Nickel Alloy Electroplated Precision Mold Cavity And Core With EDM Wire Cutting Process

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.

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.

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.

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.

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.

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.

• 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.