Hologram Electroforming: How Nickel Shims Are Made

By Rajneesh Sharma, Owner, Kiran Holographics

A hologram master holds a pattern so fine you cannot feel it with your finger. But your embossing machine works with heat, pressure and thousands of metres of film. The master itself would not survive that. So before production can start, the hologram must be copied into a strong metal plate called a nickel shim. The process that does this is called electroforming.

This guide explains how electroforming works, why it matters, and what to check when you set up electroforming tanks.

What is electroforming?

Electroforming is a process that builds a metal copy of a surface, layer by layer, using electricity. In hologram production, nickel is slowly deposited onto the master's surface in a liquid bath. Over time, the nickel builds up into a solid sheet that carries an exact copy of the hologram pattern. When this sheet is separated, it becomes a nickel shim or a copy used to make more shims.

How are nickel shims made?

1. Preparing the master: the surface of the master is made electrically conductive with a very thin metal layer, so nickel can form on it.
2. Electroforming: the master is placed in the nickel bath. An electric current moves nickel from the solution onto the master surface, building a nickel layer.
3. Separation: once the nickel reaches the right thickness, it is carefully separated from the master. It now carries the hologram pattern.
4. Making copies: this first nickel copy can be electroformed again to produce more copies, so the original master is protected.
5. Finishing the shim: the shim is cut and prepared to the size needed for the embossing cylinder.

Master, copies and shims: why the steps matter

The original master is valuable and cannot be replaced easily. Electroforming lets you make copies from copies, so the master is used as little as possible. When a production shim wears out, a new one is made from a copy, and your hologram stays the same order after order. Learn more in our hologram master plate guide.

Why electroforming quality matters

Every fault in a shim is repeated on every metre of film. Poor electroforming can cause:

• Loss of fine detail, which makes the hologram dull
• Uneven shim thickness, which causes uneven embossing
• Pits, marks or stress in the nickel
• Shims that wear out quickly on the machine

Clean tanks, a well-maintained bath and steady control are what produce shims that run long and look sharp.

What to check in electroforming tanks

1. Tank material

Electroforming tanks hold chemical solutions for long periods. Stainless steel construction resists corrosion and keeps the bath clean.

2. Tank size

The tank must be large enough for the shim sizes you need, for narrow web and wide web machines.

3. Bath control

The bath must be kept clean and at steady conditions. Good filtration and temperature control help produce even, defect-free nickel.

4. Power control

Steady, controllable current is what builds an even nickel layer. Sudden changes cause faults in the shim.

5. Training

Electroforming is a skilled process. Make sure your supplier trains your operators properly, not just installs the tanks.

Own tanks or outside supply?

Having your own electroforming setup means you can make new shims whenever you need them, without waiting on an outside supplier. If you are not ready to set up your own tanks yet, you can source ready shims from a lab while you build up your plant. Read our guide on how to start a hologram manufacturing business.

Electroforming tanks and shims from Jaipur

At Kiran Holographics, we make stainless steel electroforming tanks in-house in Jaipur as part of our master making equipment. Our own master lab also supplies master plates and nickel shims for narrow web and wide web machines, to clients in India and export markets. You can buy tanks on their own or as part of a complete turnkey hologram plant.

We have been in the holographic industry since 2002. Tell us your shim sizes and production plans, and we will suggest the right setup. Get a quote and we will reply within one working day.

About the author: Rajneesh Sharma is the owner of Kiran Holographics, Jaipur, a security hologram manufacturer since 2002. He leads the work from client designs and origination to exports and plant projects.