Ilhem Boutana, Oussama Boultif, Abdessalam Zait

Abstract: Electroforming is an advanced manufacturing process that uses electrolysis to deposit metal onto a substrate, allowing for the creation of highly intricate and detailed metal components. This technique is widely utilized in industries such as jewelry, electronics, and art, where precision and complexity are critical. Additionally, electroforming is essential in producing molds, prototypes, and high-precision parts for applications in the aerospace and automotive sectors. The process excels in generating complex geometries with exceptional accuracy. Modeling electroforming involves simulating the physical and chemical interactions during metal deposition to optimize parameters, predict performance, and improve the quality of the final product. Although modeling is complex, it plays a crucial role in enhancing the efficiency, precision, and cost-effectiveness of the manufacturing process. By simulating these factors, manufacturers can refine their methods to reliably produce high-quality electroformed components. In this study, a 2D, time-dependent, secondary current distribution model, developed in COMSOL Multiphysics, is employed to validate the electroforming of copper and nickel devices across various processes, providing valuable insights into process optimization and outcome prediction.

Keywords: Electroforming, Electrodeposition, Electroplating, Electropolishing, Numerical Modeling.

Date Published: October 15, 2024
DOI: 10.11159/jmids.2024.011

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