Electroforming as a service with a unique price-performance ratio

In the field of electroforming, we combine our expertise in developing high-quality electrolytes with the ability to apply them effectively in practical settings. This has made us an experienced partner for our customers for decades – from consultation through implementation and even beyond.

Series production made by a premium manufacturer 

We are now taking it a step further and offering electroforming (also known as electroplating or EF) as a service – from the activation of the cores (also known as models, blanks or mandrels) through the desired deposition process to the removal of the cores. For our customers, this means: Gold and platinum applications can now be reliably produced in series by their electroforming specialists – with no volume restrictions and at a price-performance ratio that is likely unmatched thanks to the bundling of resources.

Electroforming is one of the most innovative technologies for manufacturing hollow and extremely lightweight metal objects. Unlike traditional electrolytic plating, it does not refer to the surface finishing of a substrate. Instead, self-supporting metal structures are built up layer by layer on a freely moldable core.

The advantages of electroforming compared to other processes

Electroforming combines the advantages of traditional casting with those of electrolytic plating. This enables cost-effective production while ensuring product quality. The process also offers new design and weight flexibility, which is particularly beneficial to the jewelry industry.

Electroforming can thus be viewed as a highly effective combination of two worlds. This becomes particularly clear when comparing common processes based on the following criteria:

Many companies are aware of the benefits of electroforming, but they are reluctant to set up their own production lines. Common reasons for this include the investment required for complex equipment, the handling of chemicals, the need for specialized technical staff and the necessity of consistently high capacity utilization to ensure cost-effective production.

Mass production in electroforming is challenging because it requires several handling steps. In the critical deposition process, narrow process windows (chemical concentration, pH-value, temperature, and current density) must also be maintained at a stable level at all times to achieve uniform wall thicknesses and the desired level of karat.

For gold alloys, the target karat content is largely determined by the condition of the bath and process control. Final verification is typically performed on the finished part, which can make quality control during the production process more difficult. For platinum, however, shorter electrolyte operating times, tighter tolerances, and greater sensitivity to contaminants tend to make cost-effective high-volume production more difficult.

In addition to process expertise, scaling up requires additional manufacturing overhead: Mass production requires specialist staff with detailed knowledge of electroplating – including EHS expertise, such as in the handling of hazardous substances. Added to this are capital expenditures for equipment, precious metals and chemicals – resulting in higher overall fixed costs than with traditional processes. Core handling entails additional risks of rejects (e.g., warping or separation issues with thin-walled geometries) and thus potentially difficult-to-calculate variable costs.

Electroforming as a service – attractive, planable and low-risk

Starting this year, we are offering electroforming as a service – using gold (ranging from 8 karat/333 to 9 karat/375, 14 karat/585, 18 karat/750 and 24 karat/999) as well as pure platinum. We will take care of the entire plating process to ensure the precise production of hollow, ultra-lightweight jewelry components.

As an experienced manufacturer, we also assist in precisely defining specifications for electroforming. The goal is to achieve an optimal balance between quality and cost, depending on the application, field of use and target group. Typically, the following aspects, among others, are specified:

Selecting the core material
The choice of core material influences both the design and the process. In addition to commonly used waxes, low-melting-point metal alloys are also an option – depending on the desired effect and the subsequent removal method (e.g., thermal or chemical, depending on the core material).

Wall thickness
Determining an appropriate target wall thickness (typically 150–300 µm or more for 24k) to balance stability, appearance and precious metal requirements.

Precious Metal Composition
Determining the composition of precious metals to balance costs with desired quality and image factors. Additionally, a decision can be made regarding whether to use standard precious metals or recycled and certified CoC precious metals to appeal to specific customer groups.

Mechanical Finishing 
Depending on the required surface finish, mechanical finishing may be necessary. This can be achieved, for example, through manual or machine grinding or polishing.

Final gold plating (top finish)
Color and gloss matching to finalize the appearance – typically requested as a final step for 8/9k, 14k, and 18k – can be achieved using the proven AURUNA^® processes.

We are one of the leading manufacturers of electrolytes for decorative coatings and have many years of experience in electroforming. Based on this expertise, we consider ourselves a suitable partner for contract manufacturing orders in this field.

Thanks to planned investments in modern facilities and buildings, we will be able to efficiently handle even large-volume orders using our existing precious metal infrastructure, analytical capabilities and quality control systems. This gives us the opportunity to make our contract manufacturing attractive not only in terms of quality, but also with regard to the following factors.

We handle the precise and uniform layering in large-scale production environments, including material and chemical handling, in compliance with all safety and environmental regulations – at no additional cost. Furthermore, we do not charge for any production rejects (charging based on good parts).

This ensures that jointly agreed costs and production results are reliably achieved. By pooling resources, we also offer a price-performance ratio that is likely unique in the market.

A price-performance ratio that is likely unmatched in the market

With our services, we want to take contract manufacturing in the field of electroforming to a new level. We are pleased to be able to simplify access to this production process for customers and prospective interested parties – or even make it possible for them in the first place.

If electroforming might be of interest to you, we would be happy to evaluate the possibilities of our services for your specific projects, with no obligation. The production of test samples to support in decision-making is, of course, an integral part of any potential quotation process.