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Figure 1: 2.5D Data transmission flexure.
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Figure 2: Optical precision part (pinhole camera).
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Hans Berenschot (International Account Manager)
Hans Berenschot (International Account Manager)
With the introduction of Laser Direct Imaging in the lithography process, the aspect ratio and the detailed characteristics of galvanic parts are improved. And it shortens the lead time for new product launches.
Electroforming is an electrochemical deposition of metal in a photo lithographically patterned layer, forming a component with very high resolution and accuracy
Traditionally, a photo or glass mask is used to define the product structure in the photolithographic process. With a Laser Direct Imager (LDI ) this is superfluous, since the CAD file is displayed directly on the ( photosensitive layer ) of the mandrel . The omission of such a mask shortens processing time and the cost of the design iterations and ensures error free and accurate representation. In this way new applications are possible with exceptional product details and aspect ratios. By precisely controlled orienting multilayer products (2.5D) with integrated functionality are also possible
Due to the direct connection from the CAD file to the mandrel the Direct Imaging technology can effectively be used for mass production and prototype production.
The electroforming is an additive manufacturing technology, on which the company Veco is not only specialized, but led into further perfection. The cost-effective technique has its strengths in the field of High-Mix-High-Volume production with product details in the submicron range.
Also in case of extreme tolerances, very complex, clean and burr-free products, the process is very efficient compared to other processes such as laser cutting, chemical milling or punching. The advantages are as follows:
- extremely high accuracy,
- no burrs , no stress in the material , natural flat products,
- the possibility of complex shapes,
- an excellent edge sharpness,
- excellent reproducibility,
- economically cost effective parts,
- suitable for small and very large quantities and
- low tooling costs.
Overall, electroforming is a very cost-effective method for prototyping as well as for the production of small and large series.
The LDI has opened its high precision in product details and the alignment of layers, for new applications.