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Applications
Nanotechnology has become an increasingly important industry sector and new applications for the process of electroforming in nanocrystalline copper are being developed constantly. Some of these applications include rapid prototyping and manufacturing, aerospace and cryogenic engineering, specialist body armour, metal faced flexible composite tooling, metal casting alternatives, medical (surgical) applications and many more.
Rapid Prototyping (RP) - An overview of metal coating
Rapid Prototyping is the automated construction of 3D, physical objects by additive engineering; taking virtual designs from computer aided design (CAD) or animation modelling software and transforming them into very thin horizontal cross-sections - then creating each cross-section in physical space, built up one after another until the model is finished.
Rapid Prototype models lend themselves readily to being encapsulated in nanocrystalline metal. At Morganic Metal Solutions we use copper in a unique nanocrystalline form, which gives it properties closer to mild steel than to any other form of copper. For example, it has spring properties that provide great strength to RP models, yet still remain light in weight
before & after the process
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As an additional benefit metal "grown" this way has no (previous) form other than that in which it grows, which in addition to the strength of the nanocrystalline structure prevents the part from deforming.
For more information - here
Metal Faced Flexible Composite Tooling
Metal Faced Flexible Composite Tooling
After years of research by Morganic Solutions, a versatile and effective metal faced composite tool has now been fully developed that allows far easier initiation of tooling by the elimination of elaborate machining. It also provides total thermal compatibility with flexibility and the possibility of much larger, more complex moulds.
Until now, there had been numerous attempts to produce a metal face on a composite mould tool, but with no real success.
Plating of the mould face was tried on many previous occasions, but the metal shim invariably came away with the moulded part, regardless of how good the release agents were and with the problem being particularly noticeable when moulds were repeatedly passed through an autoclave.
The use of machined aluminium moulds, with their inevitable thermal mismatch, requires design concessions to allow removal of the cured part, due to contraction of the metal on cooling from cure temperatures. Also the machining of aluminium billets limits the size of a component, with several parts being required to make up a single, large component. There is now, finally, a true and extremely versatile alternative.
For more information - here
Cryogenic Engineering
The requirement for low mass, pure copper heat exchangers in cryogenic engineering had always been addressed by machining pathways into solid copper, but by manufacturing as electroforms, in nano crystalline copper, performance of these heat exchangers can improved dramatically.
Very significantly, nanocrystalline copper loses none of its mechanical properties in liquid nitrogen, which allows for complex pathways in the electroform to contain the coolant, with all relevant fittings being incorporated.
This is an excellent application of nanotechnology as internal pathways with details well beyond the capability of machining can be generated by rapid prototyping to 15 micron build accuracy. These are then encapsulated and the wax former removed to provide hermetically sealed hollow forms incorporating all fixings and or pipe work. This form can then (for example) be replicated as a stack using pure copper no thicker than 200 microns and a bellows to accommodate expansion and contraction can be readily built in.
Morganic Metal Solutions prototypes have been developed in association with Oxford University and associated companies.
For further information contact Ross Morgan here
Fine Art - Casting Alternatives
We work with many sculptors - in many different mediums. An original piece can be readily turned into a production run in copper, silver, gold etc., using a process that works at a maximum temperature of 30 deg C. As an additional benefit the metal forms come 'ready finished' and in great detail, plus there is no need for "runners and risers" as in casting.
Size is not critical although parts over approximately 1800mm by 450mm x 450mm require special tooling.
At Morganic Metal Solutions we can produce moulds on which engineering wax is vacuum and pressure cast. These are then encapsulated in metal and the wax removed for reuse - not to be confused with lost wax metal casting! The resultant forms are fully detailed, very strong and lightweight. Where required additional weight may be easily added, which said the hollow form can provide an additional dimension, visible to the eye by revealing 'windows' to the interior.
We have a passion for art and working with artists, to create unique artwork that would be impossible to achieve any other way.
We also work extensively with artists who use computers to design then fabricate their designs in SLA or SLS materials before bringing them to us for encapsulation in copper, sometimes adding a final plated finish - as for instance this wonderful chair by Lionel Dean that is currently being exhibited internationally
For more information - here
Electronics manufacturing
Various new nanotechnology applications are emerging in the electronics industry and Morganic Metal Solutions is presently liaising with industry Research and Development Teams to explore possible uses including super chilled chips on PCB's, hermetically sealed components and Chip-to-Package interconnects.
Before & after
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