Electroform Nickel Tooling Services

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Electroform Nickel Tooling
Electroform Nickel Tooling

At FET Engineering, Inc. we provide design, engineering, and CAD modeling of custom electroform molds for a range of applications and industries. Designs are thoroughly analyzed with stress analysis technology, and models are created for further evaluation and refinement in order to meet exacting standards. We specialize in the fabrication of rotocast molds, autoclave tools, polyurethane (PU) spray tools, and reaction injection molding (RIM) tools. Powder slush molds are manufactured for the hot air, hot sand, and hot oil processes utilizing a specially developed piping process to ensure even heat distribution during production. Accommodations can also be made for the incorporation of paint or adhesion spray masking.

The electroforming process is effective in producing lightweight molds of high complexity, maintaining superior resolution and precision of patterned substrates while achieving extreme tolerances. Our molds feature nickel plated aluminum cores, this gives excellent corrosion and thermal shock resistance as well as exceptional release properties. Electroformed tools are available in sizes of up to 118" in length, up to 158" in width, 72" in height, and handle up to 5 tons in part weight. Tools average a production lifespan of over 100,000 parts, with a shrink rate of 7/1000 parts. Our comprehensive tooling manufacturing service employs a range of high precision manufacturing processes. This includes high precision machining, mandrel making, pipe welding, frame and general assembly, all verified thorough comprehensive testing and inspection measures.

Testing protocols include hardness, ultrasonic thickness, and stress analysis techniques, along with CMM and Ferro Arm inspections with furnished inspection reports. Our products and processes are in conformance with stringent industry standards, including ANAB accreditation, ISO 9001:2008 and 14001:2004 certifications, NSF, SPE, and NASF compliance among others. For more details about our custom electroformed mold making capabilities, or the other products and services we offer please see the table below or contact us directly.

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Electroform Nickel Tooling Capabilities

General Capabilities
CAD Modeling
Design
Engineering
Stress Analysis
Mold Types
Powder Slush
  • Hot Air
  • Hot Sand
  • Hot Oil
Rotocast
Polyurethane (PU) Spray
RIM
Autoclacve
Process
Model Creation
Model Wrapping (Vinyl)
Mandrel
Silicone Case Models
Fabrication
Machining
Milling
Pipe Welding
Frame Assembly
Grinding
Sand Blasting
Electroform
Nickel Plating
Assembly
Materials
Aluminum Core
Nickel Plating
Masking
Paint
Adhesive Spraying
Length
Up to 118 in
Width
Up to 158 in
Height
Up to 72 in
Part Weight
Up to 5 tons
Shrink Rate
7 / 1000 parts
Parts
Over 100,000 parts/tool
Inspection
Coordinate Measuring Machine (CMM)
Ferro Arm
Testing
Hardness
Ultrasonic Thickness
Stress Analysis
Quality
Plating Tank Testing
Hot Oil Leak Check
Documentation
Inspection Reports
Additional Services
Trial Parts
Packaging
Program Management
Mold Modifications
Engineering Change Inquiry (ECI)

Additional Information

Industry Focus
Automotive
Aircraft
Plastisol Processing
Packaging
Medical
Home and Bath
Construction
Agriculture
Heavy Truck
Intended Applications
Interior Trim
Auto Trim
Door Panels
Instrument Panels
Shoe Soles
Velcro
Sink Molds (Bathtubs and Showers)
Vinyl Siding
Doors
ATV Gas Tanks
Headliners
Industry Standards
ISO 9001:2008
ANAB Accredited
ISO 14001:2004
NSF
AQA International
National Association of Surface Finishers (NASF)
Society of Plastics Engineers (SPE)
Kentucky Association of Manufacturers (KAMM )
File Formats
Rhino
CATIA
Cimitron
CRIO

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