Umicore MDS launches rollout of electroforming as a service for decorative applications

Umicore’s Business Unit Metal Deposition Solutions (MDS) is expanding its range of services to include electroforming and plans to expand its infrastructure for future mass production. The rollout is intended for manufacturers of decorative precious metal applications, including large-format jewelry such as bracelets and brooches, as well as detailed accessories such as earrings and pendants for necklaces. The goal is to provide access to mass-production-ready manufacturing of electroformed, hollow and therefore lightweight precious metal components – without the need to build up in-house equipment and process resources.

Complete process takeover from core setup to core removal

Umicore MDS is a manufacturer of electrolytes and electrodes for (precious metal) plating and has decades of experience in electroforming. This expertise in processes and chemistry forms the basis for the contract manufacturing services now being offered.

If desired, the company advises its customers on defining application specificationseven before the quotation phase, in order to balance quality requirements and costs within the respective market segment. Typical parameters include the core material and removal method (thermal/chemical), the final wall thickness (typically 150–300 µm or higher for 24-karat gold), the precious metal composition or karat and the desired surface finish.

The service itself includes the activation and preparation of the core (also known as a model, blank or mandrel), electrochemical deposition and core removal to produce self-supporting metal bodies. Umicore MDS offers electroforming with gold alloys ranging from 8 karat (333) to 9 karat (375), 14 karat (585) and 18 karat (750) up to 24 karat (999), as well as with pure platinum. Production using recycled CoC precious metal (Umicore Nexyclus™ certificate) is also available as an option.

To achieve this, Umicore MDS leverages its existing precious metal infrastructure and its AURUNA® and PLATUNA® electrolytes, which were specifically developed for electroforming. This enables special pricing structures that make the service economically attractive. Payment only for good parts delivered also offers customers a high degree of cost certainty – production rejects that arise within Umicore’s area of responsibility are not charged.

Benefits and classification of the procedure

In electroforming, a metal structure is built up additively on a moulding core. Once the deposition process is complete, the core is removed, resulting in hollow structures with high levels of detail and low weight. Contrary to electroplating, this process does not finish a substrate but instead creates a self-supporting metal structure.

Electroforming thus combines aspects of casting with electrolytic plating, enabling the production of complex, filigree and at the same time lightweight structures. Depending on the design, thin-walled geometries can, in some cases, significantly reduce the use of precious metals compared to solid-cast parts. At the same time, it is possible to meet high standards for level of detail, surface quality and resistance to abrasion and corrosion.

Series production of electroformed parts requires stable system control, safe handling and close process monitoring. To consistently achieve defined wall thicknesses and material characteristics, process parameters such as chemical concentration, pH-value, temperature and current density must be continuously monitored and maintained.

In the case of gold alloys, the target karat is largely determined by the condition of the bath and process control – verification is typically performed on the finished part. With platinum, factors such as tighter tolerances, greater sensitivity to contaminants and limited electrolyte operating times make cost-effective high-volume production difficult.

In-house series production remains unattractive to manufacturers

For many manufacturers, establishing their own in-house electroforming production line is difficult to justify from both an economic and organizational standpoint. Significant investment in equipment, the need to stock precious metals and chemicals, the requirement for specialized staff, compliance with comprehensive EHS regulations and the need for consistently high capacity utilization are considered major obstacles.

“We ensure precise and uniform layering in large-scale production environments, including material and chemical handling, while complying with all safety and environmental regulations – at no additional cost. Furthermore, we do not charge for any production rejects. This ensures that jointly agreed costs and production results can be reliably achieved. By pooling resources, we are also able to offer a price-performance ratio that is likely unique in the market,” summarizes Martin Stegmaier, Head of PGM and Decorative Precious Metal Applications in the MDS Business Unit, the benefits.

Ramp-up through 2027: from sampling to mass production

Umicore MDS plans to invest in equipment and infrastructure to expand capacity for large-volume orders. The rollout is scheduled to take place in phases: Sampling and qualification are expected to be completed by the end of the second quarter of 2026. The ramp-up to series production is planned for the end of 2026. Starting in early 2027, mass production across multiple lines is expected to be possible. Existing precious metal, analytical and quality control processes will be utilized to achieve reproducible results in all batches.

With this expanded offering, Umicore MDS intends to facilitate access to electroforming at industrial production volumes. This provides jewelry and accessory manufacturers with an exciting option for bringing electroformed designs to life – from specification definition and sample production through to scalable series and mass production.