This article delves into the fundamentals of EMI gaskets, types, and their critical role in protecting electronic devices and ensuring optimal performance in various engineering applications.

EMI Gaskets: The Unsung Heroes of Electromagnetic Interference Shielding

<h2 id="isPasted">1. excellent surface finishing that enhances optical performance</h2>Electroformed optical parts exhibit excellent surface smoothness free from defects and irregularities, which is crucial for achieving high image quality and resolution. The smooth surfaces minimize light scattering and diffraction, resulting in sharper and clearer images. This is particularly important in applications such as high-resolution imaging systems, microscopy, and telescopes, where even the slightest surface imperfections can lead to image degradation.Moreover, the high reflectivity of Electroformed metal surfaces contributes to increased light throughput and efficiency in optical systems. With <a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a> mirror-like finishing can be achieved that allows for efficient reflection and transmission of light, minimizing losses due to absorption or scattering. This is particularly beneficial in applications where light collection and efficiency are critical, such as in astronomical telescopes, spectrometers, and illumination systems. The increased light throughput and efficiency of electroformed optical parts lead to improved signal-to-noise ratios, higher sensitivity, and better overall performance of the optical system.<h2>2. superior durability and resistance that increase product reliability and longevity</h2>Electroformed optical parts demonstrate excellent resistance to environmental factors, such as moisture, corrosion, and chemical exposure, which is especially important in applications where the optical parts are exposed to harsh or corrosive environments, such as in marine or industrial settings. The ability of electroformed optical parts to withstand these environmental challenges ensures their long-term reliability and performance stability, which eliminates the need for frequent recalibration or adjustments, reducing downtime and increasing the overall efficiency of the optical system.The increased durability and reliability also translate to reduced maintenance and replacement costs over the lifetime of the optical component. Unlike other manufacturing methods that may produce parts with shorter lifespans or require frequent repairs, electroformed optical parts maintain their performance and integrity for extended periods. This longevity is particularly valuable in applications where the optical components are difficult to access or replace, such as in satellite systems or deep-sea instrumentation.<h2>3. Precision engineering capabilities that enable advanced optical designs and configurations</h2>As an&nbsp;<a href="https://www.vecoprecision.com/electroforming/electroforming-process/" rel="noopener" target="_blank">Additive Manufacturing process</a>, Electroforming technology offers the unique ability to integrate multiple optical functions into a single component. With Electroforming, it is possible to create complex optical structures that combine several optical elements. This simplifies the overall optical system, reduces the number of components required, and improves the alignment and stability of the system.Electroforming technology also offers excellent design flexibility. As Electroforming allows for the creation of complex, &nbsp;freeform optical surfaces, it enables the realization of advanced optical designs and configurations that may be challenging or impossible to achieve with traditional manufacturing methods. This design freedom opens up new possibilities for optical engineers to develop innovative and high-performance optical systems.<h2>4. Miniaturization and precision features that improve user experience</h2>Electroformed optical parts play a crucial role in enhancing the user experience. For example in consumer electronics, particularly in imaging devices such as smartphones, digital cameras, and virtual reality headsets, the high precision and surface quality of electroformed lenses and mirrors enable the capture and display of clearer and sharper images, with reduced distortions and aberrations. Users benefit from improved image quality, higher resolution, and better color reproduction, resulting in a more immersive and satisfying visual experience.The miniaturized optical parts enabled by Electroforming also allow for the design of sleeker and more portable consumer devices, further enhancing user convenience and satisfaction. This is particularly valuable in applications where size and weight are critical factors, such as in smartphones, wearable devices, and portable medical instruments. By incorporating high-precision miniaturized optical parts, manufacturers can design devices that are more compact, lightweight, and ergonomic, making them easier to carry and use on the go.In conclusion, electroformed optical parts offer a wide range of benefits, making electroformed optical parts a preferred choice for various industries, including consumer electronics, automotive, aerospace, scientific instrumentation, and medical devices.

Electroforming technology has emerged as the most suitable method for manufacturing high-quality optical parts due to its unique combination of high precision, material properties, and design flexibility.  

Applications of Electroforming: why Electroforming is the ideal solution for manufacturing optical parts

Electroforming is a metal forming process used to manufacture high-precision and high-performance components. Its unique combination of high resolution, excellent strength, chemical resistance, and unparalleled design flexibility make it the manufacturing technology of choice for fabricating advanced filtration components where precision, performance, and reliability are paramount. This article introduces typical applications of Electroforming in the field of filtration in the Food &amp; Beverage industry.<h2>sugar filtration screens</h2>In sugar manufacturing, filtration is a critical process for separating sugar crystals from the massecuite/thick juice. The performance of a&nbsp;<a href="https://www.vecoprecision.com/products/sugar-screens/" rel="noopener" target="_blank">sugar screen</a> directly impacts sugar yields and sugar quality. As the original developer and the world’s largest manufacturer, Veco manufactures Electroformed sugar filtration screens that&nbsp; deliver anti-clogging performance, smoother surfaces, enhanced durability, and higher throughput compared to conventional filtration media.<img data-fr-image-pasted="true" src="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg?width=1200&amp;height=429&amp;name=1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg" width="1200" height="429" alt="sugar sieve" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg?width=600&amp;height=215&amp;name=1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg 600w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg?width=1200&amp;height=429&amp;name=1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg 1200w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg?width=1800&amp;height=644&amp;name=1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg 1800w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg?width=2400&amp;height=858&amp;name=1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg 2400w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg?width=3000&amp;height=1073&amp;name=1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg 3000w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg?width=3600&amp;height=1287&amp;name=1%20-%20sugar%20sieve%20all%20original_BAS7503.jpeg 3600w" sizes="(max-width: 1200px) 100vw, 1200px" id="isPasted" class="fr-fic fr-dii">The Electroformed sugar screens are engineered with unique bell-mouth-shaped apertures that prevent clogging and blinding during use. This anti-clogging design provides consistent throughput and maximizes the efficiency of the filtration process. The Electroforming process also enables an ultra-smooth screen surface finish devoid of any burrs or bumps, preventing buildup on the screen surface and contributing to the self-cleaning effect. In addition, Veco’s Electroformed sugar screens last longer with less maintenance and higher efficiency. Veco Life in particular lasts up to twice as long as standard screens. What’s more, Veco provides sugar screens with exceptionally high open area, which translates to throughput increases of up to 170%, maximizing the processing capacity and sugar yields.<h2>coffee filters</h2><img data-fr-image-pasted="true" src="https://insights.vecoprecision.com/hs-fs/hubfs/_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg?width=717&amp;height=325&amp;name=_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg" width="717" height="325" alt="coffee filter" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg?width=359&amp;height=163&amp;name=_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg 359w, https://insights.vecoprecision.com/hs-fs/hubfs/_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg?width=717&amp;height=325&amp;name=_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg 717w, https://insights.vecoprecision.com/hs-fs/hubfs/_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg?width=1076&amp;height=488&amp;name=_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg 1076w, https://insights.vecoprecision.com/hs-fs/hubfs/_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg?width=1434&amp;height=650&amp;name=_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg 1434w, https://insights.vecoprecision.com/hs-fs/hubfs/_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg?width=1793&amp;height=813&amp;name=_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg 1793w, https://insights.vecoprecision.com/hs-fs/hubfs/_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg?width=2151&amp;height=975&amp;name=_edca1f47-75d7-44e7-b612-856c365d8d70-1.jpeg 2151w" sizes="(max-width: 717px) 100vw, 717px" id="isPasted" class="fr-fic fr-dii"><a href="https://www.vecoprecision.com/products/coffee-filters/" rel="noopener" target="_blank">Coffee filters</a> play a vital role in delivering optimized coffee flavor. The hole configuration directly impacts functionality and taste. Parameters like size, shape, profile, and surface smoothness are crucial to prevent clogging and channeling while allowing efficient throughput. Veco utilizes its expertise in Electroforming technology to engineer filter screens with superior hole configurations, resulting in smooth, flavorful coffee free of particulates.Electroforming enables the fabrication of coffee filters with specialized hole geometries to ensure efficient throughput, prevent clogging, and reduce flow restrictions. This includes innovative bell-shaped holes that actively repel particulates. The process also creates an ultra-smooth surface finish devoid of burrs that could hinder performance. In addition, Electroforming can produce micro-precision filter components with hole sizes and shapes not feasible with conventional metal fabrication. It also allows exceptionally high open area and throughput where needed.<h2>filtration screens for the production of MSG, edible oils, and more.</h2><img data-fr-image-pasted="true" src="https://insights.vecoprecision.com/hs-fs/hubfs/filtration_step_in_the_production-1.png?width=1024&amp;height=481&amp;name=filtration_step_in_the_production-1.png" width="1024" height="481" alt="filtration_step_in_the_production-1" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/filtration_step_in_the_production-1.png?width=512&amp;height=241&amp;name=filtration_step_in_the_production-1.png 512w, https://insights.vecoprecision.com/hs-fs/hubfs/filtration_step_in_the_production-1.png?width=1024&amp;height=481&amp;name=filtration_step_in_the_production-1.png 1024w, https://insights.vecoprecision.com/hs-fs/hubfs/filtration_step_in_the_production-1.png?width=1536&amp;height=722&amp;name=filtration_step_in_the_production-1.png 1536w, https://insights.vecoprecision.com/hs-fs/hubfs/filtration_step_in_the_production-1.png?width=2048&amp;height=962&amp;name=filtration_step_in_the_production-1.png 2048w, https://insights.vecoprecision.com/hs-fs/hubfs/filtration_step_in_the_production-1.png?width=2560&amp;height=1203&amp;name=filtration_step_in_the_production-1.png 2560w, https://insights.vecoprecision.com/hs-fs/hubfs/filtration_step_in_the_production-1.png?width=3072&amp;height=1443&amp;name=filtration_step_in_the_production-1.png 3072w" sizes="(max-width: 1024px) 100vw, 1024px" class="fr-fic fr-dii">Monosodium glutamate (MSG) is one of the most widely used food additives in the world. A critical step in MSG production is filtration to remove impurities and particulates. High-quality filtration screens are crucial for efficient MSG purification. Electroformed filtration screens are an optimal choice for MSG filtration thanks to precise pore size, smooth surfaces, high strength, and customizability. Fabricated from nickel and other high-quality alloys, electroformed screens provide durability and corrosion resistance that withstand steam sterilization and cleaning cycles in MSG production processes. Furthermore, Electroforming enables screens to be tailored to the unique particulate characteristics, viscosity, and volumes associated with MSG processes.In&nbsp;edible oil&nbsp;manufacturing, filtration is a vital process for removing contaminants and purifying crude vegetable oils. The quality of oil filtration screens directly impacts oil quality, process efficiency, and production costs. Veco’s advanced Electroforming technology can be used to produce filtration screens that optimize edible oil purification and deliver superior contaminant retention, extended lifetimes, increased durability, and maximum process efficiency to produce the highest quality edible oils. Moreover, Electroforming enables complete customization of oil filtration screen design parameters for maximized filtration performance, lifetime, and oil quality. Across the food and beverage industry, precision-engineered electroformed filtration screens have the potential to advance processing efficiency, product purity, and quality with a wide range of applications. For example:<ul><li>For wine &amp; beer production, precision-engineered filtration screens enabled by advanced Electroforming technology can effectively remove haze-forming particles and microorganisms for stability, clarity, and health safety of alcoholic beverages.</li><li>In the production of dairy products, electroformed microfiltration screens can help remove protein and lipids from milk and whey.</li><li>In juice production, high-precision electroformed screens can be used to clarify and cold-sterilize fruit and vegetable juices while minimizing product loss. In summary, Electroforming is an essential metal fabrication technology for producing high-performance filtration components. It enables excellent control over feature profiles, pore dimensions, surface smoothness, and other properties important for efficient particle capture and flow characteristics. The versatility of Electroforming also allows a wide range of filtration solutions for applications in the Food &amp; Beverage industry.</li></ul>

This article introduces typical applications of Electroforming in the field of filtration in the Food & Beverage industry.



Applications of Electroforming: filtration applications in the Food & Beverage industry

Filtration screens are essential components that are widely used across industries to separate solid particles from liquids or gases. Common applications include water purification, beverage clarification, pharmaceutical manufacturing, automotive fuel and oil filtration, air purification, etc. They serve critical purposes such as removing contaminants, classifying particles by size, protecting sensitive equipment, clarifying liquids, and more. The performance of filtration screens depends heavily on characteristics like pore size, distribution, shape, orientation, chemical resistance, and mechanical strength. Electroforming has proven to be an unparalleled manufacturing method capable of meeting the strictest demands for high-precision filtration applications. <a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a>, also known as Photo Electroforming or Lithographic Electroforming, is a versatile manufacturing process that utilizes lithography and electrodeposition processes to produce high-precision metal parts and components. The process is particularly suitable for creating complex shapes and very fine structures, which makes it ideal for manufacturing filtration applications with high precision requirements.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA3ODMxNzA1NTg0LVZlY28tRUZfY2FwYWJpbGl0aWVzLXYxLjItMy5qcGVnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 759px;" class="fr-fic fr-dib">While many fabrication techniques can be used to produce porous filtration components, Electroforming technology stands out for its high precision, superior strength, design flexibility, and advanced feature engineering.<h2>(1) high resolution</h2>The Electroforming process allows exceptionally fine control down to 1 micron, beyond what other manufacturing methods can achieve, making it especially ideal for microfiltration applications. In comparison, Laser drilling is limited to hole diameters of around 10-20 microns due to factors like beam focus limitations, thermal diffusion, and melt ejection. Micromachining techniques can reach 5 microns but have reduced material integrity at small scales, not to mention conventional machining is limited to 50 microns and above.<h2>(2) superior strength</h2>In addition to resolution, Electroforming also enables very high strength. For example, Veco’s specially developed nickel can achieve tensile strength of 2200-2300 MPa and yield strength from 1900 to 2100 MPa. The superior strength and excellent strength-to-weight ratio make it suitable for filtration applications that need to withstand high pressures and flow rates without distortion or failure. In comparison, Laser drilling induces thermal stresses and alloying effects that reduce strength. Micromachined components have reduced strength from cutting tool pressures and deflection under high forces. Welded parts also have strength reductions from grain growth and solidification defects in the weld zones. (<a href="https://www.vecoprecision.com/electroforming/design-guideline/" rel="noopener" target="_blank">learn more about the material properties of Electroformed components</a>)<h2>(3) outstanding chemical resistance</h2>Filtration applications frequently involve aggressive or reactive solvents, acids, and other chemically challenging substances at high temperatures. Electroformed filtration sieves, especially with extra coating, can provide exceptional chemical resistance under these harsh conditions. This might prevent corrosion, loss of integrity, and contamination for critical applications. On the contrary, Laser processed metals can lose corrosion resistance due to alloying, oxidization, and weld defects. Machined and welded components have exposed surface defects that reduce chemical reliability.<h2>(4) unparalleled design flexibility</h2>Electroforming's flexibility is invaluable for custom engineering filtration performance. Unlike subtractive processes which lack much adjustability, Electroforming is an Additive Manufacturing process that allows fine-tuning of the filtering component formation. This means pore sizes, shapes, densities, and other parameters can be optimized for the customer’s demands. No other standard manufacturing process offers the same design flexibility and customization possibility over micro filter features from prototyping to mass production.<h2>(5) advanced feature engineering&nbsp;</h2>Electroforming also enables the co-developing of advanced features of filtration screens to meet customers’ demands, such as pore size, pore shape, cross-section profile, etc., permitting advanced precision filtering screen engineering (<a href="https://www.vecoprecision.com/work-with-veco/" rel="noopener" target="_blank">check out our co-development approach here</a>).For example, enabling tight control of pore density and open area percentage, angled pores for a low-pressure drop, uniform thickness for consistent flow across the screen, precisely shaped pores (circular, slotted, hexagonal, etc), defined pore orientation, and complex channel networks behind the pores. Laser processes, machining processes, and chemical etching lack this level of variability and control. In conclusion, Electroforming's unique combination of high resolution, excellent strength, chemical resistance, unparalleled design flexibility, and advanced engineering capabilities make it the manufacturing technology of choice for fabricating advanced filtration components where precision, performance, and reliability are paramount. As filtration demands continue to become more challenging across diverse industries, Electroforming provides a solution for engineers to develop next-gen filtration solutions to meet the most demanding pore size, chemical, mechanical, and volume requirements to push filtration capabilities into new territories across industries.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA3ODMxNzUyMDg0LTE3MDc4MzE3NTIwODQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 768px;" class="fr-fic fr-dib">

Filtration is a vital process utilized across a tremendous range of applications. As filtration needs become more advanced and specialized, Electroforming provides unique opportunities for engineers to develop filtration media and components to meet the highest standards. 

5 reasons why Electroforming is the choice for next-gen filtration fabrication

The nozzles follow a two-dimensional grid pattern that matches the pattern of ink chambers in the printhead. While traditional inkjet printers use round nozzles, current printers typically employ a tapered, funnel-like nozzle shape. This helps optimize the drop formation process and ejection direction.<a href="https://www.vecoprecision.com/products/inkjet-nozzle-plates/" target="_blank" rel="noopener noreferrer">The inkjet nozzle plates</a> need to be precisely engineered and arranged to control the volume, speed, and direction of the ink drops, to produce sharp, high-resolution prints. Beyond the nozzle structure, surface characteristics like the hydrophobicity of the nozzle surface are critical. Any deposited ink residuals or particulates on the plate can deflect droplets or cause nozzle clogs. As this is detrimental to printhead performance and lifetime, these nozzle properties must be robust and long-lasting.<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming technology</a> has long been the technique of choice for producing inkjet nozzle plates, as it provides key advantages not feasible with other manufacturing processes. The unique bell mouth nozzle cross-section has enabled proper drop formation while the slight nozzle inset provides protection. However, through the years the industry demands become ever taller, requiring innovations in the electroforming process.Veco, as the world leader in Electroforming technology, has applied recent advancements in lithographic capabilities to overcome prior technical constraints, offering the industry's next-generation nozzle plates that can further enhance inkjet printer capabilities.Veco’s innovative processes allow nozzle diameter control down to ±0.5µm within a nozzle plate. A performance that can only be matched by the most precise manufacturing techniques. This allows adjacent nozzles to be produced with nearly identical inner profiles and exit diameters, resulting in precise, predictable droplet sizes and trajectories across all nozzles on the printhead. With minimal variation between nozzles, errors like sub-optimal drop volumes or misdirected spray are also minimized. Consistent drop formation translates to sharper printed dots and lines, especially crucial for high-density&nbsp;nozzle arrangements.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA1NTEwNzk3MDg4LTE3MDU1MTA3OTcwODgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="717" height="270" alt="inkjet nozzle dense-1" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20dense-1.png?width=359&amp;height=135&amp;name=inkjet%20nozzle%20dense-1.png 359w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20dense-1.png?width=717&amp;height=270&amp;name=inkjet%20nozzle%20dense-1.png 717w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20dense-1.png?width=1076&amp;height=405&amp;name=inkjet%20nozzle%20dense-1.png 1076w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20dense-1.png?width=1434&amp;height=540&amp;name=inkjet%20nozzle%20dense-1.png 1434w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20dense-1.png?width=1793&amp;height=675&amp;name=inkjet%20nozzle%20dense-1.png 1793w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20dense-1.png?width=2151&amp;height=810&amp;name=inkjet%20nozzle%20dense-1.png 2151w" sizes="(max-width: 717px) 100vw, 717px" class="fr-fic fr-dii"> &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; Protruding nozzles &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;Densely packed conical holesBeyond precision, Veco’s advanced Electroforming technology also enables more nozzle shape diversity. Nozzle cross-sections can be customized rather than using a one-size-fits-all design. Besides bell-mouth-shaped nozzles, conical nozzles with various taper angles and various other custom geometries can be fabricated without sacrificing accuracy and consistency. As the nozzle profile directly influences fluid performance, including drop speed and refill time, the enhanced nozzle profile diversity and customization possibility expand options for optimizing nozzles based on ink properties and printing parameters. Veco’s toolbox can create the ideal nozzle for your specific application.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA1NTEwNzk4NTI4LTE3MDU1MTA3OTg1MjgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="1624" alt="inkjet nozzle shape diversity" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20shape%20diversity.png?width=812&amp;height=293&amp;name=inkjet%20nozzle%20shape%20diversity.png 812w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20shape%20diversity.png?width=1624&amp;height=586&amp;name=inkjet%20nozzle%20shape%20diversity.png 1624w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20shape%20diversity.png?width=2436&amp;height=879&amp;name=inkjet%20nozzle%20shape%20diversity.png 2436w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20shape%20diversity.png?width=3248&amp;height=1172&amp;name=inkjet%20nozzle%20shape%20diversity.png 3248w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20shape%20diversity.png?width=4060&amp;height=1465&amp;name=inkjet%20nozzle%20shape%20diversity.png 4060w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20nozzle%20shape%20diversity.png?width=4872&amp;height=1758&amp;name=inkjet%20nozzle%20shape%20diversity.png 4872w" sizes="(max-width: 1624px) 100vw, 1624px" class="fr-fic fr-dii" style="width: 737px;">&nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; Freedom in nozzle shape &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;Freedom in the channel definitionBesides sculpting the nozzle apertures, Electroforming allows the building to integrate channels and components on the nozzle plate itself. Its&nbsp;unique capability to stack product layers allows for functional integration within a single metal part&nbsp;without the need for adhesives or bonding processes.&nbsp;Integrated pathways for ink recirculation and reclamation can be seamlessly integrated without risk of layer peeling or adhesive deterioration and sub-micron overlay accuracy can unlock new freedom in channel design.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA1NTEwNzk3MTExLTE3MDU1MTA3OTcxMTEucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="438" alt="ink channel integrated in a nozzle plate" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/ink%20channel%20integrated%20in%20a%20nozzle%20plate.png?width=219&amp;height=190&amp;name=ink%20channel%20integrated%20in%20a%20nozzle%20plate.png 219w, https://insights.vecoprecision.com/hs-fs/hubfs/ink%20channel%20integrated%20in%20a%20nozzle%20plate.png?width=438&amp;height=379&amp;name=ink%20channel%20integrated%20in%20a%20nozzle%20plate.png 438w, https://insights.vecoprecision.com/hs-fs/hubfs/ink%20channel%20integrated%20in%20a%20nozzle%20plate.png?width=657&amp;height=569&amp;name=ink%20channel%20integrated%20in%20a%20nozzle%20plate.png 657w, https://insights.vecoprecision.com/hs-fs/hubfs/ink%20channel%20integrated%20in%20a%20nozzle%20plate.png?width=876&amp;height=758&amp;name=ink%20channel%20integrated%20in%20a%20nozzle%20plate.png 876w, https://insights.vecoprecision.com/hs-fs/hubfs/ink%20channel%20integrated%20in%20a%20nozzle%20plate.png?width=1095&amp;height=948&amp;name=ink%20channel%20integrated%20in%20a%20nozzle%20plate.png 1095w, https://insights.vecoprecision.com/hs-fs/hubfs/ink%20channel%20integrated%20in%20a%20nozzle%20plate.png?width=1314&amp;height=1137&amp;name=ink%20channel%20integrated%20in%20a%20nozzle%20plate.png 1314w" sizes="(max-width: 438px) 100vw, 438px" class="fr-fic fr-dii" style="width: 756px;"> &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; an ink channel integrated into a nozzle plateIn addition, finishing the Electroformed part with protective metal coatings can produce a reliable, corrosive-resistant, and hydrophobic performance that lasts over the lifespan of the inkjet nozzle. At Veco, we are also able to provide our customers with a unique value-added service for product tracking by laser marking customers’ tracking codes or product info on individual products.As inkjet printing extends into new applications like 3D printing, bioprinting, microfluidics, solar cell manufacturing, and printed electronics, Electroformed nozzle plate performance becomes increasingly crucial. The new possibilities opened up by Veco’s Electroforming advancements offer inkjet printer manufacturers competitive advantages in engineering the next generation of printheads. The continuous advancement of lithographic and Electrodeposition processes has allowed Veco to take the next step in Electroforming nozzle plates, enabling inkjet printhead developers to innovate with higher nozzle density for greater print resolution, smaller drop volumes for finer details and graphics, optimized nozzle profiles for different ink formulation, faster print speeds through improved fluid performance, more robustness from integrated metal construction, low nozzle-to-nozzle pitch and minimal spread in first-to-last nozzle pitch not previously seen in this technology.<a href="https://insights.vecoprecision.com/cs/c/?cta_guid=8681c2ee-0a4a-407d-9e8c-85b23a7efd3f&signature=AAH58kE-bvTT0CBoBQJLErDcu0sV26Ycwg&pageId=152027346991&placement_guid=056f005b-1e5e-49f9-b6d2-99830614eb56&click=6bfd397f-cb72-41b8-b3f9-c25580e7ef4e&hsutk=3657d75bb60e675af5b57b37f1162b44&canon=https%3A%2F%2Finsights.vecoprecision.com%2Felevating-inkjet-printers-with-next-generation-electroformed-nozzle-plates&portal_id=1788947&redirect_url=APefjpGYHBpPSI52EVzCydJk0S3UCE_Qo_d8AMYS_UnDu5BvYK29R72CDhR4gsESOHH7mfk6OA4gLZ6wi7ItO7XQsAjUo2wFowLTRsRDVmsSFl2x1O7MRf9iM8TrfDlyxDeGNm-Z3CCe5kxWSuk3dl_ywdKaFIEiKNZD1h6gPtdNE2x4K5D2i0fvv8ir_Y9fL-GvmwKEg5GQEo1hx7WcmLL_kXOCvuOEEiuZyxv9YGGxMu1oAK1gDqQUjQGktt2XDsq2NNsgpJVXdFh5Kl8n-aTsB3_5lJJBWw&ts=1705478001902&__hstc=207439628.3657d75bb60e675af5b57b37f1162b44.1692535028868.1705052085230.1705478089263.30&__hssc=207439628.1.1705478089263&__hsfp=2289156809&contentType=blog-post" target="_blank" rel="noopener"><img alt="New Call-to-action" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA1NTEwNzk4MzYzLTE3MDU1MTA3OTgzNjMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii" style="width: 725px;"></a>

Inkjet printheads work by jetting tiny droplets of ink onto paper or textiles to create text and images. A key component that enables this process is the inkjet nozzle plate. 

Elevating Inkjet Printheads with Next-Generation Electroformed Nozzle Plates

<h2 id="isPasted">1. learn the basics of Electroforming</h2>Electroforming is a versatile <a href="https://www.vecoprecision.com/electroforming/electroforming-process/" rel="noopener" target="_blank">metal-forming process</a> that allows engineers to create complex, high-precision metal parts with ease. Combining high-accuracy lithography with Electrodeposition builds up products in the desired shape and thickness with ultimate control. Intricate geometries, fine details, and smooth surfaces unachievable through other fabrication methods can be easily achieved with Electroforming cost-effectively and with excellent repeatability.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1704681958950-Veco-EF_capabilities-v1.2-3.jpeg" style="width: 662px;" class="fr-fic fr-dib">In comparison with other manufacturing technologies, Electroforming stands out with its high accuracy, short lead times, low costs, burr-free parts, design flexibility, surface replication abilities, and unchanged material properties. It is the technology of choice for high-volume production of complex, ultra-precision metal components across industries.<h2 id="isPasted">2. confirm&nbsp;design feasibility with the Electroforming technology</h2>technical features:<ul><li>geometry: freedom of design for intricate metal components</li><li>precision: feature size down to 2 microns, with tight tolerances below 1 micron.</li><li>accuracy: position accuracy achievable with Electroforming reaches micron level.</li><li>dimensions:&nbsp;product size up to 1370*1370mm, &nbsp;thickness from 5µm to 1200 µm cross sections: straight-walls, tapered profiles, and bell-mouth shapes can be provided.</li><li>5D: Multi-layer solutions allow designing beyond a 2D plane.</li><li>production volume: mass volume (fast prototyping supported).</li></ul>common applications by market:<ul><li>filtration: Sieves used in aerospace, defense, pharmaceutical, food processing, oil refinery, water treatment, research, and other industries</li><li>digital printing: inkjet nozzle plates, filter plates, or nozzle guards electronics/semiconductor: testing contactors, cantilevers, test probes, lead frames, and electrical parts in medical devices such as hearing aids</li><li>medical: precision metal sieves and meshes e.g. for nebulizers, flow regulation parts optical components:&nbsp;spectrometer slits&nbsp;and apertures, beam selectors, and encoder discs&nbsp;</li></ul><a href="https://www.vecoprecision.com/electroforming/electroforming-capabilities-and-applications/" rel="noopener" target="_blank">-&gt; learn more about capabilities and applications of Electroforming</a><h2>3. explore material options of the Electroforming technology</h2>Veco offers engineers a wide selection of material options to suit their specific application needs. Nickel and copper remain the most commonly used materials in the Electroforming process. However,&nbsp;besides copper,&nbsp;Veco also provides a range of proprietary&nbsp;nickel&nbsp;options with enhanced properties.&nbsp;These include:<ul><li>Meta-Nickel:&nbsp;Offers improved thermal resilience and mechanical strength compared to standard nickel. Ideal for high-performance applications.</li><li>Sulfamate Nickel:&nbsp;A non-reflective nickel that provides high ductility and&nbsp;can endure heat treatment such as laser cutting or welding. Useful&nbsp;for freedom in further assembly and specific optical properties.</li><li>Palladium-Nickel:&nbsp;Combines bio-compatibility with superior corrosion resistance. Suitable for medical devices and implants.</li><li>HR-Nickel:&nbsp;Exhibits excellent thermal stability at high temperatures. Applicable in aerospace and automotive industries.</li><li>Veco84:&nbsp;A high-hardness nickel alloy developed by Veco. Delivers increased hardness and tensile strength.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA0NjgxMDQ4MzI3LW1hdGVyaWFsLXByb3BlcnR5LnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 661px;" class="fr-fic fr-dib" alt="material properties Electroforming">material propertyfunctional coatings to augment the characteristics of Electroformed components:<ul><li>Anti-reflective coatings improve optical clarity by reducing glare. Essential for high-precision optical systems.</li><li>Highly reflective coatings maximize light reflection. Used in solar panels, reflectors, and lighting fixtures.</li><li>Wear-resistant coatings extend the component lifetime in high-friction environments.</li><li>Corrosion-resistant coatings protect against degradation from chemicals, fluids, or salt spray.</li></ul><h2>4. co-engineering with our application engineer team</h2>To achieve the best possible solutions for the critical precision components in demand, Veco provides co-engineering support from initial design through prototyping and scaling to efficient industrial production:<ul><li>identify micro-precision challenges</li><li>envision solutions with the engineering team</li><li>rapid prototyping and iteration</li><li>seamless transition to volume production</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA0NjgxMTI0NTI4LWNvX2RldmVsb3BtZW50LWUxNTkzNjczODIxOTEyLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 712px;" class="fr-fic fr-dib">co-development with Veco<h2>5. quality assurance</h2>Parts manufactured at Veco can be produced in a variety of cleanroom environments.&nbsp;To consistently provide and guarantee our customers with the best quality, Veco has been certified to the latest version of the ISO9001 quality management system.&nbsp;In addition, we use the Six Sigma method for continuous improvement of the quality of the processes.<a href="https://www.vecoprecision.com/about-us/quality/" rel="noopener" target="_blank">-&gt;&nbsp;learn more about our quality standards here</a>Veco’s two-step quality inspection:<ul><li>After every sample production, we produce a first article inspection report (FAIR)to&nbsp;ensure all the key parameters are within the predefined bandwidth.</li><li>After the quantitative inspection, a qualitative inspection to ensure the sample is created according to the quality requirements.</li></ul>

Electroforming enables engineers to produce complex, high-precision metal parts. This article helps engineers assess if Electroforming is a suitable solution and how to proceed with successfully transferring engineering design into high-quality components step by step.

Electroforming for engineers: getting started with Electroforming step by step

R&amp;D engineers often face challenges in designing and fabricating advanced micro-precision components. This includes achieving micro-scale features to meet the challenge of miniaturization, producing optimized geometries that balance strength, weight, and functionality, and incorporating thin-walled sections and different cross-section options. All while meeting stringent surface finish and tolerance requirements for precision engineering, and developing/finding optimized alloys and compositions for enhanced performance and design demand.Electroforming is a versatile Additive Manufacturing process that allows for the production of <a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">high-precision metal parts</a> with intricate design, fine details, and tight tolerances. It can be used to create micro-scale components with complex features in <a href="https://www.vecoprecision.com/electroforming/materials-used-in-electroforming/" rel="noopener" target="_blank">a wide variety of different materials</a>. Components made through&nbsp;Electroforming also have excellent mechanical properties and surface finishing.Engineers can overcome many of these challenges and push the boundaries of possible designs beyond what other manufacturing processes can achieve, enabled by Electroforming’s capability in miniaturization, design flexibility, and material and property options.<ul id="isPasted"><li>Miniaturization capabilities:&nbsp;Electroforming provides unique capabilities in miniaturization and micro-engineering,&nbsp;capable of producing metal components with microscopic feature sizes down to 2 microns. The technology&nbsp;has&nbsp;demonstrated its ability&nbsp;to&nbsp;meet stringent tolerance demands down to ±1 micron. This allows&nbsp;Electroforming to enable next-generation innovations in&nbsp;industries such as&nbsp;microelectronics, microelectromechanical systems (MEMS), sensors, and microfluidics, as the demand for ever-smaller components with complex micro-scale features increases.</li><li>Design flexibility:&nbsp;Electroforming unlocks unprecedented design flexibility for intricate metal components. The process empowers engineers to explore creative, complex geometries without being constrained by conventional manufacturing limitations. It facilitates rapid prototyping of&nbsp;designs with sophisticated shapes and intricate details typically seen as not manufacturable with conventional manufacturing processes. In addition,&nbsp;Electroforming can construct complex geometries beyond two-dimensional designs difficult or impossible to achieve with other subtractive methods.&nbsp;The extraordinary design flexibility is further leveraged by Electroforming’s capability to produce highly complex parts without excessive tooling costs or lead times&nbsp;while maintaining the outlook of high-volume serial production.</li><li>Material and property&nbsp;control:&nbsp;Electroforming technology allows depositing metal alloys to tailor specific material properties like mechanical or thermal characteristics. Veco offers a variety of metals for Electroforming, including Meta-Nickel, Sulfamate Nickel, Palladium-Nickel, HR-Nickel, and Veco84 - Veco’s specially formulated nickel. Copper and various surface coatings are also available. Veco's expertise in Electroforming and material development further empowers engineers to optimize mechanical, thermal, electrical, magnetic, and other properties to fulfill designed function. By leveraging Electroforming technology, engineers can specify material property demand to achieve targeted performance in their innovative component designs.</li></ul><strong style="box-sizing: border-box; -webkit-font-smoothing: antialiased; text-rendering: optimizelegibility; line-height: inherit; color: rgb(55, 55, 55); font-family: Graphit, sans-serif; font-size: 1.125rem; background-color: transparent;">How Veco supports engineers with the co-engineering procedure Fully leveraging the&nbsp;capabilities of <a href="https://www.vecoprecision.com/electroforming" rel="noopener" target="_blank" style="box-sizing: border-box; -webkit-font-smoothing: antialiased; text-rendering: optimizelegibility; background: transparent; color: rgb(224, 98, 153); text-decoration-line: none;">E</a><a href="https://www.vecoprecision.com/electroforming" rel="noopener" target="_blank" style="box-sizing: border-box; -webkit-font-smoothing: antialiased; text-rendering: optimizelegibility; background: transparent; color: rgb(224, 98, 153); text-decoration-line: none;">lectroforming</a> requires&nbsp;close&nbsp;collaboration with&nbsp;Electroforming specialists.&nbsp;Veco&nbsp;is&nbsp;the world leader&nbsp;in&nbsp;Electroforming technology&nbsp;and&nbsp;has worked with various industry-leading organizations to help bring to life next-generation products, combining our expertise in precision engineering, tailored application engineering services, and customer engineers’&nbsp;demand. To achieve the best possible solutions for the critical precision components in demand, Veco provides co-engineering support from initial design through prototyping and scaling to efficient industrial production:<img src="https://insights.vecoprecision.com/hs-fs/hubfs/co_development-e1593673821912.png?width=2560&amp;height=865&amp;name=co_development-e1593673821912.png" width="2560" height="865" loading="lazy" alt="co_development-e1593673821912" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/co_development-e1593673821912.png?width=1280&amp;height=433&amp;name=co_development-e1593673821912.png 1280w, https://insights.vecoprecision.com/hs-fs/hubfs/co_development-e1593673821912.png?width=2560&amp;height=865&amp;name=co_development-e1593673821912.png 2560w, https://insights.vecoprecision.com/hs-fs/hubfs/co_development-e1593673821912.png?width=3840&amp;height=1298&amp;name=co_development-e1593673821912.png 3840w, https://insights.vecoprecision.com/hs-fs/hubfs/co_development-e1593673821912.png?width=5120&amp;height=1730&amp;name=co_development-e1593673821912.png 5120w, https://insights.vecoprecision.com/hs-fs/hubfs/co_development-e1593673821912.png?width=6400&amp;height=2163&amp;name=co_development-e1593673821912.png 6400w, https://insights.vecoprecision.com/hs-fs/hubfs/co_development-e1593673821912.png?width=7680&amp;height=2595&amp;name=co_development-e1593673821912.png 7680w" sizes="(max-width: 2560px) 100vw, 2560px" style="box-sizing: border-box; -webkit-font-smoothing: antialiased; text-rendering: optimizelegibility; border: 0px; height: auto; width: 2560px;" class="fr-fic fr-dii"><ol><li>identify micro-precision challenges To create pioneering products, micro-precision components are often required.&nbsp;In the early conceptual stages, Veco partners with&nbsp;customers’&nbsp;engineers to deeply understand product goals, use cases, and performance requirements. We identify precision demands and micro-engineering challenges needed to achieve next-generation innovation. Our expertise helps determine where&nbsp;Electroforming can provide unique benefits.</li><li>envision solutions with the engineering team Veco's&nbsp;application&nbsp;engineering&nbsp;team draws on&nbsp;their expertise and&nbsp;experience to&nbsp;develop&nbsp;the optimal&nbsp;manufacturing solution, ensuring quality and efficiency. We select the&nbsp;most suitable&nbsp;techniques, define key&nbsp;features,&nbsp;simulate designs digitally,&nbsp;control crucial&nbsp;parameters, and determine final inspection protocols. Continuous feedback and iteration during co-engineering ensures&nbsp;efficient and effective optimization of the solution.</li><li>rapid prototyping and iteration As the world leader in micro-precision parts, Veco is the first in the industry to use Laser Direct Imaging technology. As an early pioneer of LDI, Veco can rapidly prototype complex designs. It not only shortens lead time and cuts cost, but also allows for more design flexibility. As the Laser Direct Imager is capable of projecting high-resolution images directly from a CAD file, digital changes allow fast and easy adjustments to be made to new photoresists. This allows multiple test runs which is highly beneficial for sampling and testing.&nbsp;</li><li>seamless transition to volume production After exhaustive prototyping and testing, Veco helps to swiftly scale up to industrial production while maintaining consistent quality. Our expertise in design for manufacturing ensures a smooth transition, leveraging prototypes and pre-existing processes to launch efficient volume production. Support continues through the production lifecycle to ensure performance.&nbsp;</li></ol>With our collaborative co-engineering approach, Veco aims to empower engineers in various industries to achieve next-level breakthroughs by providing critical precision components and tailored Electroforming services. Interested to figure out more? Don't hesitate to reach out to <a href="https://insights.vecoprecision.com/contact-veco-1" rel="noopener" target="_blank">discuss your projects with our engineers</a>.

Electroforming provides a pathway to overcoming fabrication challenges, empowering R&D engineers to reach past the limits of conventional manufacturing processes. To fully leverage Electroforming technology and engineering creativity, Veco provides a co-engineering service to empower the engineers.

Electroforming for Engineers: overcome R&D challenges by co-engineering with Electroforming technology

tolerances &nbsp;below 1µm Electroforming&nbsp;enables extremely high precision and accuracy in producing fine details and complex geometries. It can fabricate parts with tolerances as tight as below 1&nbsp;micron. This degree of precision is enabled by combining advanced lithography with highly controlled Electrochemical deposition and accurate replication.&nbsp;The tight tolerances offered by Electroforming make it a critical technology in industries where even the smallest deviation can significantly impact the performance of the end product.various functional coatings available to meet different demands Coatings can enhance the properties of the Electroformed components, making them more suited to specific applications. At Veco, a variety of functional coatings are provided, such as anti-reflective coatings for superior optical performance, reducing glare, and enhancing the clarity of the transmitted image. In contrast to anti-reflective coatings, highly reflective coatings are used to maximize the reflection of light. They find applications in various fields, including solar energy, lighting, and optics. Moreover, With wear-resistant coatings, component lifespan can be effectively extended, while corrosion-resistant coatings can protect components against harsh environments.freedom of design Electroforming unlocks unprecedented freedom of design for intricate metal components. The Electroforming process empowers engineers to explore creative, complex geometries without being constrained by conventional manufacturing limitations. It facilitates rapid prototyping of engineer designs with sophisticated shapes and&nbsp;intricate details&nbsp;typically seen as not manufacturable with conventional manufacturing processes (<a href="https://www.vecoprecision.com/electroforming/electroforming-vs-other-technologies/" rel="noopener" target="_blank">check comparison of Electroforming and other precision metal manufacturing processes here</a> ). The extraordinary design flexibility is further leveraged by Electroforming’s capability to produce highly complex parts without excessive tooling costs or lead times.multi-layer structure Electroforming has evolved beyond its origins as a process for simple two-dimensional metal sheets and foils. Advanced multi-layer Electroforming now enables the fabrication of complex three-dimensional structures through a layer-by-layer buildup method. This layer-by-layer fabrication approach facilitates the creation of complex geometries and internal structures impossible to produce using conventional subtractive methods.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk2NTkzOTI2ODg0LXBpY3R1cmUxX3dldm9sdmVyLlBORyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 762px;" class="fr-fic fr-dib">Example of a multi-layer structuredifferent feature cross-sections Electroforming allows precise fabrication of metal parts with diverse cross-sectional shapes, &nbsp;straight-walls, tapered profiles, and bell-mouth shapes that can be produced through advanced process control. Veco utilizes <a href="https://www.vecoprecision.com/design-guideline/" rel="noopener" target="_blank">two distinct Electroforming processes -&nbsp;</a><a href="https://www.vecoprecision.com/design-guideline/" rel="noopener" target="_blank">Plating defined&nbsp;and&nbsp;Photo defined</a>. The&nbsp;plating defined&nbsp;method creates bell-mouth-shaped cross-sections by modulating current density during plating. The&nbsp;photo-defined&nbsp;technique uses patterned resist layers of varying thickness to form straight-walled geometries. These two methods&nbsp;can be&nbsp;combined to provide engineers with a high degree of design flexibility to meet specific functional needs.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk2NTkzOTEwNjQ2LXBpY3R1cmUyIHdldm9sdmVyLlBORyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 762px;" class="fr-fic fr-dib">Example of multiple&nbsp;position accuracy down to 1 µm The position accuracy achievable with Electroforming reaches the micron level. This micro-scale accuracy empowers the fabrication of components with intricate details positioned exactly as designed, making it an ideal choice for applications where precision is paramount, such as in the fields of optics, aerospace, medical devices, and microelectronics.available materials As the industry-leading Electroforming specialist, Veco expands material capabilities, offering not just commonly used Nickel and Copper, but also a variety of proprietary alloys tailored for specific applications. These include Meta-Nickel for thermal resilience and mechanical robustness, Sulfamate Nickel for high ductility and low internal stresses, Palladium-Nickel for bio-compatibility in combination with superior resistance, HR-Nickel for thermal stability, and Veco84 - Veco’s specially formulated nickel with superior hardness and strength.feature size down to 2 µm Electroforming is&nbsp;capable of producing metal components with microscopic feature sizes down to 2 microns.&nbsp;With this micro-scale resolution, Electroforming facilitates the production of miniaturized components with delicate details for applications from micro-electronics to micro-optics. Tiny holes, channels, pillars, and other geometries can be incorporated to meet mechanical, fluidic, or optical requirements.product size up to 1370*1370mm Electroforming provides a scalable solution for large yet intricate metal parts. Through advanced equipment and process control, Electroformed parts can be fabricated with dimensions up to 1370 x 1370 mm. The combination of part size and precision empowers innovation in new domains that demand both high accuracy and macro-scale dimensions.product thickness from 5µm to 1200 µm Electroforming enables precise control over a broad deposit thickness range spanning from micrometers to millimeters - thin layers down to 5 microns and thicker deposits up to 1200 microns. This broad thickness range allows Electroforming to meet the needs of diverse applications from delicate MEMS structures to robust macro-scale components.

Electroforming is a versatile Additive Manufacturing process for the production of high-precision and complex metal parts. This article provides an overview of key features and capabilities that make Electroforming a crucial manufacturing technology for engineers to get acquainted with.

Electroforming for Engineers: key features and capabilities of Electroforming technology

Veco, as the world&#39;s leading specialist in Electroforming, offers high-precision Electroforming with Nickel, in a variety of unique blends or alloys suitable for particular engineering demands, such as Veco84 Nickel, Sulfamate Nickel, Palladium-Nickel (alloy), HR-Nickel, and Meta-Nickel.&nbsp;Below, you&#39;ll find detailed information about these nickel variants. Each of these materials brings unique properties and advantages.Veco84 Nickel is a uniquely engineered material designed to exhibit superior hardness and strength. Its hardness typically falls within the 620 to 660 HV range, making it a mechanically robust material. With its smooth, glossy finish, it offers both functional strength and aesthetic appeal. In addition to hardness, Veco84 boasts superior tensile and yield strength relative to other Electroformed materials. Its tensile strength can extend up to 2200-2300 MPa, while its yield strength can vary from 1900 to 2100 MPa. However, for applications necessitating high-temperature resilience or superior corrosion resistance, other types of nickel might be more suitable.Sulfamate Nickel,&nbsp;while having a lower hardness of 185-200 HV compared to other nickel variants, presents a unique set of strengths. Its high ductility and low internal stresses grant it greater flexibility, enabling bending and shaping without resulting in cracks. This nickel variant also surpasses Veco&rsquo;s other nickel types in terms of chemical and corrosion resistance, making it an optimal choice for applications necessitating high-temperature resilience and industries such as aerospace, electrical, and general engineering that require ductile components. Furthermore, the ductility of Sulfamate Nickel can be increased through annealing, although this process does lead to a softer material with correspondingly reduced strength. In addition, Sulfamate Nickel is deposited with low stress and outstanding uniformity, resulting in high-quality, reliable, and durable parts.PdNi is a robust Electroformed Palladium-Nickel alloy with superior corrosion and chemical resistance. This allows it to better withstand acids, chloride environments, and other harsh media. Importantly, it also exhibits bio-compatibility, which is important for certain applications such as medical products in direct contact with the human body. In terms of mechanical properties, PdNi offers a high hardness of up to 530 HV, a tensile strength of 1750-1950, and a yield strength of 1700-1750. The carefully balanced composition of Palladium and Nickel yields an ideal amalgamation of corrosion resistance, mechanical strength, and functional properties. Thanks to this unique combination of properties, PdNi finds utility in an array of applications, from chemical processing equipment to components in the telecommunications industry.HR-Nickel is a unique form of nickel developed by Veco that can withstand high temperatures without significant degradation or failure. During the plating process of HR-Nickel, proprietary additives are employed, bypassing the use of traditional organic hardeners which often undermine the thermal stability of nickel. In terms of mechanical properties, HR-Nickel has a hardness of approximately 470 HV. It exhibits a tensile strength of about 1680 MPa, while its yield strength lies in the range of 1100-1300 MPa. This combination of properties makes HR-Nickel a durable and reliable choice for applications exposed to high thermal conditions.Meta-Nickel is a nickel blend with a hardness of up to 340 HV. This material is particularly suitable for laser-cutting and laser-welding processes, making it an optimal choice for multi-technology solutions. In terms of mechanical properties, Meta-Nickel exhibits a tensile strength of approximately 1070 MPa and a yield strength of around 780 MPa. In addition, Meta-Nickel can withstand operating temperatures up to 200&deg;C without compromising its strength and ductility. This makes it a versatile material for various applications requiring both thermal resilience and mechanical robustness.For a comprehensive comparison of all nickel types with standard SS316L or SS304, learn more about our material introductions here, you can also find detailed information to help guide your material selection process.<a href="https://www.vecoprecision.com/" target="_blank" rel="noopener noreferrer">Interested in talking to an engineer instead?</a> We&#39;re more than happy to assist. Our team of experienced engineers is available to answer your questions, provide expert advice, and guide you through your design and engineering process.

Electroforming is an Additive Manufacturing process specialized for the production of high-precision metal parts. Nickel, due to its expansive range of mechanical properties, aesthetic appeal, and resistance to corrosion, has become the most widely used material for this process. It not only enables the reproduction of extremely fine details but also permits the deposition of materials with high hardness. Electroforming technology allows depositing metal alloys to tailor specific material properties like mechanical or thermal characteristics.

Electroforming for Engineers: tailoring materials and properties to meet engineering demands

(1) A complex design&nbsp;can be&nbsp;easily achieved with Electroforming, efficiently and cost-effectively.One of the biggest challenges engineers face is managing the costs associated with designing and producing&nbsp;complex parts. As part complexity increases, manufacturing expenses tend to rise exponentially due to&nbsp;extra tooling costs, additional set-up and changeover times,&nbsp;and&nbsp;longer processing time, among others. This makes complex designs economically unfeasible for many applications - forcing engineers to limit themselves to &quot;manufacturable&quot; designs.With Electroforming, complex shapes with intricate details and fine features that are difficult to achieve using <a href="https://www.vecoprecision.com/electroforming/electroforming-vs-other-technologies/" rel="noopener" target="_blank">traditional metal&nbsp;</a><a href="https://www.vecoprecision.com/electroforming/electroforming-vs-other-technologies/" rel="noopener" target="_blank">manufacturing</a><a href="https://www.vecoprecision.com/electroforming/electroforming-vs-other-technologies/" rel="noopener" target="_blank">&nbsp;techniques</a> can be quickly tested and implemented, with tooling costs that do not scale with complexity. Thus, Electroforming decouples part complexity from manufacturing expense. This allows engineers to maximize design freedom without worrying about significantly higher costs for more complex designs.&nbsp;(2) Electroforming offers&nbsp;precise&nbsp;control&nbsp;over&nbsp;material&nbsp;properties.Material properties matter greatly to engineers, with different applications requiring very specific combinations of properties.&nbsp;Choosing&nbsp;the right material for the job is crucial, but in reality, a material&#39;s properties depend far more on its internal structure than its basic composition.Electroforming is a manufacturing process that allows precise control over a material&#39;s&nbsp;microstructure&nbsp;and resulting properties. By adjusting Electroforming conditions like current density, pH, and additives, you can alter properties like conductivity, hardness, and elasticity. Does your application require corrosion resistance or low reflectivity or does it come into contact with the human skin? That&rsquo;s where coatings come in. A layer of material such as palladium or gold can be coated followed by an Electroforming process.&nbsp;This allows engineers to think in terms of the properties needed for an application, rather than the materials, opening up new possibilities.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691402667200-1691402667200.png" alt="Electroforming_Encoder_Discs" width="717" height="287" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Electroforming_Encoder_Discs.jpg?width=359&height=144&name=Electroforming_Encoder_Discs.jpg 359w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Electroforming_Encoder_Discs.jpg?width=717&height=287&name=Electroforming_Encoder_Discs.jpg 717w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Electroforming_Encoder_Discs.jpg?width=1076&height=431&name=Electroforming_Encoder_Discs.jpg 1076w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Electroforming_Encoder_Discs.jpg?width=1434&height=574&name=Electroforming_Encoder_Discs.jpg 1434w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Electroforming_Encoder_Discs.jpg?width=1793&height=718&name=Electroforming_Encoder_Discs.jpg 1793w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Electroforming_Encoder_Discs.jpg?width=2151&height=861&name=Electroforming_Encoder_Discs.jpg 2151w" sizes="(max-width: 717px) 100vw, 717px" class="fr-fic fr-dii">Electroformed optical parts&nbsp; (3) Electroforming gives options for different cross-sectional shapes to meet different design needs.Engineers often need metal parts with precise cross-sectional shapes to meet&nbsp;certain&nbsp;design requirements&nbsp;or&nbsp;enable specific&nbsp;application&nbsp;functions.&nbsp;This&nbsp;is not easily achievable with other metal manufacturing technologies, which usually provide little control over localized cross-sectional details and shapes beyond constant thickness parts.Electroforming enables the fabrication of micro-precision metal parts with different<a href="https://www.vecoprecision.com/design-guideline/" rel="noopener" target="_blank">&nbsp;</a>cross<a href="https://www.vecoprecision.com/design-guideline/" rel="noopener" target="_blank">-</a>sections, both straight-walled profiles and complex tapered-hole shapes can be achieved due to advanced control of the process. At Veco, <a href="https://www.vecoprecision.com/design-guideline/" rel="noopener" target="_blank">2&nbsp;types of Electroforming processes are available</a>,&nbsp;namely Electroforming Overgrowth&nbsp;and&nbsp;Electroforming Thick&nbsp;Resist. The Overgrowth technique enables the fabrication of tapered cross-sections through variable current density plating, while&nbsp;the Thick Resist method&nbsp;controls&nbsp;the&nbsp;thickness of&nbsp;patterned resist layers to create straight-walled profiles.&nbsp;Finally, these methods can be combined to&nbsp;provide engineers with a high degree of design flexibility considering functional or performance demands for their micro components.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691402708750-1691402708750.png" alt="inkjet hole shape-2" width="717" height="309" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20hole%20shape-2.png?width=359&height=155&name=inkjet%20hole%20shape-2.png 359w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20hole%20shape-2.png?width=717&height=309&name=inkjet%20hole%20shape-2.png 717w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20hole%20shape-2.png?width=1076&height=464&name=inkjet%20hole%20shape-2.png 1076w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20hole%20shape-2.png?width=1434&height=618&name=inkjet%20hole%20shape-2.png 1434w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20hole%20shape-2.png?width=1793&height=773&name=inkjet%20hole%20shape-2.png 1793w, https://insights.vecoprecision.com/hs-fs/hubfs/inkjet%20hole%20shape-2.png?width=2151&height=927&name=inkjet%20hole%20shape-2.png 2151w" sizes="(max-width: 717px) 100vw, 717px" class="fr-fic fr-dii">left: straight-walled shape &nbsp;right: tapered-hole profiles(4) Electroforming is more than 2D.Electroforming is a metal-forming process that has traditionally been associated with creating two-dimensional metal parts, such as plates, sheets, and foils. This has long been seen as a main disadvantage of Electroforming to many engineers who desire more complex geometries. However, modern advances are enabling electroformed parts to move beyond these 2D limitations.Multi-layer&nbsp;Electroforming allows building up complex 3D geometries layer by layer&nbsp;- more&nbsp;structures can be&nbsp;added to the high-precision metal parts&nbsp;by&nbsp;Electroforming over a mandrel for one layer, then repeating for successive layers.&nbsp;It is an important technique that expands Electroforming into complex 3D shapes beyond its 2D origins and enables almost limitless part geometries to be produced. The delicate and precise 3D structures it can produce open up new possibilities for more advanced applications.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691402709065-1691402709065.png" alt="multi-layer" width="1396" height="591" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/ADMIN%20-%20Veco/2.%20Content%202023/Design%20Assets/multi-layer.jpg?width=698&height=296&name=multi-layer.jpg 698w, https://insights.vecoprecision.com/hs-fs/hubfs/ADMIN%20-%20Veco/2.%20Content%202023/Design%20Assets/multi-layer.jpg?width=1396&height=591&name=multi-layer.jpg 1396w, https://insights.vecoprecision.com/hs-fs/hubfs/ADMIN%20-%20Veco/2.%20Content%202023/Design%20Assets/multi-layer.jpg?width=2094&height=887&name=multi-layer.jpg 2094w, https://insights.vecoprecision.com/hs-fs/hubfs/ADMIN%20-%20Veco/2.%20Content%202023/Design%20Assets/multi-layer.jpg?width=2792&height=1182&name=multi-layer.jpg 2792w, https://insights.vecoprecision.com/hs-fs/hubfs/ADMIN%20-%20Veco/2.%20Content%202023/Design%20Assets/multi-layer.jpg?width=3490&height=1478&name=multi-layer.jpg 3490w, https://insights.vecoprecision.com/hs-fs/hubfs/ADMIN%20-%20Veco/2.%20Content%202023/Design%20Assets/multi-layer.jpg?width=4188&height=1773&name=multi-layer.jpg 4188w" sizes="(max-width: 1396px) 100vw, 1396px" class="fr-fic fr-dii">complex part with 3D features(5) Electroforming is a versatile solution for both fast prototyping and mass production.Engineers face challenges when seeking a manufacturing solution that can accommodate both fast prototyping and high-volume mass production. <a href="https://www.vecoprecision.com/electroforming/electroforming-vs-other-technologies/" rel="noopener" target="_blank">Conventional manufacturing methods</a> typically require different tooling and setups which adds time and cost. This places burdens on engineers to compromise on prototypes, over-invest in fixed tools early on, or delay production.Electroforming is a remarkably versatile process that excels at both rapid prototyping and mass production applications. Even if design changes are required, rapid iterations can be implemented quickly without extra tooling or process changes. This enables tweaks and adjustments at little expense. Electroforming gives engineers the ultimate freedom to bring innovative designs to market with minimal limitations,&nbsp;with&nbsp;the versatility to meet&nbsp;complex&nbsp;demands&nbsp;from&nbsp;fast&nbsp;prototyping&nbsp;to mass production.<a href="https://insights.vecoprecision.com/cs/c/?cta_guid=8681c2ee-0a4a-407d-9e8c-85b23a7efd3f&signature=AAH58kGvr-Tb0fCHEZkIGFeqr4EnJG2GBg&pageId=127177626531&placement_guid=056f005b-1e5e-49f9-b6d2-99830614eb56&click=5669ff55-f218-4793-b00a-2b6819dcbf00&hsutk=97710d8cef260b164f288d3460335fe3&canon=https%3A%2F%2Finsights.vecoprecision.com%2Felectroforming-for-engineers-5-reasons-electroforming-has-revolutionized-complex-part-design&portal_id=1788947&redirect_url=APefjpEWHQFJ5qigcvMvrAFfvQN2mDKy1ajE5lVdQyw6kLJJ36B7xxekst49SLZyLqM2eJZqa_C9kqF0IazGHSNxnjcEwsFBST7QG0F3AxahKn9qCIcmZ-Luh9qRUFZUeAhd3LE_qqxw0FZqtUiysEx1yAUrKhfHCeefjHSFuy1bik-U7mkpt5qsyp9r28P0DrxCNN3ojGW6OOnz8YxcuhrqDU5t7cojt7E37Fa-06yWm18bRT5viY_ore6GDrSMEUXyqK1KTFi2u9mCpsYpvXr7uEBnoYmX7fMFflV5IwksnPimi0NODcw&__hstc=207439628.97710d8cef260b164f288d3460335fe3.1683536443459.1690960985610.1691402181808.27&__hssc=207439628.2.1691402181808&__hsfp=3269552837&contentType=blog-post" target="_blank" rel="noopener"><img alt="New Call-to-action" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691402709779-1691402709779.png" class="fr-fic fr-dii"></a>

Veco’s unique Advanced Lithographic Electroforming process also referred to as Advanced Photo Electroforming, promises a move towards the frontier of precision engineering, incorporating micro precision, complex features, and freedom of design, all of which empower next-gen innovations across industries facing the challenge of miniaturization. This blog introduces 5 reasons to choose Electroforming in terms of freedom of design. 

Electroforming for Engineers: 5 Reasons Electroforming Has Revolutionized Complex Part Design

Electroforming is an Additive Manufacturing technique based on the electrodeposition process, with the unique advantages of high dimensional precision and replication accuracy. As miniaturization continues to be a driving force across various industries, Advanced Lithographic Electroforming is gaining significant attention for its ability to fabricate micro-precision components. It excels at achieving strict dimensional tolerances and intricate geometries, making it a crucial solution in the ever-evolving landscape of manufacturing. &nbsp;The scalability of Advanced Lithographic Electroforming sets it apart from traditional Electroforming processes. Due to its non-contact nature, it can efficiently handle high production volumes while maintaining consistent quality and precision across numerous micro-precision components. &nbsp;This article dives into Advanced Lithographic Electroforming, as well as micro-scale LIGA Electroforming technologies such as UV LIGA and X-Ray LIGA. &nbsp;&nbsp;Electroforming technology<a href="https://www.vecoprecision.com/electroforming/" rel="nofollow" target="_blank">Electroforming</a> is a metal fabrication process that works on the principle of electrodeposition, similar to Electroplating. It can be used to produce metal parts by electrochemically depositing metal onto a mold, as well as to replicate metal parts with high precision. Common metals for the Electroforming process include nickel, gold, copper, etc.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688694809913-1688694809913.png" class="fr-fic fr-dii" style="width: 345px;">Image: Electroforming bath The electrodeposition process starts with a conductive mandrel which is placed in an electrolytic bath and the electrodes pass a DC through the solution. The DC current converts ions into a metallic deposit on the conductive areas of the mandrel until the desired thickness has been achieved. Compared to other traditional metal forming technologies, for example, casting, forging, stamping, or deep drawing, Electroforming can deliver mass volume at superior accuracy and extreme design complexity, due to the fact that it can replicate the shape of the mandrel at extreme accuracy.Advanced Lithographic Electroforming &nbsp;Veco, as the world leader and largest independent supplier of Electroforming, has been moving the industry forward, with unparalleled experience in Electroforming, advanced lithography technology, and accumulated knowledge of metallurgy. Veco&rsquo;s unique Advanced Lithographic Electroforming is also referred to as Advanced Photo Electroforming. At Veco, <a href="https://insights.vecoprecision.com/how-to-accelerate-your-lead-time-with-the-laser-direct-imager" rel="nofollow" target="_blank">LDI(laser direct imager)&nbsp;</a>is used to expose the photoresist layer directly on the substrate. It allows for rapid prototyping and design changes, as the laser patterns can be easily adjusted and updated without the need to create new physical masks or tools. This flexibility enables faster and more cost-effective iterations in the design process, compared to the time-consuming and expensive process of fabricating new glass tools for each design change.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688694811302-1688694811302.png" class="fr-fic fr-dii">Image: Electroforming processAt Veco nowadays, 90% to 95% of our photolithography process is done by Laser Direct Imaging. The combination of LDI and our leading Electroforming technology has enabled us to further push the boundaries of the industry with our Advanced Lithographic Electroforming, providing our customers with <a href="https://www.vecoprecision.com/products/" rel="nofollow" target="_blank">high-precision metal components&nbsp;</a>of higher quality, at lower cost, and with a quicker turnaround.LIGA Electroforming: UV LIGA, and X-Ray LIGALIGA is a German acronym for &quot;Lithographie, Galvanoformung, Abformung&quot;, which translates to &quot;Lithography, Electroplating, and Molding&quot;. In LIGA Electroforming, a photoresist such as SU-8 or PMMA is patterned using photolithography to create a mandrel for electrodeposition.UV LIGA is a LIGA process that uses UV light to expose photoresist through a photo mask. With UV LIGA, a thicker layer of photoresist can be penetrated, enabling a higher aspect ratio, which is an advantage in many applications. X-Ray LIGA is another variation of the LIGA process that uses X-ray radiation instead of UV light to expose the photoresist. The process involves placing a substrate coated with a thick layer of photoresist in an X-ray synchrotron beam, which exposes the photoresist in the desired pattern. With X-ray, even thicker layers of photoresist can be penetrated, allowing for extremely high aspect ratios exceeding 100:1, which is not achievable with UV LIGA or LDI processes. &nbsp;Comparison of LDI-empowered Lithographic Electroforming and LIGA Electroforming technologiesWhen comparing LDI-empowered Advanced Lithographic Electroforming and LIGA Electroforming technologies such as UV LIGA and X-Ray LIGA, many factors come into play. Here we compare on level of precision, cost efficiency, and scalability:Precision:&nbsp;LDI-empowered Advanced Lithographic Electroforming has a high resolution comparable to UV LIGA and X-Ray LIGA, enabling the fabrication of high-precision microstructures.Cost Efficiency:&nbsp;The production cost of LDI-empowered Advanced Lithographic Electroforming is significantly lower compared to UV LIGA and X-Ray LIGA due to the avoidance of expensive photomasks and long exposure times.Scalability:&nbsp;LDI-empowered Advanced Lithographic Electroforming is the most scalable while X-Ray LIGA has very limited production volume, and UV LIGA can be used for mass production but limited volume. Moreover, it has high repeatability and lower costs compared to LIGA Electroforming technologies.In summary, <a href="https://www.vecoprecision.com/electroforming/" rel="nofollow" target="_blank">Advanced Lithographic Electroforming</a> offers the necessary high precision and geometry complexity for micro precision metal parts, combined with fast prototyping, high volume suitability, and cost efficiency, making it the ideal process across the product lifecycle from prototypes to mass production.Table.&nbsp;Technical specifications of Advanced Lithographic Electroforming&nbsp;and LIGA Electroforming<table><tbody><tr><td width="66">Technical Specification</td><td width="115">LDI&nbsp;</td><td width="119">UV LIGA</td><td width="124">X-Ray LIGA</td></tr><tr><td width="66">Exposure</td><td width="115">UV laser</td><td width="119">UV light</td><td width="124">X-ray</td></tr><tr><td width="66">Resolution</td><td width="115">High</td><td width="119">High</td><td width="124">Very high (due to shorter X-ray wavelength)</td></tr><tr><td width="66">Aspect ratio</td><td width="115">Limited (due to thin layers of photoresist and limited depth penetration depth)</td><td width="119">High (due to thick layers of photoresist and good depth penetration depth)</td><td width="124">Extremely high, exceeding 100:1 (due to excellent depth penetration depth)</td></tr><tr><td width="66">Prototype Speed</td><td width="115">Fast (as no photomask is needed)</td><td width="119">Moderate (photomask required)</td><td width="124">Slow ( photomask and synchrotron beam time required)</td></tr><tr><td width="66">Scalability</td><td width="115">Highly suitable</td><td width="119">Suitable, but limited volume</td><td width="124">Very limited</td></tr><tr><td width="66">Cost efficiency</td><td width="115">Significant cost advantage</td><td width="119">Moderate</td><td width="124">Very expensive</td></tr></tbody></table>Interested to learn more about Advanced lithographic Electroforming? Don&#39;t miss out on our <a href="https://insights.vecoprecision.com/en/whitepaper-electroforming" rel="nofollow" target="_blank">Electroforming Whitepaper</a>. <a href="https://insights.vecoprecision.com/cs/c/?cta_guid=8681c2ee-0a4a-407d-9e8c-85b23a7efd3f&signature=AAH58kFkKPnUtJCRK1CHCYXTtSEf7t7wyA&pageId=119192099647&placement_guid=056f005b-1e5e-49f9-b6d2-99830614eb56&click=a0850858-5f29-47f0-9183-94d56e729154&hsutk=97710d8cef260b164f288d3460335fe3&canon=https%3A%2F%2Finsights.vecoprecision.com%2Fpushing-the-boundaries-of-electroforming-advanced-lithographic-electroforming-and-liga-processes-explained&utm_referrer=https%3A%2F%2Finsights.vecoprecision.com%2F&portal_id=1788947&redirect_url=APefjpElcWiQ5IDVkWUYwM75pSOItjPDaezc2tHHx3Hp-b6sAr6hRvvnwv3_uCmAl766-ebGupVuQTPVFNbewS5OI54ia1-9A-Lm13XGGP3uKLhwjNdAKnWD3y6xIwOiJVMOCWPv-6wxRHhpORAzeO4ZKLB6-NLqilLMgWpH7R7G-ZZ3-zZvxiSfHqGchb8lY6Ec_LV7CeW6KZqo0RYQP2Q1IN3wrTrrKl5DHyJEg9nBrrna5w-Y3DBadt3CJueh3y7cO5pK4yPPw5YkBQJZi7mrBXBjWGFgn3J95xjTOkvboK447YexGqc&__hstc=207439628.97710d8cef260b164f288d3460335fe3.1683536443459.1688636740626.1688693220882.20&__hssc=207439628.2.1688693220882&__hsfp=3269552837&contentType=blog-post" rel="nofollow" target="_blank"><img alt="New Call-to-action" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688694809997-1688694809997.png" class="fr-fic fr-dii"></a>

Compared with LIGA Electroforming technologies such as UV LIGA and X-Ray LIGA processes, Advanced Lithographic Electroforming is the most ideal process from prototyping to mass production.

Pushing the Boundaries of Electroforming: Advanced Lithographic Electroforming and LIGA Processes explained

Electroforming is an Additive Manufacturing technique based on the electrodeposition process, with the unique advantages of high dimensional precision and replication accuracy. As miniaturization continues to be a driving force across various industries, Advanced Lithographic Electroforming is gaining significant attention for its ability to fabricate micro-precision components. It excels at achieving strict dimensional tolerances and intricate geometries, making it a crucial solution in the ever-evolving landscape of manufacturing. &nbsp;The scalability of Advanced Lithographic Electroforming sets it apart from traditional Electroforming processes. Due to its non-contact nature, it can efficiently handle high production volumes while maintaining consistent quality and precision across numerous micro-precision components. &nbsp;This article dives into Advanced Lithographic Electroforming, as well as micro-scale LIGA Electroforming technologies such as UV LIGA and X-Ray LIGA. &nbsp;&nbsp;Electroforming technology<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a> is a metal fabrication process that works on the principle of electrodeposition, similar to Electroplating. It can be used to produce metal parts by electrochemically depositing metal onto a mold, as well as to replicate metal parts with high precision. Common metals for the Electroforming process include nickel, gold, copper, etc.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg4Njk0MjI0MTQyLUVGIGJhdGgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">Image: Electroforming bathThe electrodeposition process starts with a conductive mandrel which is placed in an electrolytic bath and the electrodes pass a DC through the solution. The DC current converts ions into a metallic deposit on the conductive areas of the mandrel until the desired thickness has been achieved. Compared to other traditional metal forming technologies, for example, casting, forging, stamping, or deep drawing, Electroforming can deliver mass volume at superior accuracy and extreme design complexity, due to the fact that it can replicate the shape of the mandrel at extreme accuracy.Advanced Lithographic Electroforming &nbsp;Veco, as the world leader and largest independent supplier of Electroforming, has been moving the industry forward, with unparalleled experience in Electroforming, advanced lithography technology, and accumulated knowledge of metallurgy. Veco&rsquo;s unique Advanced Lithographic Electroforming is also referred to as Advanced Photo Electroforming. At Veco, <a href="https://insights.vecoprecision.com/how-to-accelerate-your-lead-time-with-the-laser-direct-imager" rel="noopener" target="_blank">LDI(laser direct imager)&nbsp;</a>is used to expose the photoresist layer directly on the substrate. It allows for rapid prototyping and design changes, as the laser patterns can be easily adjusted and updated without the need to create new physical masks or tools. This flexibility enables faster and more cost-effective iterations in the design process, compared to the time-consuming and expensive process of fabricating new glass tools for each design change.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688694293994-EF+process+gif.gif" style="width: 766px;" class="fr-fic fr-dib">Image: Electroforming processAt Veco nowadays, 90% to 95% of our photolithography process is done by Laser Direct Imaging. The combination of LDI and our leading Electroforming technology has enabled us to further push the boundaries of the industry with our Advanced Lithographic Electroforming, providing our customers with <a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">high-precision metal components&nbsp;</a>of higher quality, at lower cost, and with a quicker turnaround.LIGA Electroforming: UV LIGA, and X-Ray LIGALIGA is a German acronym for &quot;Lithographie, Galvanoformung, Abformung&quot;, which translates to &quot;Lithography, Electroplating, and Molding&quot;. In LIGA Electroforming, a photoresist such as SU-8 or PMMA is patterned using photolithography to create a mandrel for electrodeposition.UV LIGA is a LIGA process that uses UV light to expose photoresist through a photo mask. With UV LIGA, a thicker layer of photoresist can be penetrated, enabling a higher aspect ratio, which is an advantage in many applications. X-Ray LIGA is another variation of the LIGA process that uses X-ray radiation instead of UV light to expose the photoresist. The process involves placing a substrate coated with a thick layer of photoresist in an X-ray synchrotron beam, which exposes the photoresist in the desired pattern. With X-ray, even thicker layers of photoresist can be penetrated, allowing for extremely high aspect ratios exceeding 100:1, which is not achievable with UV LIGA or LDI processes. &nbsp;Comparison of LDI-empowered Lithographic Electroforming and LIGA Electroforming technologiesWhen comparing LDI-empowered Advanced Lithographic Electroforming and LIGA Electroforming technologies such as UV LIGA and X-Ray LIGA, many factors come into play. Here we compare on level of precision, cost efficiency, and scalability:Precision:&nbsp;LDI-empowered Advanced Lithographic Electroforming has a high resolution comparable to UV LIGA and X-Ray LIGA, enabling the fabrication of high-precision microstructures.Cost Efficiency:&nbsp;The production cost of LDI-empowered Advanced Lithographic Electroforming is significantly lower compared to UV LIGA and X-Ray LIGA due to the avoidance of expensive photomasks and long exposure times.Scalability:&nbsp;LDI-empowered Advanced Lithographic Electroforming is the most scalable while X-Ray LIGA has very limited production volume, and UV LIGA can be used for mass production but limited volume. Moreover, it has high repeatability and lower costs compared to LIGA Electroforming technologies.In summary, <a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Advanced Lithographic Electroforming</a> offers the necessary high precision and geometry complexity for micro precision metal parts, combined with fast prototyping, high volume suitability, and cost efficiency, making it the ideal process across the product lifecycle from prototypes to mass production.Table.&nbsp;Technical specifications of Advanced Lithographic Electroforming&nbsp;and LIGA Electroforming<table><tbody><tr><td width="66">Technical Specification</td><td width="115">LDI&nbsp;</td><td width="119">UV LIGA</td><td width="124">X-Ray LIGA</td></tr><tr><td width="66">Exposure</td><td width="115">UV laser</td><td width="119">UV light</td><td width="124">X-ray</td></tr><tr><td width="66">Resolution</td><td width="115">High</td><td width="119">High</td><td width="124">Very high (due to shorter X-ray wavelength)</td></tr><tr><td width="66">Aspect ratio</td><td width="115">Limited (due to thin layers of photoresist and limited depth penetration depth)</td><td width="119">High (due to thick layers of photoresist and good depth penetration depth)</td><td width="124">Extremely high, exceeding 100:1 (due to excellent depth penetration depth)</td></tr><tr><td width="66">Prototype Speed</td><td width="115">Fast (as no photomask is needed)</td><td width="119">Moderate (photomask required)</td><td width="124">Slow ( photomask and synchrotron beam time required)</td></tr><tr><td width="66">Scalability</td><td width="115">Highly suitable</td><td width="119">Suitable, but limited volume</td><td width="124">Very limited</td></tr><tr><td width="66">Cost efficiency</td><td width="115">Significant cost advantage</td><td width="119">Moderate</td><td width="124">Very expensive</td></tr></tbody></table>Interested to learn more about Advanced lithographic Electroforming? Don&#39;t miss out on our <a href="https://insights.vecoprecision.com/en/whitepaper-electroforming" rel="noopener" target="_blank">Electroforming Whitepaper</a>. <a href="https://insights.vecoprecision.com/cs/c/?cta_guid=8681c2ee-0a4a-407d-9e8c-85b23a7efd3f&signature=AAH58kFkKPnUtJCRK1CHCYXTtSEf7t7wyA&pageId=119192099647&placement_guid=056f005b-1e5e-49f9-b6d2-99830614eb56&click=a0850858-5f29-47f0-9183-94d56e729154&hsutk=97710d8cef260b164f288d3460335fe3&canon=https%3A%2F%2Finsights.vecoprecision.com%2Fpushing-the-boundaries-of-electroforming-advanced-lithographic-electroforming-and-liga-processes-explained&utm_referrer=https%3A%2F%2Finsights.vecoprecision.com%2F&portal_id=1788947&redirect_url=APefjpElcWiQ5IDVkWUYwM75pSOItjPDaezc2tHHx3Hp-b6sAr6hRvvnwv3_uCmAl766-ebGupVuQTPVFNbewS5OI54ia1-9A-Lm13XGGP3uKLhwjNdAKnWD3y6xIwOiJVMOCWPv-6wxRHhpORAzeO4ZKLB6-NLqilLMgWpH7R7G-ZZ3-zZvxiSfHqGchb8lY6Ec_LV7CeW6KZqo0RYQP2Q1IN3wrTrrKl5DHyJEg9nBrrna5w-Y3DBadt3CJueh3y7cO5pK4yPPw5YkBQJZi7mrBXBjWGFgn3J95xjTOkvboK447YexGqc&__hstc=207439628.97710d8cef260b164f288d3460335fe3.1683536443459.1688636740626.1688693220882.20&__hssc=207439628.2.1688693220882&__hsfp=3269552837&contentType=blog-post" rel="noopener" target="_blank"><img alt="New Call-to-action" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg4NjkzNzI1NjgyLTE2ODg2OTM3MjU2ODIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a>

20230707-Pushing the Boundaries of Electroforming: Advanced Lithographic Electroforming and LIGA Processes explained

3D printing is a well-known Additive Manufacturing technique, it can create three-dimensional objects by depositing materials layer by layer. Processes such as SLA (stereolithography) and DLP (digital light processing) are in particular known for high precision and resolution. While it is compatible with various materials, including polymers, metals, and ceramics, and commonly used in rapid prototyping as it enables fast design iterations, it may not achieve the same level of precision as other techniques such as Electroforming and lacks the capacity for high volume production runs.&nbsp;<a href="https://insights.vecoprecision.com/electroforming-vs.-3d-printing-whats-the-difference" rel="noopener" target="_blank">-&gt; Learn more about the comparison of Electroforming and 3D Printing</a>Laser Cutting uses focused laser beams to cut through materials, creating precise patterns and shapes. With Laser Cutting, intricate patterns with tight tolerances can be achieved. Although there are other advantages such as high precision and a wide range of compatible materials, it also has some limitations, such as HAZ (heat affected zones) which is thermal damage from the laser process.<a href="https://insights.vecoprecision.com/electroforming-vs.-laser-cutting-whats-the-difference" rel="noopener" target="_blank">-&gt; Learn more about the comparison of Electroforming and Laser Cutting</a>Micro Milling is a Subtractive Manufacturing process that involves the removal of material using rotating cutting tools with very small diameters. This technique works with various materials, such as metals, ceramics, and polymers, and can achieve tight tolerances and smooth surface finishes. On the other hand, due to its vibration/rotating feature, an additional process for stabilization might be required when high precision cannot be compromised.<a href="https://insights.vecoprecision.com/large-volumes-small-parts-a-comparison-between-electroforming-and-micro-milling" rel="noopener" target="_blank">-&gt; Learn more about the comparison of Electroforming and Micro Milling</a>Micro punching uses robust &lsquo;masters&rsquo; to punch holes in (mostly metal) substrates. As nozzle specifications have ever tighter tolerances, fewer masters can be used in parallel to reduce the variation. This slows down the production process while increasing the price.<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a>&nbsp;is an additive manufacturing method that combines lithography with highly controlled electrodeposition which is highly suitable to create metal parts with micro holes of any shape. The lithography allows for small feature sizes with tight tolerances while electrodeposition grows a large number of parts in parallel without local damage or deformations. By combining several lithography and electrodeposition steps Electroforming can also integrate micro nozzles with channels, distance holders, or filtration structures.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTIzODU4Nzg5LVNjcmVlbnNob3QgMjAyMy0wNi0wNyBhdCAxNS40MS41OS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">Examples of electroformed nozzles&nbsp;When comparing 3D printing, Laser Cutting, Micro Milling, and Electroforming, many factors come into play. The choice of technology for producing micro-fabricated nozzle plates depends on the specific requirements of the application and the desired characteristics of the final product. Here we compare 4 key factors: Precision, Customization, Scalability, and Material capability.Precision: Electroforming offers the highest precision and accuracy, down to the sub-micron level, making it ideal for intricate structures and fine features. Laser cutting and Micro Milling offer good precision but may not achieve the same level of detail as Electroforming. 3D printing provides moderate precision, depending on the specific technology used (SLM, EBM, etc.).Customization: Electroforming allows for a high degree of customization, enabling the creation of complex geometries tailored to specific applications and the integration of additional functionalities such as channels into a single part. Laser cutting and Micro Milling also offer customization capabilities, but their potential may be limited by the complexity of the desired design. 3D printing provides the greatest design freedom, allowing for the creation of complex geometries and internal structures that may be challenging or impossible to achieve with other methods.Scalability:&nbsp;Electroforming is well-suited for large-scale production due to its high repeatability and consistency across multiple production runs. Laser cutting offers a moderate level of scalability, depending on the specific setup and materials used. Micro Milling and 3D printing are better suited for small-scale production or rapid prototyping, as their efficiency may decrease in larger-scale applications.Material Compatibility:&nbsp;Electroforming is focused explicitly on metal deposition, making it suitable for producing metal nozzle plates. Laser cutting and Micro Milling are also adaptable to a wide range of materials, such as metals, plastics, and ceramics. 3D printing can work with different materials depending on the specific technology, with metal 3D printing techniques like SLM and EBM being particularly relevant for nozzle plates.In conclusion, Laser cutting, and Micro Milling provide normal precision and flexibility for applications not driven by extreme accuracy, while 3D printing offers unparalleled design freedom and material efficiency but is not comparable in precision. Electroforming excels in precision, customization, and scalability, making it particularly suitable for high-resolution and large-scale applications.Electroforming: Additive Manufacturing atom by atom<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a> is an advanced Additive Manufacturing technology specialized for producing <a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">high-precision metal parts</a>. Its uniqueness is that you can grow metal parts atom by atom, providing extreme accuracy and high aspect ratios. This process involves the use of an electric current to deposit layers of metal onto a substrate or mold, resulting in a highly accurate and precise reproduction of the original shape.There are several key benefits that make Electroforming particularly well-suited for the production of <a href="https://www.vecoprecision.com/products/micro-nozzle-plates/" rel="noopener" target="_blank">micro-nozzle plates</a>. Micro-nozzle plates require a high degree of accuracy and precision to function properly, and the Electroforming process can achieve this level of precision with a high degree of consistency. In addition, the Electroforming process is able to produce complex shapes with a high level of detail, which is critical in the production of micro-nozzle plates. These plates typically include a large number of very small nozzles, which require a high degree of accuracy and precision in order to function properly. Finally, Electroforming is a highly efficient and cost-effective manufacturing process, which is important in producing micro-nozzle plates. These plates are typically used in high-volume applications, where the ability to produce large quantities of parts quickly and efficiently is critical.<a href="https://insights.vecoprecision.com/cs/c/?cta_guid=8681c2ee-0a4a-407d-9e8c-85b23a7efd3f&signature=AAH58kEMSQR3cdQZ8AGE7ZNxiT4RQ2CXcQ&pageId=112575129227&placement_guid=056f005b-1e5e-49f9-b6d2-99830614eb56&click=a5ddf881-0995-423e-accb-0f06b9110c8c&hsutk=97710d8cef260b164f288d3460335fe3&canon=https%3A%2F%2Finsights.vecoprecision.com%2Fthe-making-of-micro-precision-nozzle-plates-3d-printing-laser-cutting-micro-milling-and-electroforming-compared&portal_id=1788947&redirect_url=APefjpGd17WwmSDSm36cLF2XSoWjfQRHaa43B7la0_L-iM6yd-D3msMSyL_7WOcYhUunyYIO9Rnsyy6LZCiOKrgHSMm8dby6zx5aCkXoasfmrsiuGZ_KHd0HAKKcBiFDkw-30qOT32Hm9umHkcLDapHM6Z8qhrUHjo-Q6ZwFjNpCD86sdetQ8OV3iMLhYUCkyjf5p_sMHhOL_paAFhBBOh4FWI4QEgFpDxhInOyzVBM5W8zyCK_WZyamYi8Cb3kQp3UEpbm9qCgC_E0gLpsxb4dPtklv9wwWrXyHKsRtHYAk440OnPMAonY&__hstc=207439628.97710d8cef260b164f288d3460335fe3.1683536443459.1686041795655.1686123279027.13&__hssc=207439628.3.1686123279027&__hsfp=2288638424&contentType=blog-post" rel="noopener" target="_blank"><img alt="New Call-to-action" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTIzODIyNDI1LTE2ODYxMjM4MjI0MjUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a>

Micro-fabricated nozzle plates are used in various industries, such as inkjet printing, medical devices, and flow control. Manufacturing these nozzle plates requires precision and accuracy to achieve the desired performance. Several production technologies can be used to manufacture micro-fabricated metal nozzle plates, such as 3D printing, Laser Cutting, Micro Milling, Micro Punching, and Electroforming. 

In this article, we will introduce these production technologies, and illustrate how to find your preferred process for the production of micro-fabricated nozzle plates based on key features such as precision, customization, scalability, and material compatibility.

The making of micro-precision nozzle plates: 3D Printing, Laser Cutting, Micro Milling, Micro Punching, and Electroforming compared

<a href="https://www.vecoprecision.com/products/micro-nozzle-plates/" rel="noopener" target="_blank">Micro-fabricated metal nozzle plates</a> are characterized by their extremely small size, intricate features, and complex design. Such metal plates found applications in numerous industries, with some of the most common applications including&nbsp;<a href="https://www.vecoprecision.com/products/inkjet-nozzle-plates/" rel="noopener" target="_blank">inkjet nozzle plates</a>,&nbsp;<a href="https://www.vecoprecision.com/products/nebulizer-plates/" rel="noopener" target="_blank">nebulizer plates</a>, and flow control plates. Micro nozzle plates in inkjet printing: the critical part for high-quality printing (and more)<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzNTM2NTExMzM2LTE2ODM1MzY1MTEzMzYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="inkjet_nozzle_plate-997660-edited" width="750" height="192" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/inkjet_nozzle_plate-997660-edited.jpg?width=375&height=96&name=inkjet_nozzle_plate-997660-edited.jpg 375w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/inkjet_nozzle_plate-997660-edited.jpg?width=750&height=192&name=inkjet_nozzle_plate-997660-edited.jpg 750w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/inkjet_nozzle_plate-997660-edited.jpg?width=1125&height=288&name=inkjet_nozzle_plate-997660-edited.jpg 1125w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/inkjet_nozzle_plate-997660-edited.jpg?width=1500&height=384&name=inkjet_nozzle_plate-997660-edited.jpg 1500w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/inkjet_nozzle_plate-997660-edited.jpg?width=1875&height=480&name=inkjet_nozzle_plate-997660-edited.jpg 1875w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/inkjet_nozzle_plate-997660-edited.jpg?width=2250&height=576&name=inkjet_nozzle_plate-997660-edited.jpg 2250w" sizes="(max-width: 750px) 100vw, 750px" class="fr-fic fr-dii">In inkjet printers, micro nozzle plates serve as an integral component of the print head, working seamlessly with other elements to regulate the ink flow. As the single most critical component of an inkjet print head, the quality of these nozzle plates directly influences the overall printing performance of the system.&nbsp;<a href="https://www.vecoprecision.com/products/inkjet-nozzle-plates/" rel="noopener" target="_blank">Micro-fabricated inkjet nozzle plates</a> play a pivotal role in depositing ink onto the printing substrate by precisely controlling droplet size, shape, and velocity. This meticulous control is crucial for maintaining exceptional print quality, characterized by vibrant colors and sharp resolution. The development of new materials and contactless printing applications have opened up new possibilities for inkjet printing in various industries, making inkjet nozzle plates even more crucial to the performance of these systems. Inkjet printing can now be used to deposit a wide range of functional materials onto various surfaces, including conductive inks for flexible electronics, living cells for tissue engineering, and silver paste for solar cells, and the role of inkjet nozzle plates becomes increasingly important across industries. (<a href="https://insights.vecoprecision.com/from-solar-cells-to-endless-applications-across-industries-inkjet-printing-revolution-enabled-by-electroforming-technology" rel="noopener" target="_blank">learn more about applications from textile printing to solar cell printing enabled by the inkjet printing revolution and Electroforming technology</a>) Micro nozzle plates for drug delivery: the key part for precise aerosol control&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzNTM2NTEyMTQ1LTE2ODM1MzY1MTIxNDUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="nebulizer" width="1305" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=653&height=223&name=nebulizer.png 653w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=1305&height=445&name=nebulizer.png 1305w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=1958&height=668&name=nebulizer.png 1958w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=2610&height=890&name=nebulizer.png 2610w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=3263&height=1113&name=nebulizer.png 3263w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=3915&height=1335&name=nebulizer.png 3915w" sizes="(max-width: 1305px) 100vw, 1305px" class="fr-fic fr-dii" style="width: 758px;">In the medical industry, micro nozzle plates can be used to control the release of drugs in targeted delivery systems, improving medical outcomes. In a mesh nebulizer, the&nbsp;<a href="https://www.vecoprecision.com/products/nebulizer-plates/" rel="noopener" target="_blank">nebulizer plate</a> is located within the medication chamber, where it plays a key role in converting liquid medication into an inhalable aerosol. Mesh nebulizers work by employing a vibrating mesh plate with numerous tiny holes. As the liquid medication passes through these holes, the plate vibrates at a high frequency, transforming the liquid into a fine mist to be inhaled by the patient.&nbsp; It is the micro-fabricated nozzle plate/mesh plate that ensures the medication is broken down into uniformly sized droplets, facilitating more effective delivery to the lungs and enabling better absorption of the medication. Moreover, the way the micro-fabricated nebulizer plate efficiently converts liquid medication into fine mist helps reduce medication waste, ensuring that the patient receives the correct dosage. Micro nozzle plates for flow control: the essential part for ultimate flow control<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzNTM2NTEyNDk4LTE2ODM1MzY1MTI0OTgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="flow" width="1320" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/flow.png?width=660&height=230&name=flow.png 660w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/flow.png?width=1320&height=460&name=flow.png 1320w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/flow.png?width=1980&height=690&name=flow.png 1980w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/flow.png?width=2640&height=920&name=flow.png 2640w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/flow.png?width=3300&height=1150&name=flow.png 3300w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/flow.png?width=3960&height=1380&name=flow.png 3960w" sizes="(max-width: 1320px) 100vw, 1320px" class="fr-fic fr-dii" style="width: 758px;">In flow control applications where precise control over fluid or gas flow is crucial, micro nozzle plates play a significant role. These tiny plates consist of an array of micro-sized nozzles or intricate features, engineered to accurately manage the flow rate, pressure, and direction of fluids or gases in a wide range of industries, such as aerospace, automotive, medical devices, and chemical processing. They regulate the passage of fluid or gas through carefully designed microscopic openings, size, and shape, which can be tailored to meet the specific requirements of a given application. By adjusting these parameters, it is possible to achieve precise control over fluid dynamics, such as laminar or turbulent flow, and maintain consistent flow rates and pressures.The importance of the micro nozzle plates in the performance of&nbsp;<a href="https://www.vecoprecision.com/products/flow-discs/" rel="noopener" target="_blank">flow control applications</a> lies in their capability to enhance precision by providing exceptional control, which is vital for applications where minor variations in flow can significantly affect system performance or product quality. Moreover, by accurately controlling the flow of fluids or gases, micro nozzle plates contribute to increased efficiency in various processes, leading to reduced energy consumption, minimized waste, and lower operational costs.&nbsp;Electroforming technology: the hero behind the sceneSeveral production technologies can be used to manufacture micro-fabricated metal nozzle plates, such as Laser Cutting, 3D Printing, Micro Milling, and Electroforming.&nbsp;<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a> is a particularly suitable manufacturing process for fabrication of the micro-precision nozzle plates due to its unique capabilities in creating highly precise, complex, and intricate structures. See below some key features that make Electroforming the winning option.<ul><li>High precision:&nbsp;Electroforming allows for the creation of extremely precise components with tight tolerances down to +- 1 micron. This level of accuracy is essential for micro-precision nozzle plates, as even minor variations in size or shape can impact their performance and overall functionality.</li><li>Complex geometries:&nbsp;Electroforming can produce components with complex geometries that would be difficult or impossible to achieve using other manufacturing methods. This capability is vital for micro-precision nozzle plates, which often require intricate structures and complex design features to ensure optimal performance.</li><li>Burr-free and Stress-free:&nbsp;Electroforming is an Additive Manufacturing process that grows metal atom by atom, resulting in burr-free and stress-free components. This is especially important for micro-precision nozzle plates, as burrs or residual stresses could negatively affect the performance of the nozzle and the overall system.</li><li>Scalable Production:&nbsp;Electroforming is a scalable manufacturing process that can be used for fast prototyping to high-volume production. This makes it an ideal choice for manufacturing micro-precision nozzle plates, not to mention the excellent reproducibility of Electroforming technology.&nbsp;</li><li>100% Quality: At Veco, our high-precision micro nozzle plates are measured by fully-automated measurement systems. Together with our inspection team, we can guarantee 100% inspection with zero defects.</li></ul><a href="https://insights.vecoprecision.com/cs/c/?cta_guid=8681c2ee-0a4a-407d-9e8c-85b23a7efd3f&signature=AAH58kFS0zhiXmhLYpqiVDoO76s_B5_Gzg&pageId=110633636659&placement_guid=056f005b-1e5e-49f9-b6d2-99830614eb56&click=4b9b99d6-e521-45fe-a55b-f54f0e33fdce&hsutk=97710d8cef260b164f288d3460335fe3&canon=https%3A%2F%2Finsights.vecoprecision.com%2Fharnessing-the-potential-of-micro-precision-how-micro-fabricated-metal-nozzle-plates-empower-applications-across-industries&portal_id=1788947&redirect_url=APefjpFQbsFLL1Ps2VI0tF0bDu0i8i6tIA0e44eSICNZBeRb6PE9Cx4sKEVuYzG7UfGJGrUe1dmrcn0BZGyd0FC_cJw0Ocr2AzN6G0GdZ2b82MKpftTkPAoUBiou8umhw8KWGQEhWVWl2VcfdhbS-F5J3PB5d6vEvw&__hstc=207439628.97710d8cef260b164f288d3460335fe3.1683536443459.1683536443459.1683536443459.1&__hssc=207439628.1.1683536443459&__hsfp=1580378404&contentType=blog-post" rel="noopener noreferrer" target="_blank"><img alt="New Call-to-action" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzNTM2NTExNTEyLTE2ODM1MzY1MTE1MTIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a>

The world of precision technology is constantly evolving, and one of the innovations that have gained significant attention in recent years is the development of micro-fabricated metal nozzle plates. These tiny, intricate components are revolutionizing industries across the board, with various applications in fields like Inkjet Printing, Medical, and Flow Control. In this article, we'll explore the key features of these nozzle plates, their applications, and how they empower important industry applications. 

Harnessing the potential of micro precision: how Electroformed micro nozzle plates empower applications across industries

The <a href="https://www.vecoprecision.com/products/inkjet-nozzle-plates/" rel="noopener noreferrer" target="_blank">Inkjet nozzle plate</a> is the single most critical component of an inkjet print head. These small and precise components are designed for high-performance jetting to distribute ink droplets with accuracy, speed, and longevity. Located at the heart of an inkjet printhead, an inkjet nozzle plate controls the formation and distribution of the microscopic droplets of ink that form the printed images on different surfaces. It contains tiny capillaries, or narrow channels, that are etched/lasered/Electroformed on the plate surface. When pressurized, ink flows through these channels and out of the nozzle, forming a precisely dosed droplet.The quality and performance of an inkjet nozzle plate depend on several factors. These include the shape, size, and number of the nozzles, their diameter, and the overall surface area of the plate. Additionally, the type of material used to produce the inkjet nozzle plate is also important. The most common materials used in inkjet nozzle plates include stainless steel, nickel, brass, copper, aluminum, and plastic. Each of these materials has its own advantages and disadvantages in terms of production and printing quality.Several methods are available for producing inkjet nozzle plates, such as Electroforming, Chemical Etching, and laser cutting. <a href="https://www.vecoprecision.com/electroforming/" rel="noopener noreferrer" target="_blank">Electroforming</a> is one of the most popular technologies for producing inkjet nozzle plates. It utilizes electrical current to grow thin metal layers on the substrate material. This technique produces high-precision nozzle structures with accurate control over the etched shapes and sizes. Additionally, electroforming allows for combining different metals, allowing for the cost-effective production of complex designs.As the industry-leading specialist in Electroforming and with over 25 years of experience with inkjet nozzle plates, Veco offers customized inkjet nozzle plates manufactured by Advanced Lithographic Electroforming. With our&nbsp;<a href="https://www.vecoprecision.com/electroforming/what-is-electroforming/" rel="noopener noreferrer" target="_blank">Advanced Lithographic Electroforming technology</a>, advanced features such as multi-layer nozzles can be achieved with high accuracy and reproducibility.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc5NDAzMzgyNjg0LW11bHRpIGxheWVyIHN0cnVjdHVyZS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 623px;" class="fr-fic fr-dib">Multi-layer nozzle allowing for integrated functionalitySee below how a customized inkjet nozzle plate is produced with Electroforming in 5 steps:1. &nbsp;A well-controlled process as a solid base After determining the requirements of the customer in a technical discussion, the production process can start.First, a custom metal plate (mandrel) with a patterned photoresist layer on top is made. Onto this mandrel, the metal is grown during the electroforming process. This step is very important because the final dimensions of an electroformed part are directly influenced by the accuracy of the mandrel.Before starting the process, the mandrel is strictly measured, determining the shape and size of the holes in the inkjet nozzle plate. The holes in the produced nozzle plate will have the exact dimension the customer requires, with no flats or blockings. The variety of diameters of each nozzle can be as good as within &plusmn; 1&micro;m between parts.&nbsp; Recent lithographic developments allow for even tighter aperture size control down to &plusmn;500nm, a nozzle pitch of 30&micro;m, and more freedom in defining the aperture shape. A well-controlled photolithographic process as a solid base tackles any unwelcome surprises.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc5NDAzNzk5NjE2LTE2Nzk0MDM3OTk2MTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">Left: High-definition photoresist pillars, densely packed and with a high aspect ratio. Right: Resulting nickel sheet grown between the pillars with tightly defined holes.2. &nbsp;Using the correct method to control accuracy Once the mandrel is finished, it is time for the electroforming process.Usually, the overgrowth method is applied to shape the apertures. This means growing the metal over the thin layer resist, creating bell mouth-shaped apertures with tightly controlled dimensions.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1679404883690-1679404883690.png" style="width: 760px;" class="fr-fic fr-dib">Left: Protruding nozzle. Right: Straight-sloped nozzle.&nbsp; Examples of different possible nozzle forms.3. &nbsp;Protecting the plated productAfter the electroforming process, gold or palladium-nickel coating can be applied to protect the inkjet nozzle plate and prevent corrosion. Another round of process control is done subsequently to ensure the process&#39;s quality is consistent.4. &nbsp;Delivering 100% QualityAfter electroforming and plating are done, every nozzle is checked with an image analyzer that measures all the holes with submicron accuracy. It also detects any disturbance of the holes which might lead to a bad printing performance.After this, the products are ultrasonically cleaned and packaged under clean room conditions before shipping.5. &nbsp;Traceability of nozzle plates by laser marking and data sharingTo provide the customer with unique and valuable tracking data, the nozzle plates can be laser marked with a unique text or code. These codes can be read by our customers with scanning equipment and are vital for traceability and constant improvement. Customers can also read data regarding the specifications of the hole, for example, size and pattern. This helps customers determine the effect of a certain inkjet nozzle on the printed pattern, helping them learn and improve!Using Electroforming technology to produce inkjet nozzle plates provides several advantages, including greater accuracy and detail in the printing process. The precise contours and dimensions of the nozzles are reliably reproduced with consistently high tolerances. Furthermore, the combination of different metals allows manufacturers to achieve the desired level of hardness, wear resistance, and corrosion resistance for their nozzle plates. Finally, electroforming offers a low-cost and highly efficient manufacturing process, reducing production times and costs significantly.To learn more about Electroforming and how it can benefit your application, <a href="https://insights.vecoprecision.com/en/whitepaper-electroforming" rel="noopener noreferrer" target="_blank">download Whitepaper Electroforming here.</a>

Inkjet nozzle plates are one of the most important components of inkjet print heads,  as the quality of the nozzle plates directly determines the resulting printing performance of the whole system. This article introduces what an inkjet nozzle plate is, how this important component works, and how it is manufactured.

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