Review—Electroforming Process for Microsystems Fabrication

Being an unconventional technique of additive micro-manufacturing, electroforming has garnered significant interest from various industrial sectors because of its capability to offer advanced micro-manufacturing competences with high precision in achieving dimensional uniformity and replication accuracy at a small scale. This paper reports a comprehensive review of the electroforming process as a microsystem fabrication technique. This process is superior to 3D printing, stereolithography, selective laser sintering, physical and chemical vapor deposition, etc. in many aspects due to its unique properties. It can deposit a variety of metals and alloys, including precious metals, making it appropriate for various applications in the microfabrication domain. This article covers the fundamental aspects of electroforming, its history, the current state-of-the-art advancements, the modeling associated with it, and its importance in an industrial context. Additionally, the article discusses the advantages and limitations of this technique and their respective microsystem applications. Finally, it concludes with a discussion on the future prospects and potential advancements in the field of electroforming, contributing to the development of microsystems.