Material-Compatible Electroforming Molds for Aluminum | ±0.005mm High Precision

Core Advantages: Precision, Compatibility & Reliability

1. ±0.005mm High Precision for Aluminum & Beyond

• Micron-Level Control: With dimensional tolerance as tight as ±0.005mm, these molds excel at reproducing intricate details—from thin aluminum walls (0.1–2mm) and micro-textures to asymmetrical structures (e.g., aerospace brackets or electronic connectors).
• Consistent Feature Replication: Electroforming technology captures fine geometries (e.g., 0.05mm micro-ribs or threaded inserts) with 99.9% fidelity, critical for aluminum parts requiring tight assembly or functional precision.
• Surface Finish Excellence: Achieve Ra ≤0.01μm surface smoothness on molded aluminum parts, eliminating post-processing needs and enhancing part performance (e.g., reducing friction in moving components).

2. Broad Material Compatibility for Versatile Production

• Aluminum Expertise: Optimized for aluminum alloys (6061, 7075, etc.), ideal for lightweight, high-strength parts in automotive, drones, and industrial machinery.
• Multi-Material Support: Compatible with other substrates including copper, nickel alloys, and even plastic-aluminum composites—enabling seamless production of hybrid components (e.g., aluminum-electronic part assemblies).
• Material-Specific Tuning: Molds are tailored to handle material-specific properties, such as aluminum’s thermal conductivity, ensuring uniform cooling and preventing warping during production.

3. Durable Electroforming for Long-Lasting Performance

• Robust Construction: Made from high-purity electroformed nickel or nickel-cobalt alloys, the molds resist wear and corrosion—supporting ≥100,000 production cycles for aluminum parts without accuracy degradation.
• Thermal Stability: Withstand temperatures up to 200°C, making them suitable for high-temperature aluminum forming processes or post-molding treatments (e.g., anodizing or coating).
• Low Maintenance: Smooth, non-stick surfaces reduce material adhesion, minimizing downtime for cleaning and extending mold lifespan.

Application Scenarios: Where Precision & Compatibility Matter

• Aerospace & Defense: Production of lightweight aluminum structural parts, sensor housings, and precision brackets requiring ±0.005mm tolerance.
• Electronics: Molding aluminum heat sinks, connector shells, and chassis components with micro-features for thermal management and connectivity.
• Automotive: Manufacturing aluminum trim, valve components, and ADAS (Advanced Driver-Assistance Systems) parts needing tight dimensional control.
• Industrial Machinery: Producing aluminum gears, guides, and tooling components where material compatibility and precision drive performance.

Tailored to Your Needs: Customization & Support

• Material-Specific Optimization: Adjust mold design for your target material (e.g., tuning for aluminum’s flow properties or copper’s conductivity) to maximize part quality.
• Size Flexibility: Support aluminum parts ranging from small (φ5mm micro-components) to medium-sized (500×300mm panels), with custom cavity configurations for multi-part production.
• DFM Expertise: Our engineers analyze your part design to optimize mold geometry for material compatibility and precision—reducing trial-and-error and accelerating production.

Our Service Commitment

• Quality Assured: All molds undergo 100% 3D inspection (via CMM with ±0.001mm accuracy) to verify ±0.005mm tolerance compliance.
• Material Traceability: Full documentation for mold materials and electroforming processes, ensuring compliance with industry standards (ISO 9001, AS9100 for aerospace).
• Technical Support: Dedicated teams provide guidance on material pairing, production parameters, and maintenance to maximize mold performance and lifespan.