A two- to three-mm thick electroformed nickel mould can have early cracking when exposed to thermal load cycles. The investigators obtained monotonic properties of electroformed nickel at various temperatures and identified the underlying causes of fatigue. Then, they used finite element modelling to analyze the mold. They discovered that overconstraining in service resulted in excessive thermal stresses, which led to an accelerated crack initiation. They also proposed several remedies to prevent failures.
The electroformed mould is a good option when the precision is important. A mould that is perfectly proportioned will have a higher quality surface than a mould that has been electroformed using a more expensive method. The latter is also a good choice for complex true geometric shapes with thin walls. It is an excellent option for high repeatability. And as with all other types of abrasive materials, it is easy to etch the surface.
An electroformed mould will have an extremely high quality finish. The metal used will have a smooth surface with no imperfections. The metallic insert will have a smooth surface and an electroformed mould will be able to resist heat. However, an electroformed mould is not a perfect match for all materials. A good example of an electroformed mould is one where the material is not too thin. It may have a thin wall, but it is too thick to support the plastic.