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Servometer produces parts by the process of electrodeposition, building thin layers of metal onto a precision-machined mandrel and chemically removing the mandrel. Electroforming technology is centuries old, yet Servometer has refined its technique to make intricate parts with unusual shapes, thin walls, deep crevices and other design features. Tightly controlled electrodepositing baths ensure the highest part quality. Modern test instruments, over 120 years of in-house design engineering experience, and highly skilled chemists ensure exceptional quality.
Electroforming
| The process begins with a piece of Aluminum. |  |
| Next, the internal geometry of the electroform or bellows is machined into the Aluminum. This machined part is called a mandrel. |  |
| After inspection, nickel (nickel alloy), copper, gold, silver or combinations thereof, are electrodeposited (electroplated) onto the mandrel to precise wall thicknesses. The thickness of the electroform is dependent on the time and current in the plating process. |  |
| Following post-plate inspection, the plated mandrel is trimmed to produce the desired end configuration dimensions. |  |
| Finally, the aluminum mandrel is dissolved in caustic solution leaving behind the completed electroform or bellows. At this point, special finishes or coatings may be applied. Bellows are leak-tested and spring rate tested as required. |  |
Servometer’s electroforming process is especially crafted for tolerance-critical, miniature parts. The precision electroforming process produces hollow parts with walls as thin as 0.0003″ [.008 mm]. Miniature applications include electrical contact springs with walls 0.0005″ [.013 mm] thick for circuit boards and flexible nickel bellows just 0.020″ [.51 mm] diameter for laboratory instruments. Larger parts are produced with walls up to 0.025″ [0.64 mm] thick. Servometer has even electroformed ultra lightweight reflectors several feet in diameter.
Electroforms can add the structural rigidity and temperature capability of metal with only the weight of plastic. Materials such as nickel, copper, gold, silver or a combination thereof can be used with custom finishes on the inside or outside surfaces. Servometer also offers different types of materials depending on the installation method; for example, if the part is going to be welded or brazed, the chemistry of the nickel can be altered to accommodate the installation requirements. The metal composition is critical to the performance and ruggedness of the electroform.
Complex geometry is achievable. Aluminum mandrels can be combined prior to plating to yield a seamless electroform assembly. Engineering design, machining and tooling are controlled at Servometer’s New Jersey facility.
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