High Precision Nickel Alloy Electroplated Mold Cavity And Core With Milling Drilling Process

Suitable For High-Precision Molded Parts (Complex Hole Systems, Precision Grooves) | ±0.001mm Critical Feature Tolerance | Works With Engineering Plastics (PC, PEEK), Light Metals (Aluminum Alloys) & Micro-Composites

Engineered for molds requiring "ultra-precise holes/grooves + stable nickel alloy performance," our high-precision nickel alloy electroplated mold cavities and cores combine two critical processes: electroforming (for uniform, stress-free nickel alloy bases) and precision milling/drilling (for micron-level hole/groove shaping). Unlike standalone electroforming (limited in hole accuracy) or machining (prone to hard alloy wear), this hybrid approach delivers ±0.001mm tolerance for hole diameter and position—critical for parts where "even 0.002mm misalignment ruins function," such as automotive sensor lens mounts or medical connector pins. Whether molding high-temperature plastics or light metals, these molds balance precision, durability, and assembly compatibility.

Milling and drilling solve the "electroforming limitation" of low hole/groove precision, enabling micro-scale structural control:

• Complex Hole System Processing: Drills multi-row micro-holes (0.07-0.5mm diameter) with ±0.001mm hole position accuracy and ≤0.0008mm coaxiality—ideal for automotive ADAS sensor molds (where hole alignment fixes lens focus) or medical connector molds (0.09mm pin holes for signal transmission).
• High-Precision Groove Shaping: Mills narrow grooves (0.08-2mm width) with ±0.001mm tolerance and ≤0.001mm parallelism, critical for industrial gear molds (tooth slot accuracy) or optical component sliding rails (smooth movement).
• No Hard Alloy Wear: Uses carbide-tipped milling/drilling tools optimized for nickel alloy (50-55 HRC), avoiding edge chipping or tool deformation—ensuring consistent precision across 100+ mold units.

The two processes work in tandem to eliminate errors, ensuring every feature meets strict standards:

• Electroplating’s Stable Base: Deposits uniform nickel alloy layers (thickness tolerance ±0.0005mm) to form the cavity/core structure, avoiding "thin-wall deformation" that plagues machined-only molds.
• Milling/Drilling’s Fine Trimming: Corrects minor electroforming deviations (e.g., 0.0015mm surface unevenness) and shapes holes/grooves to ±0.001mm—ensuring molded parts fit seamlessly into assemblies.
• Dimensional Stability: Electroplated nickel alloy has low thermal expansion (13.1*10⁻⁶/℃), while milling/drilling’s low heat input preserves this stability—molds maintain tolerance even after 150,000+ production cycles at 200℃.

Electroplated nickel alloys enhance mold lifespan, while milling/drilling’s smooth finishes reduce wear from repeated molding:

• Corrosion Resistance: Nickel-copper alloy resists industrial coolants, medical disinfectants, and humidity—preventing rust that distorts hole/groove dimensions.
• Wear-Proof Performance: Nickel-cobalt alloy (50-55 HRC) stands up to abrasive materials (e.g., glass-filled PEEK, aluminum alloys), extending mold life to 200,000+ cycles (vs. 80,000 cycles for standard steel molds).
• Low Maintenance: Milling/drilled holes/grooves have Ra ≤0.008μm smoothness, reducing material adhesion (e.g., plastic residue) — cleaning time is cut by 40%, and mold downtime minimized.

Our molds excel in industries where "micron-level hole/groove accuracy = product functionality":

• Automotive Electronics: Molds for ADAS sensor housings (0.1mm lens-mounting holes, ±0.001mm position accuracy) and EV battery connector cavities (multi-row 0.09mm pin holes) — meets IATF 16949 standards.
• Medical Devices: Custom cores for micro-connector molds (0.07mm signal holes, biocompatible pure nickel) and surgical instrument handle molds (precision grooves for grip texture) — complies with ISO 13485.
• Industrial Automation: Molds for precision gear blanks (0.2mm tooth slots, ±0.001mm width tolerance) and robotic arm component cavities (high-coaxiality mounting holes) — aligns with ISO 9001 quality requirements.
• Optical Components: Cavities for lens housings (0.5mm threaded holes, ≤0.0008mm coaxiality) and laser module slots (0.15mm width, parallelism ≤0.001mm) — meets ISO 10110 optical standards.

We adapt every aspect of the mold to your unique hole/groove requirements:

• CAD-Driven Customization: Accepts 3D CAD files (STEP, IGES) to replicate your exact hole layout (e.g., 5-row 0.1mm holes with 0.3mm spacing) or groove design (e.g., spiral grooves for fluid flow).
• Parameter Tuning: Adjust hole diameter (0.07-5mm), groove width (0.08-10mm), and depth (0.1-20mm) — our engineers optimize milling/drilling speeds (15,000-30,000 RPM) to avoid nickel alloy deformation.
• Material Matching: Recommend alloys based on your molding material: nickel-cobalt for abrasive plastics, nickel-copper for chemical-exposed parts, pure nickel for medical biocompatibility.

• Quality Inspection: 100% testing via CMM (±0.0005mm accuracy) for hole/groove dimensions, and laser confocal microscopy for surface finish — every mold includes a detailed inspection report.
• Traceability: Full documentation package: nickel alloy material certificates (99.95% purity verified), electroplating logs (current density, electrolyte temperature), and milling/drilling records (tool type, RPM, feed rate).
• Technical Support: Dedicated engineers advise on hole/groove design optimization (e.g., "adding 0.005mm draft to deep grooves for easier demolding") and troubleshoot production issues (e.g., material adhesion in holes).

Whether you need a mold with 0.07mm micro-holes for medical connectors or 0.2mm precision grooves for automotive sensors, our high-precision nickel alloy electroplated cavities and cores—enhanced by milling and drilling—deliver the accuracy, durability, and assembly compatibility your products demand. Backed by ±0.001mm tolerance and factory-grade quality control, they ensure every molded part meets your strictest functional standards.