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Nickel Shims: Durable Molds for the Replication of Structures

Nickel shims are replication molds which are widely used in prototyping and for the industrial production of micro or nanostructures. Nickel shims are manufactured by electroforming, a specialized electrodeposition process. They are produced as either thick or flexible molds and utilized to transfer structures with high fidelity.

Size: up to 1.5 m x 1.7 m
Thickness: from 40 µm – 5 mm

Material: pure nickel 300 HV

Nickel Shims: Durable Molds for the Replication of Structures

Nickel shims are replication molds which are widely used in prototyping and for the industrial production of micro or nanostructures. Shims are manufactured by electroforming, a specialized electrodeposition process. They are produced as either thick or flexible molds and utilized to transfer structures with high fidelity.

Size:

up to 1.5 m x 1.7 m
Thickness:

from 40 µm – 5 mm

Material:

pure nickel 300 HV

Application of Nickel Shims to Transfer Micro and Nanostructures

The fabrication of micro and nanostructures requires precise methods and can be both time-consuming and costly. The result is a delicate master that can’t be replicated on a large scale or used for mass replication. By electroforming nickel shims from such master templates, the goal is to secure the master by transferring the structure into durable copies. Nickel shims guarantee multitude of usages and a high-quality molding and replication of nano and microstructures. Master templates come in different substrates and at 3D AG we have specialized in electroforming nickel shims from various substrate materials – from thick steel or glass plates, to delicate UV resins and polymers.

Next to securing structures, nickel shims are utilized as durable molds for mass replication. They can be cut to any customized size or shape and manufactured as thick inserts, or flexible sleeves. A common field of use of nickel shims is inserts for injection molding or sleeves for

roll-to-roll processes, as well as many other applications.

Advantages of Nickel Shims

The real advantage of nickel shims is the versatility of application. For R&D with small scaled structures in the lab, for the production of prototypes, or for industrial manufacturing – nickel shims are a reliable tool for the replication of structures.

Cost effective
High fidelity of structure & minimal shrinkage
High endurance & long lifetime
Durability yet flexibility

Electroforming nickel shims with Micro & Nanostructures

Nickel Shim Family: Sustainably Preserving Structures

Nickel shims are primarily electroformed to have multiple copies of a structure from a master template. These copies of the structure can then be used for industrial replication whilst preserving the originating master. Masters can be created in many different base materials such as glass, PMMA, wafers, and many other substrates, which are manufactured by different technologies such as laser lithographie, diamond turning and more. The goal behind electroforming nickel shims lies in preserving the micro and nanostructure and creating durable molds.

At 3D AG we take it a step further and follow the concept of creating entire nickel shim families. Each copy holds the opposite polarity and represents a generation of the nickel shim family. The generations and nickel shim family branches are created to sustainably preserve the structure and use it for industrial replication for many years. From each branch of the nickel shim family tree, more template nickel shims are created to electroform multiple copies of the structure, with the goal not to create too many generations.

Shim Family Tree: Sustainably preserving structures

3D AG Nickel Shims Represented in Various Industries

The nickel shim families we manufacture at 3D AG are applied in various industries - if as molds for display production, sleeves for roll-to-roll processes of high security features, or as inserts for photonic applications - partner with 3D AG for the industrial replication of your structure.

Large Format Nickel Shims

3D AG has invested years of research to develop a custom made process with custom made electroforming baths. Next to the ability of electroforming nickel shims from nearly any base substrate, our electroforming specialists produce nickel shims in various sizes as replication molds . Whilst injection molding inserts or imprinting stamps are usually of a smaller size, roll-to-roll processes or other industrial replication needs large format nickel shims as durable molds. At 3D AG we can electroform shims up to the size of 1500 mm x 1700 mm, and they can also be welded to sleeves for consistent and controlled manufacturing.

Upscaling by UV Step-and-Repeat Imprinting

In many cases micro and nanofabrication is limited to a small size, for example wafer scale. 3D AG has developed an in-house step and repeat imprinting process, also called recombination. It allows upscaling a structure to large format masters, from which later also nickel shims can be manufactured. These large format nickel shims can then be used in wide web replication as molds. Structures can be recombined to an endless pattern or according to any layout provided, our high precision process to receive upscaled molds.