1. Seamless, Complex Geometries
Build intricate forms without welds or joins — improving integrity and reducing assembly cost.
2. Micron-Scale Precision
Achieve dimensional tolerances and finishes unmatched by other manufacturing methods.
3. Lightweight Strength
Tailor wall thickness for stiffness only where required, reducing weight without compromising durability.
4. Material & Design Freedom
Work with multiple metals or alloys, forming parts impossible to cast, forge, or machine.
5. Scalable Production
Our automated lines — from robotic linear systems to the AMALIE carousel — allow seamless transition from concept to volume manufacturing.
Precision metal manufacturing at the atomic scale.
Electroforming is a metal-forming process that builds parts atom by atom using controlled electrodeposition.
Unlike traditional machining or casting, where material is removed or poured, electroforming grows metal directly onto a mould or mandrel, creating components with exceptional accuracy, surface quality, and design freedom.
Once the desired thickness is achieved, the mandrel can be removed or retained depending on the application — producing seamless, complex shapes that are impossible or uneconomical to make by conventional means.
A precisely machined or additively manufactured mandrel defines the part’s geometry.
The mandrel is submerged in an electrolytic bath containing metal ions.
Under electrical current, these ions deposit onto the mandrel, forming a dense, high-purity metal layer
This process allows tight control of wall thickness, composition, and microstructure, enabling bespoke material performance and near-net-shape accuracy.
At Ultima Forma, we specialise in a range of high-performance electroformable metals and alloys, chosen for their mechanical, thermal, and corrosion properties.
The Core Materials we have on demand:
Nickel (Ni): High strength, excellent corrosion resistance, and dimensional stability — ideal for aerospace and tooling.
Copper (Cu): Superior thermal and electrical conductivity, suited for thermal management and EMI shielding.
Nickel-Cobalt (NiCo): Enhanced hardness and wear resistance, perfect for erosion protection and demanding environments.
→ Download the data sheets for these materials here
Below is a complete list of electroformable materials we can work with based on customer needs:
We are continuously developing multi-layer and graded material systems — combining metals to achieve localised functionality (e.g., hardness at edges, flexibility in the core, or conductivity in specific regions).
These capabilities allow us to tune properties across a single structure, delivering lighter, stronger, and more efficient designs.
Predicting performance before production.
At Ultima Forma, we use advanced Computer-Aided Engineering (CAE) tools to simulate and validate every stage of a component’s design — from electroforming and thermal management to hydrogen containment and HIP processing.
Our in-house modelling allows us to accelerate development, reduce physical prototyping, and optimise designs for both performance and manufacturability.
