Nickel Alloy Electroplated Precision Mold Cavity And Core With EDM Wire Cutting Process
Compatibility
Suitable for precision engineering parts (complex geometry, micro-features) with ±0.002mm dimensional accuracy. Compatible with high-purity metals (nickel alloys, copper) and precision plastics.
Product Specifications
| Attribute |
Value |
| Product Name |
Custom Mold Cores (Precision Engineering) – Electroforming Process |
| Highlight |
Factory-direct supply, electroformed complex geometry, micron-level precision, fully customizable |
| Tolerance |
±0.002mm (critical features: micro-ribs, thin walls); ±0.005mm (general areas) |
| Hardness |
45-50 HRC (pure nickel); 50-55 HRC (nickel-cobalt alloy); 48-52 HRC (nickel-copper alloy) |
| Feature |
Ra ≤0.01μm surface finish, no internal stress, corrosion-resistant, high replication fidelity (99.9%) |
| Processing Method |
Factory-integrated electroforming (nickel ion deposition) + CNC trimming (precision calibration) |
| Material |
High-purity nickel (99.95%), nickel-cobalt (15-20% Co), nickel-copper (10-15% Cu) |
| Application |
Aerospace precision components, medical micro-devices, optical instrument parts, industrial metrology tools |
As a factory specializing in electroforming for precision engineering, we directly supply custom mold cores that solve "complex geometry + high precision" pain points—challenges traditional machining (CNC, EDM) can't address. Our core strength lies in integrating the full electroforming process in-house: from designing conductive masters to depositing uniform nickel alloy layers, then calibrating to ±0.002mm tolerance.
Core Advantages: Factory Electroforming + Direct Supply = Precision & Efficiency
Electroforming: Master of Complex, Precision Mold Cores
Electroforming's "layer-by-layer deposition" logic outperforms traditional machining for precision engineering needs:
- Complex Geometry Replication: Creates mold cores with 0.05mm micro-ribs, 0.08mm thin walls, or 3D curved surfaces—ideal for aerospace sensor housings (irregular cavities) or medical microfluidic chips (tiny flow channels) that CNC can't shape without distortion.
- Micron-Level Precision: Controls nickel alloy deposition to ±0.001mm thickness, then trims to ±0.002mm dimensional tolerance—critical for metrology tool mold cores (where 0.003mm deviation ruins measurement accuracy).
- Stress-Free Structure: Electroformed mold cores have no internal stress (unlike machined cores, which risk warping under heat), ensuring stable performance across 150,000+ production cycles.
Factory Direct Supply: Faster Lead Times & Lower Costs
As the manufacturer (not a distributor), we streamline the process for precision engineering clients:
- Shorter Turnaround: In-house electroforming eliminates middleman delays—prototyping takes 10-15 days (vs. 20+ days from distributors), and mass production (100+ units) takes 20-25 days.
- Cost Savings: Direct supply cuts 15-20% of distributor markup, while in-house process optimization (e.g., reusable master molds for small batches) reduces custom mold core costs further.
- Full Process Control: We own every step—from master mold design to final inspection—so we can adjust parameters (e.g., nickel alloy composition, deposition speed) in real time to meet your unique requirements.
Nickel Alloy Durability: Built for Precision Engineering Demands
Our mold cores use high-performance nickel alloys tailored to precision engineering's harsh conditions:
- Wear Resistance: Nickel-cobalt alloy (15-20% Co) with 50-55 HRC hardness resists abrasion from high-pressure molding of engineering plastics (PEEK, LCP) or metal powders—ideal for aerospace part production.
- Corrosion Resistance: Nickel-copper alloy (10-15% Cu) stands up to coolants, disinfectants, and industrial fluids, making it suitable for medical device mold cores (contact with bodily fluids) or metrology tools (used in cleanrooms).
- Thermal Stability: Withstands temperatures up to 300°C (nickel-chromium variants), supporting high-temperature molding of precision components like automotive engine sensors or aerospace turbine parts.
Application Scenarios: Precision Engineering Fields We Serve
Our direct-supply, electroformed custom mold cores are critical for industries where "micron-level error = failure":
- Aerospace & Defense: Mold cores for avionics sensor housings (0.05mm micro-grooves for wire routing) and turbine blade cooling channel inserts (complex 3D geometry) — meets AS9100 standards.
- Medical Devices: Custom cores for microfluidic chip molds (0.1mm flow channels) and surgical instrument handles (biocompatible pure nickel) — complies with ISO 13485.
- Optical Instruments: Mold cores for lens mounts (Ra ≤0.01μm surface finish to avoid light scattering) and laser component housings (±0.002mm tolerance for alignment) — aligns with ISO 10110 optical standards.
- Industrial Metrology: Cores for precision gauge molds (e.g., caliper jaws) where dimensional stability ensures long-term measurement accuracy — meets ISO 9001 quality requirements.
Tailored to Your Precision Engineering Needs: Customization Support
We don't just supply mold cores—we collaborate to solve your unique challenges:
- Design Collaboration: Our engineers review your 3D CAD files (STEP, IGES) to optimize for electroforming (e.g., reinforcing 0.08mm thin walls, adjusting draft angles for easy demolding) — reducing redesigns by 80%.
- Material Customization: Choose nickel alloy based on your application: pure nickel for biocompatibility, nickel-cobalt for wear resistance, or nickel-copper for corrosion protection.
- Batch Flexibility: Support small-batch (1-10 units) prototyping for R&D projects and large-batch (1000+ units) production for mass manufacturing—with consistent precision across all orders.
Our Service Commitment (Factory Direct Advantage)
- Quality Assurance: 100% inspection via CMM (±0.0005mm accuracy) and laser confocal microscopy (for surface finish) — every mold core comes with a detailed inspection report.
- Traceability: Full documentation package: nickel alloy material certificates, electroforming process logs (current density, electrolyte temperature), and CNC trimming records — meets global precision engineering standards.
- Technical Support: Dedicated engineers provide post-delivery support (e.g., mold maintenance tips, troubleshooting production issues) — available 24/7 for urgent precision projects.
Whether you need 1 custom mold core for a metrology tool prototype or 500 for aerospace sensor production, our factory-direct electroformed mold cores deliver the precision, durability, and efficiency your precision engineering projects demand. Backed by ±0.002mm tolerance and in-house process control, we turn your complex designs into reliable production tools—fast and cost-effectively.
