What is the difference between Electroforming and other manufacturing techniques? This post will review on Cost Efficiency, Lead Time, Design Complexity, and Quality/Accuracy.
Electroforming vs. 3D Printing
(1) Cost Efficiency
A 3D printer and its corresponding materials can be cheaper than electroforming equipment, so 3D Printing seems more cost-effective when
you want to create just a small amount of products yourself in-house. When you are going for industrial-scale production, however, the higher the volume, the more favorable Electroforming becomes.
(2) Lead Time
3D Printing of metal parts is still in its infancy. The technique entails printing with minuscule
metal powdered parts. After printing, the metal needs to be heated (sintered) in order to suture. In addition to the time-consuming sintering process, the printed layers also need to dry so that they don’t sag. These two steps both take a considerable amount of time, which
makes 3D Printing a relatively slow procedure for fabricating metal parts. Additionally, 3D Printing can only deal with one part at a time. Electroforming, on the other hand, is much
faster a process, during which you can grow a large number of parts simultaneously (in one
electrolytic bath).
(3) Design Complexity
Electroforming allows for great design flexibility as it requires almost no tooling investment and that it has a very short lead time. With regard to material, however, Electroforming mainly works with nickel and copper. For medical applications, for instance, nickel components can be coated with a layer of a PdNi alloy. 3D Printing also allows for a high level of design flexibility and the range of material usage is much wider.
(4) Quality/Accuracy
Electroforming allows you to grow material on a micro scale, resulting in absolute accuracy and high aspect ratios. The standard deviation of electroformed parts is less than 1% of the material’s thickness. Orifices of just a couple of microns are no exception. 3D Printing can currently achieve a 100-micron range of precision at its best. The technique can be 100 times less precise than electroforming.
Electroforming vs. Laser Cutting
(1) Cost Efficiency
When it’s a small volume production or prototyping, Laser Cutting can be more cost-effective than Electroforming. When it’s industrial mass production, however, Laser Cutting loses its advantage in costs and Electroforming becomes the favorable option.
(2) Lead Time
With Laser Cutting, you can’t produce multiple parts simultaneously, while with Electroforming you can. Compared to Laser Cutting, which can only deal with one component after another, Electroforming is a process that can harvest a large number of products in every run. When production volume is very low, Laser Cutting
might have an advantage in speed over Electroforming. However, when it is industrial production, the lead time of Electroforming is shorter.
(3) Design Complexity
Electroforming and Laser Cutting are both highly flexible regarding design. When the design is very complex, however, Laser Cutting might take a much longer time since it can only
deal with one part/feature after another while Electroforming works on the complete design
simultaneously and can harvest a large amount of product in one run. When it comes to materials, Electroforming has some limitations while Laser Cutting can work with a wider range of materials.
(4) Quality/Accuracy
Electroforming is a high-precision manufacturing process that does not change the properties of metals such as hardness, grain structure, or ductility. With Electroforming, you can harvest ultra-precision thin metal parts burr- and stress-free. Laser Cutting, on the other hand, is a thermal process that results in thermal stress, as well as micro burrs.
Thus, compared to Laser Cutting, Electroforming is the more optimal choice when it is large volume production of precision thin metal parts, especially when the design is complex and quality/accuracy demand is high. When it is about material choice, Laser Cutting has the advantage over Electroforming.
Electroforming vs. Stamping
(1) Cost Efficiency
Unlike Electroforming which features no tooling cost, Stamping always requires substantial investment in tooling and installation: both monetary wise and time-wise. One stamping dies can easily cost thousands of dollars, not to mention the extra costs for setting up and maintenance costs over time.
(2) Lead Time
With Stamping, the lead time can be 6-8 weeks only for preparing the tooling. Even after the stamping tool is completed, extra time (and costs) will incur for setting up the tooling in the stamping press. With Electroforming, lead time is a matter of days. Compared to those who still stamp their precision metal components, you can receive your ultra-precision electroformed parts even before their stamping tool is ready!
(3) Design Complexity
Electroforming allows for more design flexibility as it requires no hard tooling and that it has a very short lead time, while with Stamping modifying a design means making a completely new die and investing in tooling and setting up all over again. This also means that Electroforming is perfect for a small amount of prototyping as well as industrial production. When it comes to material choice, however, Stamping allows for more flexibility than Electroforming.
(4) Quality/Accuracy
Electroforming is an ultra-precision micro-manufacturing technology. With Electroforming, a higher level of accuracy and precision can be achieved. Moreover, electroformed parts are
completely burr- and stress-free while stamped parts feature partial burrs and stress at the cutting edge. Although minor burr or stress can be acceptable for some applications, it might be a stumbling block for your next breakthrough.
Thus, compared to Stamping, or Micro Stamping, Electroforming has a shorter lead time, lower costs, better quality, and more design flexibility (when the material is not an issue).
To learn more about the benefits of Electroforming, and how it can drive continuous innovation for you as an engineer, download the Whitepaper Electroforming here.
Interested to learn more about Electroforming?
Download the Whitepaper on Electroforming here.
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