Dimensional accuracy studies of copper shells used for electro-discharge machining electrodes made with rapid prototyping and the electroforming process

Within the framework of forging, production implementations lead to creation of specific tools. Generally, the electro-discharge machining (EDM) process is used to create forms in matrices that cannot be machined. Then manufacturing problems are transferred on electrodes. However, rapid prototyping (RP) brings new solutions in the tool creation field. Thus, many and original ways to obtain electrodes have been developed. This work deals with the dimensional accuracy of electroplated copper electrodes on positive shape. We demonstrate that because of their lack of dimensional performances, electrodes obtained with this process are not satisfactory for industrial use. However they remain interesting for their short manufacturing time, as well as for outline phase. These electrodes can be interesting for machining matrices of parts requiring only beautiful appearance.