coldshields design guide

Design Guidelines &
Considerations for Coldshields

Coldshield design features and specifications should conform to the mandrel or internal dimensions of the coldshield taking into account the mandrel to coldshield interface.

Nearly any shape is possible when utilizing as expendable mandrel but common sense and coordination with our electroforming team early in the design process may help reduce production costs.

The mandrel will be CNC machined or made on a screw machine so mandrel costs can vary based on the coldshield configuration, i.e. one that is not optically and mechanically centric could be significantly more costly to manufacture.  Also, features should be considered in mandrel design so that secondary machining operations at system interface and alignment are reduced.

While most coldshields are small, special consideration may be required which account to expansion of the mandrel in higher temperature plating processes, specific mandrel materials or larger assemblies.

Electroforming process considerations include understanding that external corners and radii will plate at approximately two times the nominal plating rate while internal corners plate at one half the nominal rate.  This will result in variations in the external dimensions of the coldshield and should be considered in the design process.  Minimizing sharp corners and tight radii will minimize this electroforming anomaly. Proprietary masking processes developed by Opti-Forms has reduced this electroforming anomaly.

The coldshield performance may be based on minimizing mass; the structural or mechanical characteristics can be maximized through good design that will minimize plating thickness for rigidity.

Why a Coldshield?

Infrared detectors (camera arrays etc.) require shielding from stray and unwanted IR radiation to obtain optimal signal-to-noise figures on a desired target.  Many of these coldshields are cryogenically, or electronically, cooled as in military and aerospace applications. They may however not remain in the cooled state all the time and need to be available with minimal delay.  The ultra-low mass and thin wall characteristics of the Opti-Forms coldshield allow minimum cool down time before maximum detector performance is achieved.

Talk to our Sales Group about Coldshields

Custom Reflector Designs

Opti-Forms has extensive experience in radiant energy systems, electro-optical and electromechanical systems and enhanced spectral performance coatings. Opti-Forms can assist in seeking a cost-effective design for any reflector application whatever the challenge.

Electroforming can consistently replicate difficult to fabricate shapes from a single master tool, which significantly reduces per part costs. Production capabilities expand further with additional master tools. Electroforming provides both design and fabrication versatility from large (32 inch diameter) reflectors to very small (.045 inch) medical instrument tips.

The electroforming process is capable of producing exotic or complicated surface geometry at a substantial cost saving over other conventional manufacturing methods. Aspheric contours generated by computer designs as well as conic sections such as paraboloids, ellipsoids, hyperboloids and off-axis segments can be produced in volume with repeated accuracy. Traditional optical fabrication techniques cannot compete with this cost effective production process.

Opti-Forms has computer-aided design engineering facilities for 2-D and 3-D parametric component design for fast turn-around of new products and/or tooling. This CAD technology allows aconic surfaces to be generated, which maximize radiant energy system performance. Computer generated geometry is easily transformed into master tooling utilizing "in house" CNC machining technology.