will allow companies to produce larger quantities of complicated pieces at a fraction of precision machining costs. The pieces can also be manufactured at precise tolerances with less manpower requirements. For actual experimental trials, the Electroforming Advisor System can reduce environmental costs by 90% and turnaround time and costs by 80% compared to current technology.

For more information see the Point of Contact for this survey.