Electroforming system and method

Abstract

A method for electroforming a component that includes a first housing and a second housing, where the second housing can define a conformable electroforming reservoir with a base structure. An electrically insulating sheet covers at least a portion of the base structure and defines a fluid passage where the component is to be located.

What is claimed is: 
     
         1 . A method of forming a conformable electroforming reservoir, the method comprising:
 obtaining a component geometry;   determining a geometry of a multi-piece conformable housing based on the component geometry;   shaping a frame based on the determining the geometry of the multi-piece conformable housing;   providing a set of apertures with the frame;   determining a location of at least one auxiliary anode based on the component geometry, wherein the at least one auxiliary anode is provided with a portion of the frame;   applying a mesh to the frame to form a base structure; and   covering an exterior of the base structure with a polyethene/polypropylene sheet, wherein the set of apertures extend radially beyond the polyethene/polypropylene sheet.   
     
     
         2 . The method of  claim 1  wherein the shaping of the frame further comprises assembling the frame as a plurality of frame segments wherein the plurality of frame segments define the frame. 
     
     
         3 . The method of  claim 2  wherein the providing the set of apertures includes at least one aperture formed with or coupled to each of the plurality of frame segments. 
     
     
         4 . The method of  claim 2  wherein at least one of the plurality of frame segments includes a shield. 
     
     
         5 . The method of  claim 1  wherein the determining of the geometry of the multi-piece conformable housing based on the component geometry maintains an equal distance between the component and the frame. 
     
     
         6 . The method of  claim 1 , further comprising fluidly coupling the set of apertures with a fluid passage defined by the polyethene/polypropylene sheet. 
     
     
         7 . The method of  claim 1 , wherein applying the mesh to the frame includes applying the mesh to at least one opening of the frame such that the mesh spans the at least one opening. 
     
     
         8 . The method of  claim 1 , further comprising coupling a shield to the frame. 
     
     
         9 . The method of  claim 1  wherein providing the set of apertures further comprises providing at least one inlet aperture and at least one outlet aperture. 
     
     
         10 . The method of  claim 9 , further comprising controlling a flow of electrolytic fluid to different portions of the multi-piece conformable housing. 
     
     
         11 . The method of  claim 10 , wherein controlling the flow of electrolytic fluid includes controlling a flow rate through at least one of a valve or a nozzle coupled to each of the set of apertures. 
     
     
         12 . The method of  claim 10 , wherein providing the at least one inlet aperture includes providing at least one inlet aperture having an inlet portion and a narrowed portion, wherein the narrowed portion includes a smaller cross section than the inlet portion. 
     
     
         13 . The method of  claim 1 , wherein apply the mesh further comprises providing a mesh comprising one or more of titanium, platinum, tungsten, or noble metals. 
     
     
         14 . A method of forming a multi-piece conformable housing adapted for electroforming a component, the method comprising:
 obtaining a component geometry;   determining a geometry of a multi-piece conformable housing based on the component geometry;   shaping a frame based on the determining the geometry of the multi-piece conformable housing;   applying a mesh to the frame to form a base structure; and   coupling a cover to at least a portion of the base structure, wherein the cover lies over the mesh.   
     
     
         15 . The method of  claim 14 , further comprising coupling a shield to one or more portion of the frame. 
     
     
         16 . The method of  claim 14 , further comprising coupling an electrically insulating sheet to at least a portion of the base structure, wherein the electrically insulating sheet defines a fluid passage. 
     
     
         17 . The method of  claim 16 , further comprising providing a set of apertures with the frame and fluidly coupling the set of apertures with the fluid passage. 
     
     
         18 . The method of  claim 14  wherein the determining of the geometry of the multi-piece conformable housing based on the component geometry maintains an equal distance between the component and the frame. 
     
     
         19 . The method of  claim 14 , further comprising controlling a flow of electrolytic fluid to different portions of the multi-piece conformable housing. 
     
     
         20 . A method of forming a multi-piece conformable housing adapted to receive a component for a system for electroforming a component, the system comprising a first housing forming a dissolution reservoir, the dissolution reservoir containing an electrolytic fluid, a first anode coupled to or at least partially located within the first housing, and a second housing defining the multi-piece conformable housing, the method comprising:
 obtaining a component geometry;   determining a geometry of a multi-piece conformable housing based on the component geometry;   shaping a frame based on the determining the geometry of the multi-piece conformable housing, wherein the frame includes an opening;   applying a mesh to the frame to form a base structure, wherein the mesh spans the opening and is spaced from the component; and   coupling an electrically insulating sheet to at least a portion of the base structure, wherein the electrically insulating sheet lies over the mesh and defines a fluid passage, the component to be located in the fluid passage.