Nickel Alloy Electroplated Precision Mold Cavity And Core (Customizable) With Multi-Axis Machining Process

Suitable For Complex Geometry Parts (3D Curved Surfaces, Deep Cavities, Asymmetrical Features) | ±0.001mm Critical Tolerance | Works With High-Performance Materials (PEEK, Titanium Alloys, Glass-Filled Plastics)

Engineered to solve the "complex 3D geometry + high precision" dilemma in mold-making, this customizable nickel alloy electroplated mold combines two game-changing processes: electroforming (for stress-free, uniform nickel alloy bases) and multi-axis machining (for micron-level trimming of 3D curves, deep cavities, and asymmetrical features). Unlike traditional 3-axis machining (limited by flat/linear cuts) or standalone electroforming (struggling with sharp 3D edges), this hybrid approach delivers ±0.001mm tolerance for parts like aerospace turbine blade cavities (with 3D curved cooling slots) or medical instrument housings (with asymmetrical grip contours). Built with high-performance nickel alloys, it balances durability and precision—critical for high-cycle production of complex components.

Multi-axis (5-axis/6-axis) machining eliminates the "flaws of flat machining," enabling molds with intricate 3D features that traditional methods can’t replicate:

• 3D Curve Accuracy: Cuts 3D curved surfaces (e.g., optical lens mount cavities) with ±0.001mm deviation from CAD designs—critical for parts where "0.002mm curve error ruins assembly" (e.g., aerospace sensor housings).
• Deep Cavity & Undercut Handling: Machines deep cavities (depth-to-width ratio 5:1) and undercuts (0.1mm clearance) without tool collision—ideal for medical instrument molds (with hidden grip grooves) or automotive transmission part cavities (with internal ribs).
• Reduced Setup Errors: 5-axis 联动 (5-axis 联动) machining consolidates 3+ traditional setups into 1, cutting "repositioning errors" by 90%—ensuring 3D features (e.g., a cavity’s curved wall + adjacent hole) align to ±0.0008mm.

Electroforming lays a stress-free, uniform nickel alloy base—critical for maintaining multi-axis machined precision over time:

• Stress-Free Structure: Nickel ions deposit layer-by-layer (0.001mm per hour), creating a mold base with no internal stress (unlike machined steel, which warps under heat). This ensures 3D features stay within ±0.001mm tolerance across 150,000+ production cycles.
• Uniform Material Density: Electroplated nickel alloy has 99.9% density (no porosity), avoiding "weak spots" that cause wear in high-stress areas (e.g., deep cavity corners).
• Surface Perfection: Electroforming delivers Ra ≤0.01μm as a base, which multi-axis machining refines to Ra ≤0.008μm—ideal for parts where surface smoothness impacts function (e.g., fluid flow in medical device cavities).

The right nickel alloy ensures the mold withstands the demands of complex part production:

• Wear Resistance: Nickel-cobalt alloy (50-55 HRC) resists abrasion from high-pressure molding of glass-filled plastics (e.g., 30% glass-filled PA) or metal powders—extending mold life to 200,000+ cycles.
• Corrosion Resistance: Nickel-chromium alloy stands up to coolants, disinfectants, and industrial fluids—critical for medical molds (contact with bodily fluids) or aerospace molds (exposed to hydraulic fluids).
• Thermal Stability: Withstands 280℃+ (nickel-chromium variants), supporting high-temperature molding of PEEK (250℃) or titanium alloy MIM (200℃).

Our molds excel in industries demanding "intricate 3D shapes + micron-level accuracy":

• Aerospace & Defense: Molds for turbine blade cooling channel cavities (3D curved slots, 0.1mm width) and avionics sensor housings (asymmetrical 3D contours) — meets AS9100 standards.
• Medical Devices: Custom cores for surgical instrument handle molds (undercut grip grooves, 0.15mm depth) and endoscope component cavities (3D curved lumens for fluid flow) — complies with ISO 13485.
• Automotive High-Performance Parts: Molds for transmission gear cavities (internal 3D ribs for strength) and EV battery connector housings (asymmetrical 3D slots for wire routing) — aligns with IATF 16949.
• Optical Engineering: Cavities for lens mounts (3D curved seats, Ra ≤0.008μm) and laser module housings (3D alignment features, ±0.001mm tolerance) — meets ISO 10110 optical standards.

We turn your most complex CAD models into production-ready molds, with zero compromise on precision:

• Geometry Customization: Accepts 3D CAD files (STEP, IGES, STL) for any 3D feature—from spiral grooves (0.08mm width) to 3D asymmetrical cavities (depth 50mm). Our engineers optimize multi-axis toolpaths to minimize cutting time without sacrificing accuracy.
• Alloy Matching: Recommend nickel alloy based on your production: nickel-cobalt for high-wear materials, nickel-chromium for corrosion-exposed parts, pure nickel for optical-grade surface finish.
• Prototype & Validation: Produce 1-2 prototype molds (14-18 days) to test 3D feature functionality—using 3D scanning (±0.0005mm accuracy) to verify curve/undercut compliance before full production.

• Quality Inspection: 100% testing includes:
  • 3D CMM scanning (±0.0005mm) for 3D feature accuracy;
  • Laser confocal microscopy (Ra ≤0.008μm surface verification);
  • Stress testing (thermal cycling to 280℃) to confirm dimensional stability.
• Traceability: Full documentation package: nickel alloy material certs, electroplating logs (current density, electrolyte temperature), and multi-axis machining records (toolpaths, feed rates).
• Technical Support: Dedicated engineers advise on 3D design optimization (e.g., "adding 0.005mm draft to deep undercuts for easier demolding") and provide post-delivery training on mold maintenance.

Whether you need a mold for 3D curved aerospace parts or asymmetrical medical devices, our nickel alloy electroplated cavities and cores—enhanced by multi-axis machining—deliver the complexity, precision, and durability your production demands. Backed by ±0.001mm tolerance and 5-axis precision, they ensure every complex part meets your strictest functional standards.