Customizable Nickel Alloy Electroplated Precision Mold Cavity And Core With Grinding Polishing Process
Compatibility
Suitable For High-Gloss & Precision Molding (Optical, Medical, Automotive) | Ra ≤0.008μm Mirror Finish
Product Specifications
| Attribute | Value |
|---|
| Product Name | Customizable Nickel Alloy Electroplated Precision Mold Cavity and Core |
| Highlight | Tailored designs, grinding-polished mirror surfaces, nickel alloy durability |
| Tolerance | ±0.002mm (critical features); ±0.005mm (general areas) |
| Hardness | 48-53 HRC (nickel-cobalt); 43-47 HRC (pure nickel) |
| Feature | Ra ≤0.008μm surface finish, corrosion-resistant, custom geometry support |
| Processing Method | Electroplating (base forming) + Precision grinding + Polishing (surface refinement) |
| Material | High-purity nickel (99.95%), nickel-cobalt (12-18% Co), nickel-chromium (10-15% Cr) |
| Application | Optical lenses, medical diagnostics, automotive lighting, high-end electronics |
Engineered for parts where surface perfection and custom geometry are critical, our customizable nickel alloy electroplated mold cavities and cores combine electroforming (for complex shape replication) with precision grinding and polishing (for mirror-like finishes). Ideal for industries demanding both tight tolerances (±0.002mm) and ultra-smooth surfaces (Ra ≤0.008μm), these molds turn your unique designs into high-performance production tools.
Core Advantages: Customization + Grinding Polishing = Surface Excellence
Ra ≤0.008μm Mirror Finish: Critical for Optical & Functional Performance
The grinding and polishing process elevates surface quality beyond standard electroforming, making these molds indispensable for light-sensitive or friction-critical parts:
- Grinding for Flatness: Precision grinding (with 0.001mm feed rates) ensures cavity/core flatness within 0.002mm, eliminating "waviness" that distorts optical parts (e.g., lens molds).
- Polishing for Smoothness: Multi-stage polishing (from 1μm to 0.05μm abrasives) achieves Ra ≤0.008μm—so molded parts (like automotive LED reflectors) reflect 95%+ light without scattering.
- Consistent Finish Across Custom Shapes: Even for curved, asymmetrical, or deep-cavity designs (e.g., medical catheter molds), our process maintains uniform smoothness, preventing fluid turbulence or light distortion.
Full Customization: Adapt to Your Unique Geometry
We tailor every aspect of the mold to match your part’s design, no matter how complex:
- Geometry Flexibility: Support for custom features like micro-grooves (0.05mm wide), undercuts, 3D curved surfaces, and thin walls (0.07mm)—ideal for lab-on-a-chip devices or optical prisms.
- Size Customization: Molds range from micro-components (φ2mm) to large panels (500*300mm), with grinding/polishing scaled to maintain precision across all sizes.
- Alloy Tuning: Choose nickel alloy based on your needs: pure nickel for biocompatibility (medical), nickel-cobalt for wear resistance (high-volume production), or nickel-chromium for corrosion resistance (outdoor automotive parts).
Nickel Alloy Durability: Long-Lasting Performance in Demanding Cycles
Built to withstand repeated use while preserving their mirror finish, these molds deliver reliability:
- Wear Resistance: Nickel-cobalt alloy (12-18% Co) resists abrasion from molding materials (e.g., glass-filled plastics), maintaining Ra ≤0.01μm even after 150,000+ cycles.
- Corrosion Resistance: Nickel-chromium variants stand up to cleaning agents (e.g., isopropyl alcohol in electronics production) and bodily fluids (medical molds), avoiding surface degradation.
- Thermal Stability: Withstands temperatures up to 280°C, suitable for molding high-heat resins (PEEK, PSU) used in automotive underhood parts.
Application Scenarios: Where Surface & Customization Matter Most
Our customizable, grinding-polished molds excel in industries where surface quality directly impacts performance:
- Optical Engineering: Producing lens molds (Ra ≤0.008μm ensures light transmission) and laser component cavities (no surface defects to scatter beams).
- Medical Diagnostics: Molding microfluidic chip cavities (smooth walls prevent sample trapping) and diagnostic slide molds (uniform surface for consistent test results).
- Automotive Lighting: Creating LED reflector molds (mirror finish for bright, even light) and headlight lens cavities (precision geometry for beam focus).
- High-End Electronics: Manufacturing smartphone camera module molds (surface smoothness for image clarity) and sensor housing cores (custom shapes for compact device design).
Tailored to Your Needs: Customization Support
We work with your team to turn designs into optimized molds:
- DFM Collaboration: Our engineers review your 3D CAD files to recommend geometry tweaks (e.g., adding draft angles to deep cavities) that enhance grinding/polishing results and reduce costs.
- Surface Finish Customization: Adjust Ra values (from 0.008μm to 0.02μm) based on your part’s needs—no over-engineering, just the right finish for performance.
- Prototype to Production: Start with a custom prototype mold (7-10 days) to validate surface quality and geometry, then scale to mass production with identical precision.
Our Service Commitment
- Quality Verified: 100% surface finish testing via laser confocal microscopy (measures Ra to ±0.001μm) and CMM inspection for tolerance compliance.
- Traceability: Full documentation (material certs, grinding/polishing logs, electroplating parameters) to meet ISO 9001, ISO 13485 (medical), and ECE R112 (automotive lighting) standards.
- Technical Support: Dedicated team advises on alloy selection, surface finish requirements, and mold maintenance to preserve mirror quality over time.
Whether you need a custom mold for a one-of-a-kind optical part or high-volume medical components, our nickel alloy electroplated cavities and cores—refined by grinding and polishing—deliver the surface perfection, precision, and customization your production demands. Backed by Ra ≤0.008μm smoothness and ±0.002mm tolerance, they ensure every molded part meets your strictest standards.
