Electroforming Process and Application to Micro/Macro Manufacturing
ABSTRACT Electroforming is the highly specialised use of electrodeposition for the manufacture of metal parts. This paper describes the process principles and mechanisms of electroforming, outlining its advantages and limitations. A review of modelling and simulation of electroforming and experimental analysis work is also presented. The metals that can be electroformed successfully are copper, nickel, iron or silver, thickness up to 16 mm, dimensional tolerances up to 1 μm, and surface finishes of 0.05 μm Ra. The ability to manufacture complex parts to close tolerances and cost effectively has meant that electroforming has applications both in traditional/macro manufacturing and new micromanufacturing fields. These include tooling; mould making; fabrication of microelectromechanical systems (MEMS) and the combination of lithography, electroforming and plastic moulding in the LIGA process. Applications in micro-optics and medicine are included.
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ABSTRACT: Inaugurated in June 2012, the Carapace at Castelbuono Estate Winery in Italy is a highly interesting example of biomorphic architecture. The structure, an artistic creation of world-renowned sculptor Arnaldo Pomodoro, is reminiscent of a tortoise shell that conveys a sense of protection: the Carapace structure guards wine barriques in the same way that the tortoise carapace protects the animal. Zoomorphic aspects are further exhibited by symbols on the roof, which remind observers of cuttlefish bone, a recurring element in the artistic production of Maestro Pomodoro. The roof was constructed by assembly of single copper plates with a rough surface in accordance with the design of the artist. Therefore, determining the appropriate production process was crucial. Electroforming was selected as the method to achieve a challenging architectural goal.Frontiers of Architectural Research. 01/2013;
- International journal of electrochemical science 01/2014; · 3.73 Impact Factor
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ABSTRACT: Through a bioreplication approach, we have fabricated artificial visual decoys for the invasive species Agrilus planipennis— commonly known as the Emerald Ash Borer (EAB). The mating behavior of this species involves an overflying EAB male pouncing on an EAB female at rest on an ash leaflet before copulating. The male spots the female on the leaflet by visually detecting the iridescent green color of the female’s elytra. As rearing EAB and then deploying dead females as decoys for trapping is both arduous and inconvenient, we decided to fabricate artificial decoys. We used a dead female to make a negative die of nickel and a positive die of epoxy. Decoys were then made by first depositing a quarter-wave-stack Bragg reflector on a polymer sheet and then stamping it with a pair of matched negative and positive dies to take the shape of the upper surface of an EAB female. As nearly 100 artificial decoys were fabricated from just one EAB female, this bioreplication process is industrially scalable. Preliminary results from a field trapping test are indicative of success.Journal of Bionic Engineering 04/2013; 10(2):129-138. · 1.14 Impact Factor