specialist materials used in electroforming from Veco
May 11, 2026 8:56:21 AM By Clare LambElectroforming is a precision metal‑forming process in which metal is deposited onto a conductive mould (or mandrel) by electroplating until the deposited layer is thick enough to be self‑supporting. Electroforming form Veco produces a freestanding metal component with extremely high dimensional accuracy and surface fidelity.
Because electroforming relies on controlled electrochemical deposition, only certain materials can be used successfully. The choice of material affects mechanical strength, conductivity, corrosion resistance, cost, and suitability for specific applications such as aerospace, semiconductors, green tech solutions, and medical devices.
Significantly, the specialist materials we use can be combined in one product to meet specific demands of the application.
This article explores the most common materials that we electroform, their properties, and typical uses.
general requirements for electroforming materials
For a material to be suitable for electroforming, it must meet several criteria:
- Electrochemical stability in aqueous plating baths
- Ability to form uniform, adherent deposits
- Reasonable control over grain size and internal stress
- Compatibility with available electrolytes and anodes
In practice, this limits electroforming primarily to metals and metal alloys.
All electroformed metallic components can be produced on a mandrel that is made from copper, brass or stainless steel dependent on the complexity of shape and features required.
copper
Copper is a widely electroformed metal due to its excellent electrical conductivity and ease of deposition.
Key Properties
- Very high electrical and thermal conductivity
- Good ductility
- Relatively low cost
- Easily plated with low internal stress
Applications
- Electrical components and waveguides
- RF and microwave parts
- Direct to chip (D2C) cooling
- EMI shielding
Copper electroforms can be reinforced or plated with nickel to improve mechanical strength or wear resistance.
nickel
Nickel is the most common material we use for high‑precision and structural applications.
Key Properties
- High tensile strength
- Excellent wear resistance
- Good corrosion resistance
- Can be deposited with very low internal stress
- Replicates fine surface details extremely well
Variants
- Pure nickel (Veco-84) – high ductility and strength
- Nickel sulfamate – also pure nickel -preferred for low‑stress electroforming
- Nickel – Palladium alloy for biocompatibility and corrosion
Applications
- Filtration
- High precision mesh
- Nozzle plates
- Optical and holographic components
- Aerospace parts
- Medical devices
- MEMS (micro‑electromechanical systems)
gold
Gold can be electroformed when chemical inertness and conductivity are paramount.
Key Properties
- High optical reflection
- Exceptional corrosion resistance
- Stable electrical performance
- Biocompatible
- Relatively soft unless alloyed
Applications
- Optical components
- High‑reliability electrical contacts
- Medical and dental components
- Microelectronics and MEMS
Limitations
-
- high material cost
- Lower mechanical strength unless alloyed
conclusion
Electroforming is a highly versatile manufacturing technique, but it is inherently material‑selective. Significantly, the specialist materials we use can be combined in one product to meet specific demands of the application.