A hybrid process for complex-shaped parts electroforming

Electroforming is a nonconventional manufacturing process of metallic parts by using electrodeposition on a pre-shaped cathodic mandrel. It can produce a metallic structure and builds the material by atom level. Smooth free surface and normal edge deposition are important to the electroforming of complex-shaped parts. A hybrid electroforming process combining mechanical particle polishing and auxiliary cathode was proposed to improve the quality of the free surface and inhibit the over-deposition on the mandrel edge. The smooth effect of particle polishing on the growing deposit surface was theoretical analyzed. The effect of the auxiliary cathode for a complex model with freeform surface was simulated. Contrast electroforming tests were performed in a bath without any addition agents under different conditions. The results positively proved the smooth effect and the overgrowth inhibition effect of the hybrid process. A nickel complex sample with smooth free surface and inconspicuous edge overgrowth was successfully electroformed.