Abstract: This invention relates to an electroforming device and a process used to electroform a metal layer on an inner surface of a female mandrel. The electrolytic solution flows only through an electrolytic solution passageway that defines the inner surface as the walls of the passageway. The mandrel may include more than one electrolytic solution passageway, or multiple mandrels may be used in a sequential order to mass produce the electroforms.

Abstract: There is disclosed an apparatus for depositing metal on a member comprising: (a) a first electrode comprising a first corrugated side; (b) a second electrode having the same polarity as the first electrode and comprising a second corrugated side, wherein the second corrugated side is disposed opposite the first corrugated side, and spaced therefrom; (c) a channel defined by the first corrugated side and the second corrugated side for movement of the member therebetween, wherein the channel has a plurality of alternating expansive areas and constrictive areas; and (d) a conveyor device for transporting the member through the channel.

Abstract: An electroforming/electrodeposition process and apparatus includes a first electrode, a second electrode spaced from the first electrode, a channel defined by the first and second electrodes and at least one electrically nonconductive or poorly conductive shield disposed adjacent at least one electrode. The shield(s) define(s) a region of the channel wherein the surface of a mandrel placed in that region experiences substantially uniform current density. The apparatus may contain additional electroforming/electrodeposition and/or other steps and may be arranged in a carousel apparatus with one or more mandrels to permit continuous operation of the apparatus.

Abstract: An apparatus for depositing metal which provides a brushless electrical current continuity between a member, such as an electroforming mandrel or an electroplating rack, and a current source, comprising: (a) an electrode; (b) a member, spaced apart from the electrode, wherein the member defines a space that is partially or fully filled with a first conductive liquid in electrical contact with the member; (c) a second conductive liquid electrically isolated from the electrode; and (d) connecting means for electrically connecting the first conductive liquid and the second conductive liquid.

Abstract: An apparatus is disclosed for depositing metal on a mandrel which provides a brushless electrical current continuity between the mandrel and a current source, comprising: (a) a metal deposition vessel; (b) an electrode disposed in the vessel; (c) a mandrel disposed in the vessel, spaced apart from the electrode; (d) an electrically conductive liquid disposed in the vessel; (e) an electrolytic solution disposed in the tank; (f) a layer of a substantially electrically nonconductive material disposed between the electrolytic solution and the conductive liquid; and (g) connecting means for electrically connecting the mandrel and the conductive liquid, coupled to the mandrel.

Abstract: A composite metal article is disclosed comprising at least a first elongated electroformed hollow member and a second electroformed elongated hollow member, each of the hollow members comprising at least a first sleeve and a second sleeve, one sleeve of each of the hollow members having a perimeter larger than the perimeter of the other sleeve of the same member, at least a segment of the outer surface of one sleeve of the second elongated hollow member being adjacent to and substantially surrounded by the inner surface of one sleeve of the first elongated hollow member.

Abstract: An electroforming process is described comprising providing an elongated electroforming mandrel core, applying a substantially uniform coating of a molten, inert, inorganic, homogeneous, electrically conductive metal or metal alloy to the mandrel core, the metal or metal alloy having a melting point and a surface tension less than the melting point and surface tension of the mandrel core, immersing the mandrel core bearing the coating in an electroforming bath having a surface tension less than the surface tension of the metal or metal alloy, depositing an electroformed metal layer on the coating, the electroformed metal layer having a melting point greater than the metal or metal alloy, melting the metal or metal alloy, and removing the electroformed metal layer from the mandrel core.