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Electroforming Development Room

 Recently 「Micro systems」fields such as MEMS orμTAS etc. have been changing from experimental stage into practical stage. Although it is said that these related parts have problems as bottleneck for mass product like production efficiency or cost because of they are made by using semiconductor technology.

 It is said that one of these solutions is the development of MEMS mold that is essential to use mold shape transcription to resin etc.

  In order to meet market requirements 、we develop Ni series alloy electroforming or ultraprecise mold or producing multiple electroformed mold by master model which is made from semiconductor process, besides developing the process of enlargement mold by putting together these molds, we are aiming at establish consistency production technology from master model to electroformed mold.

 

Develop Ni series alloy electroforming

 Nano imprint technology which transcripts precise structure to resin etc. by using mold has recently gained the spotlight. Nano imprint process includes optical (UV)nano imprint 、heat nano imprint etc..

 Especially heat nano imprint can be applied to various of thermoplastic resin , therefore it is used to optical elements or bio related elements.

Although、the method of transcription is pressuring the mold during thermoplastic resin heated more than glass-transition temperature, so that it has durability problem and lower the hardness in Ni electroforming.

 Therefore we are developing high strength Ni series alloy electroforming which does not fall hardness around 300℃.

 Besides, there are requests that rising hardness of mold surface 、we are developing around 700HV(HRC60) Ni alloy or around 500Hv(HRC50) Ni alloy.

Produce fine structure mold by machine processing

 Regarding mold which produces optical parts such as aspherical lens or diffuser panel etc. 、these are processed by using monocrystal diamond byte on the materials such as electroless Ni-P plating or anoxic copper.

 Although, there are flashes or pinholes etc. problems that occurs during processing and attributed to processing materials, on the other hand it needs to make master model for electroforming processing that is considerate to master model's material or electroforming process.

 Therefore、we are developing prototype product development including material development such as electroless Ni-P plating or copper plating which is good at processability etc..

Develop enlargement process of fine structure mold

 There are various methods to produce fine structure such as machine processing, exposure to light (aligner, stepper) and electron beam, however it is said that these methods are limited to produce approximately 300mm degree fine structure except machine processing.. Machine processing can produce more than 300mm degree fine structure, however it depends on the shape of cutter, so that it can only produce a few micron degree of fine structure at present.

 Therefore we are developing method of producing multiple molds from single fine structure mold (master model ) and method of enlargement mold by putting multiple molds together.

 

 Following is the case which produces the size of 80mm × 80mm mold  from 20mm × 20mm fresnel lens mold.

 

 

■Evaluation/ Result

Above case is quoted from the National Federation of Small Business Associations report in 2009

Ikex Industry Co., Ltd comprehensively utilizes management system based on
AS 9100(Electroforming Plant only), ISO 9001・14001 and OHSAS 18001 specifications.

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