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Electroforming is the only fabrication method resulting in stress-free metal bellows. The alternatives - rolling, welding, hydroforming - subject the material to cold working or heat-induced stresses, compromising the components' strength, durability and performance under load.
In electroforming, metal is uniformly electroplated onto a conductive substrate of the desired configuration, called a mandrel. Subsequently, the mandrel is chemically dissolved, leaving behind a stress-free electroformed bellows, as shown in the illustration.
Due to their stress-free nature and high alloy strength, electroformed NiColoy® bellows outperform the alternatives, especially in precision dynamic applications.

NiCoForm's advanced mass-electroforming technology and its trademark high performance alloy, NiColoy® result in stress- and pore-free bellows with otherwise unattainable part-to-part consistency. Freedom from stress assures the materials' reliable performance in extension, compression, bending and rotation. NiColoy®'s combination of high elasticity, strength, corrosion resistance and low tendency for crack formation assures the unsurpassed performance characteristics of NiColoy® bellows, far exceeding those of their nickel counterparts.

• NiColoy®'s higher Modulus of Elasticity, Ultimate Tensile and Yield Strengths than conventional electroformed nickel (see table), translates into greater elasticity, higher pressure and torque ratings for NiColoy® bellows
  
  
• NiColoy® bellows can be produced with walls as thin as 0.0004” (10 µm), and diameters as low as 0.03” (0.75 mm) - much smaller than possible with alternate methods - making them ideal for precision sensing applications. On the other end of the spectrum, bellows up to 10” (250 mm) in diameter and 25” (625 mm) long have been electroformed
  
  
• NiCoForm's advanced electroforming technology results in stress free bellows.  This increases their durability under cyclical loads. Usually fabricated for a minimum life of 250,000 cycles, designs can be tailored for  infinite as well as shorter cycle rating
  
  
• Homogeneous and nonporous, NiColoy® bellows can be used to seal out aggressive chemicals, moisture and dust in critical applications.  Gold, Rhodium and other coatings can further increase the bellows corrosion resistance  and improve their contact performance in electronics. Leak testing of bellows can be performed by helium mass spectrometry up to 10^-9 ccHe/sec

• NiColoy® retains its strength and elastic properties in a wider range of temperatures than nickel - from cryogenic to 600°F. In certain cases, the material can be successfully used at even higher temperatures

• NiCoForm's optimized electroforming processes maximize wall uniformity and reduce the in-process time, resulting in high spring rate consistency, high yields and fast delivery
  

• NiColoy® bellows can be hermetically attached to mating components by welding, brazing, soldering, electrojoining and the use of adhesives